Detailed Project Report on truck tyre retreading with cold process

TRUCK TYRE RETREADING WITH COLD PROCESS
 [CODE NO. 3137]  


What is retreading?


‘Retreading’ means taking a worn casing of good structural quality and putting it through a process which completely renews the tread of the tyre and sometimes the sidewall rubber. The rebuilt tyre is then subjected to a curing process where the new rubber is vulcanised to the casing and the tread pattern is formed.

Over the years tyre manufacturers have invested heavily in product development to deliver tyres that not only have a ‘first life’ but are also designed to perform equally as well in subsequent second and even third lives. Stronger casings, improved re-manufacturing techniques, a variety of specialist rubber compounds, coupled with the need to recycle and reduce the negative impact on the environment has lead to a sustained growth in the retread industry.

A retread tyre starts life as a worn tyre, where perhaps the tread is down to 2-3 mm and may have been previously re-grooved, or one that's been punctured and needs a repair. The first part of the process is to inspect the tyre to see whether it meets with our stringent quality guidelines.

Retreading of damaged tyre is done by conventional hot matrix curing in most curing in most cases. But recently a new technology has been developed called procured Tread Rubber Retreading process which is commonly known as cold process retreading. In this process, procured tread rubber  already has at read pattern on it eliminating the need for a tread matrix at vulcanizing stage. Tread Rubber is procured alongwith other new raw materials.

Retreading tyre by procured method give 50% more mileage than the tyre by conventional process.

Initial inspection

At initial inspection a visual and tactile examination of the casing takes place, then a non destructive shearography test or scan is completed. This detects inherent separations in the carcass that are otherwise invisible and would remain undetected by the naked eye. If accepted after this stage it will then go through the complete retread process.


COST ESTIMATION

Plant  Capacity                               :       44.00 Tyres/day                                
Land & Building (5000 Sq.Mt)    :    Rs. 1.62 Cr
Plant & Machinery                         :    Rs. 33.92 Lacs
Working Capital for 2 Months    :    Rs. 1.04 Cr
Total Capital Investment             :    Rs. 3.09 Cr
Rate of Return                              :    32%
Break Even Point                         :    48%


INTRODUCTION    
CONSTRUCTION OF TYRES    
USES AND APPLICATION    
B.I.S. SPECIFICATION    
RAW MATERIAL REQUIRED FOR PRE-CURED RETREADING PROCESS    
PROPERTIES    
MARKET SURVEY    
INTERNATIONAL VS. INDIAN EXPERIENCE IN TYRE RETREADING:
SIMILARITIES & DIFFERENCES    
MARKET POSITION OF TYRE RETREADING    
OVERVIEW OF TYRE RETREADING INDUSTRIES IN ETHIOPIA    
GLOBAL RUBBER TYRE MARKET    
DETAILED IMPORT DATA OF: TYRE RETREADING    
DETAILED EXPORT DATA OF: TYRE RETREADING MACHINE    
PRESENTLY FEW RUNNING TYRE RETREADING WORK    
MANUFACTURING PROCESS OF RETREAD TYRE BY COLD PROCESS    
PROCESS IN DETAILS OF TYRE RETREADING    
PROCESS FLOW DIAGRAM    
PRINCIPLES OF PLANT LAYOUT    
PLANT LOCATION FACTORS    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
PROJECT IMPLEMENTATION SCHEDULES    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF RAW MATERIALS (GLOBAL)    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF PLANT AND MACHINERY (GLOBAL)    
COMPLETE PLANT SUPPLIERS    
DETAILS OF THE MACHINERY USED IN TYRE RETREADING    


APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET