GENERAL TYRE AND RUBBER

COMPANY OF PAKISTAN LIMITED

INTERNSHIP REPORT
SUBMITTED BY

SHAHARYAR ADIL
EP#1442064
INDUSTRIAL TRAINING
COURSE#624
APPLIED CHEMISTRY AND CHEMICAL TECHNOLOGY
UNIVERSITY OF KARACHI

SUBMITTED TO

Mr. BILAL KAZMI

28-03-2020
 ACKNOWLEDGEMENT:

 First of all, I would like to thank Almighty ALLAH, The most Gracious and Most Merciful.

 I would specially like to thankful to respectable Dr. Riaz Ahmed (Associate Professor and

Chairperson of Applied Chemistry And Chemical Technology, University Of Karachi) for

conducting an internship in General Tyre And Rubber Company Of Pakistan ltd and providing me

a practically learning platform.

 I am highly thankful to Mr. Bilal Kazmi under the supervision of him and by his cooperation I am

able to complete my internship report.

 I am very thankful to honorable Mr. Moiz Sarwar (Division Manager Of Compounding

Department) providing me the opportunity for Internship Training Program with a proper daily

schedule for training.

 I wish to express my deep gratefulness to Mr. Khalid Khan (Executive Compounding

Department) sharing a process and operation of tire manufacturing and guidelines about how

to observe a process.

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S# CONTENT Page#

1 Introduction to Industrial Training 3

2 Company’s profile 4-5
3 Weekly job summary 6-9
4 Mixing 10
5 Extrusion 11-12
6 Calendaring 12-14
7 Stock Preparation 14
8 Bias Tyre Building 15
9 Radial Tyre Building 15-16
10 Steelastic 16
11 Tyre Curing 16-17
12 Motorcycle Tyre Building 18
13 Motorcycle And Auto Tube Department 18
14 Bladder and Flapper 19
15 Utility Department 19-21
16 Raw Material Ware House 22
17 Finish Goods Ware House 22
18 Quality Assurance 22
19 Health Safety Environment 23
20 Quality Control 23
21 Material Testing Lab 23
22 Production Planning and Control 23
23 Product Industrialization 24
24 Compounding 24
25 Findings 25
26 Suggestions 26
27 Conclusion 27

Page 2 of 27
 CHAPTER # 1

INTRODUCTION

INDUSTRIAL TRAINING:

The industrial training is a compulsory course (3 credit hours) for all students of final year.

It is an activity to enhancing and improving the skills and knowledge of the students.

The purpose of the Industrial Training is to provide exposure for the students on practical field. Through
this exposure, students will have better understanding towards the real working environment.

This industrial training helps the student to know about the latest techniques, methods implementing
into an organization and responsibilities of different departments and their roles in manufacturing.

Industrial training objectives:

To provide a practically learning platform to the students.

To develop the skills in application theory to practical work situation.

To prepare the students for their professional careers.

To aware the student about organization structure, manufacturing and business operation, and
administrative functions.

To improve the students creativity skills and sharing ideas.

To learn the technical knowledge.

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 Chapter # 2

COMPANY’S PROFILES/BACKGROUNDS

COMPANY’S PROFILE:

The General Tyre and Rubber Company of Pakistan Limited (GTR) came into existence in 1963, at Landhi
Karachi and commenced its production in July 1964.

The Company was then established by General Tyre International Corporation (GTIC) of USA, with a total
capacity of only 120,000 tires per annum.

GTIC sold 90% of their shares to the present owner M/s Bibojee Services Ltd. in 1977 and retained 10%
of the ownership. In 1985, the Company completed a major expansion, which took the capacity to
600,000 tires annually.

Continental AG, Germany’s number one tyre manufacturer purchased GTIC in 1987. It provides
Technical Assistance to GTR under a program, which includes training of our people, formulations,
recipe, and selection of equipment and approved suppliers. GTR under this agreement with Continental
is bound to follow all rules and regulations provided by Continental including the given quality
standards.

COMPANY’S BUSINESS ACTIVITY:

Being a public listed Company; the current main sponsors of the Company beside Bibojee Services are
Pak Kuwait Investment Company and Continental AG. The remaining shares are held by the general
public.

GTR has four market segments .These are:

1. The Original Equipment Manufacturers – Vehicle assemblers

2. The Replacement or the After market
3. Government Departments/Institutions
4. The Export Market

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GTR sells its tires in replacement market through more than 150 nationwide authorized dealers /
distributors most of whom have been working with GTR for more than three generations setting a
milestone on customer loyalty and satisfaction.

It has offices / warehouses in four major cities of Pakistan and intends to add another new office soon.
All automotive tires produced by us are covered with warranty.

PRODUCTS:

1. PASSENGER CAR TYRES

2. LIGHT TRUCK TYRES
3. TRUCK AND BUS TYRES
4. TRACTOR TYRES
5. MOTORCYCLE TYRES
6. RICKSHAW TYRES

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 CHAPTER # 3

WEEKLY JOBS SUMMARY

1ST WEEK:

DATE JOB TITLE SUMMARY

21-01-2020 MIXING It includes mixing of raw
materials to make a master and
finish compound of rubber.
22-01-2020 TRIPLEX/SINGLE EXTRUDER Making of tread and sidewall
(components of tyre) by using
finish compound.
24-01-2020 DUAL EXTRUDER Making of tread and sidewall for
truck bus and tractor.

4 ROLL CALENDER Making a sheet of fabric coated

with rubber compound called
ply (reinforcing material).
25-01-2020 STOCK PREPARATION Cutting of ply sheet of desired
length and prepare stock.

BEAD Steel cord coated with rubber

compound in a ring form.

BAND BUILDING Making a band of ply for tactor

and truck bus tyres.

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2ND WEEK:

DATE JOB TITLE SUMMARY

27-01-2020 PESSENGER AND TRUCK TYRE Making of green tyre (uncured
BUILDING(BIAS TYRE) form of tyre) by assembling
components on rotating drum.
28-01-2020 STEELASTIC AREA Steel cord coated with rubber,
forming a flat sheet called steel
belt
RADIAL(TUBELESS) TYRE BUILDING Making of green tyre by
assembling components.

29-01-2020 TYRE CURING Tyre curing takes place by

vulcanization.

31-01-2020 MOTORCYCLE TYRE BUILDING Making green tyre by assembling

components on rotating drum

MOTORCYCLE TUBE Manufacturing of tube for

motorcycle tyre

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3RD WEEK:

DATE JOB TITLE SUMMARY

01-02-2020 AUTO TUBE Manufacturing of tube for car,
tractor, truck, passenger
vehicles.
BLADDER Making of bladder, part of curing
press machine.

FLAPPER Making of flapper, material

between rim and tube

03-02-2020 UTILITY Electricity, water, gas supply,

producing steam, water
treatment.
04-02-2020 RAW MATERIAL WAREHOUSE Placement of Raw material,
stock area.

07-02-2020 FINISH GOODS WAREHOUSE QC approved tyre packed and

dispatch to warehouse.

08-02-2020 QUALITY ASSURANCE Assuring quality of product ,

according to certified standards

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4TH WEEK:

DATE JOB TITLE SUMMARY

10-02-2020 HEALTH SAFETY ENVIRONMENT Monitoring health and safety of
organization, employees and
environment.
11-02-2020 QUALITY CONTROL Monitoring quality during
manufacturing of components
on floor and finished tyre.
12-02-2020 PRODUCTION PLANNING AND Making production plan and
CONTROL monitoring daily production
schedule to achieve production
target.
14-02-2020 MATERIAL TESTING LAB Testing of raw material,
intermediate and finished
product.
15-02-2020 PRODUCT INDUSTRIALIZATION Prepare design of tyre and mold,
provide specifications for
manufacturing and assembling a
tyre components and all
mechanical equipment they
handle.
17-02-2020 COMPOUNDING Selecting a raw material and
making a recipe according to
tyre properties.

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 CHAPTER # 4

TECHNICAL CONTENTS

 MIXING:

In this operation raw materials are mixed in a mixer by rotors called banbury mixer, to form a
homogenous rubber material called compound. The ingredients are generally provided to the plant in
pre weighed packages. Measure ingredients placed on a conveyer system and the mixer is charged to
initiate mixing. Raw materials for mixing are rubber, additives, rubber process oil and sulfur.

The mixing is carried out in two stages due to temperature rising, if temperature is too high then the
rubber scorching takes place, therefore first making master batch and then finish batch.

MASTER BATCH:

It is a first stage of mixing except sulfur the other raw materials rubber, additives, carbon and rubber
process oil are mixed to make a rubber compound in the form of sheet. The temperature range for this
batch is 140-150°C. when raw materials are charged into mixer, the mixing starts and mixed material
dropped on a sheeter mill which makes a sheet of rubber compound, this sheet passes from dip tank
solution containing promol (anti adhesive agent) to prevent sticking of sheet to each other, the sheet
passes through cooling line to cool down temperature and master batch in the form of sheet are stored,
batch weight is 200kg.

FINISH BATCH:

It is a second stage of mixing, the master batch and sulfur and activators are charged in a mixer to form
a sheet of rubber compound. The temperature range is 95-105°C. sulfur helps in vulcanization in tyre
curing. The mixing material drop on sheeter mill to make a sheet of rubber compound passes from dip
tank solution and cooling line , and finish compound sheet are stored, and ready for making different
components of tyre.

MIXER:

In mixing department there are three mixers PLC based are installed for mixing.

F-270, HF-270 and E320 TSR.

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 EXTRUSION:

Extrusion is a process used to create objects of a desired cross sectional profile with the help of die of
desired cross section.

In General Tyre extrusion is carried out by three different extruders;

1. SINGLE EXTRUDER

2. DUAL EXTRUDER

3. TRIPLEX EXTRUDER

These extruders are used to make components of tyre:

Tread (a component of tyre which came in contact with road).

Sidewall (component exist between tread and bead).

SINGLE EXTRUDER:

It is used to make tread/sidewall for motorcycle and rickshaw tyres. It consist of one screw shaft and
one hopper. It is also called cold feed extruder because compound without any milling (heating) charged
into extruder through hopper. The small pins are fitted inside to blend rubber compound properly. The
screw shaft move compound towards the die through which the desired shape of tread and sidewall in a
form of long strips obtained. The cusion gum (adhesive material) attached at the base of tread for easy
application of different components of tyre. The tread/sidewall long strip passes through conveyer belt
to cooling line where water is showered to decrease temperature. Blowers are installed to dry water.
Cutting is carried out through cutter of desired length of tyre. Stored in a sheffer truck (a moveable
vehicle with racks).

DUAL EXTRUDER:

It is used to make tread/sidewall for truck bus, tractor and passenger tyres. It is also called hot feed
extruder because the finish compound heated before feeding to extruder. Two different compounds
used in this extruder. Finish compound heated by roller mill and through conveyer, feed to the extruder.
The screw shafts move compound towards die which gives the shape to compound i.e tread/sidewall.
An adhesive material at the base of tread attached by crosshead extruder. The extruded profile pass

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through cooling line and cut according to desired length and stored for transporting to tyre building
department.

TRIPLEX EXTRUDER:

It is used to make tread/sidewall for radial tyres. It is also called cold feed extruder. Three different
compounds used in this extruder. The screw shafts move compounds towards die, the extruded profile
pass through cooling line and cut at specific length by automatic cutter and stored.

 4 ROLL CALENDER:

It is a process to coated a fabric with rubber compound and forms a thin sheet as reinforcing material
for tyre. Nylon and polyester fabric used in this process.

PROCESS:

Rubber compound is feed to four roll calendar through following mills.

1. Breakdown mill ( to break the rubber compound)

2. Warm up mill ( to heat up the rubber compound)

3. Blending mill ( to mix the rubber compound)

4. Feeding mill (feed rubber compound to roller number 1 & 2 and 3 & 4)

Fabric feed to 4 roll calender through different steps;

LET OFF UNIT:

Fabric roll placed at let off unit to unwind the fabric.

SPLICING UNIT:

When fabric roll completely let off, another fabric roll placed at let off unit make a joint of fabric end to
end through splicing in the presence of rubber sheet by hot press.

LOCKING AND TENSION UNIT:

Provide tension to the fabric to prevent creasing.

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CENTRING UNIT:

Centering the fabric.

BANANA ROLL:

Adjusting the width of fabric for easy penetration of rubber compound. Fabric feed between roller
number 3 and 2.

4 ROLL CALENDER:

The rubber compound feed between roller number 1 & 2 and 3 &
4 through wig wag unit which spreading the rubber onto the
roller. The fabric feed between roller number 2 and 3. The rubber
compound coated a fabric at top and bottom to make a fine
sheet.

PERFORATION UNIT:

Roller contains small pins and making a hole in a calendered

sheet to remove air trapped during process.

COOLING AREA:

This area contains 10 stainless steel rotating drum, circulating cold water inside placed in a vertical
position .

ACCUMULATOR:

The calendered sheet accumulate in this unit which helps in changing the wind up roll.

WIND UP UNIT:

The winding unit divided into two section to allow continuous operation of the line, when a wind up
roller is completely rolled and has to change with another. The sheet wind up in a fabric roller to
prevent sticking of sheet with each other.

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WRAPPING UNIT:

The wind up roll wrapped in a plastic sheet, and store in a stock area.

 STOCK PREPARATION:

This area divided into three section. Stock preparation, band building and bead building.

STOCK PREPARATION:

This section preparing stock of ply (reinforcing material ) for all tyres. The calendered fabric sheet roll
cut at specific angle and length for bias tyres and preparing roll of ply for transporting to bias tyre
building. The ply for radial tyres cut at 0° and rolls are transported to radial tyre building. Four machines
are used for cutting FC1, FC2, FC3 and FC4.

BAND BUILDING:

Making band of ply for tractor and truck bus tyres in a crisscross pattern. The band covered with fabric
and transported to tyre building area. Two machines are used to make band of ply. BB1 and BB2.

BEAD BUILDING:

Bead is a component of tyre to hold the tyre on a rim. The steel cord of brass coated and rubber
compound used to make bead. Turn of bead depend on quantity of steel wire used. If three steel wire
used then number of turn should be three.

Two machines used to making bead. Steel wire let off from bobbin, rubber compound adhere on steel
wire through extruder and round up according to specifications.

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 TYRE BUILDING AREA:

There are two types of tyre building,

Bias Tyre Building ( tyre containing tube )

Radial Tyre Building (Tubeless Tyre)

BIAS TYRE BUILDING:

All components of tyre tread, band of ply, bead, chaffer, breakers are
assembled in this area to make a green tyre ( uncured form of tyre ) of
truck bus, tractor and passenger tyres. Components assembled on
rotating drum manually.

Bead placed on bead applier, band placed on drum, edges of band turn in
by turning tool, bead applied on both sides, band edges turn out to cover
bead, tread applied at the centre with the help of laser light indicating
centre of tyre and sidewall placed around tread and green tyre is ready for
curing process.

RADIAL TYRE BUILDING:

Radial tyre is a tubeless tyre. Radial tyre assembled in two stage. Carcass
and then green tyre is formed.

CARCASS:

It is a first stage to make a radial green tyre. Carcass components assembled on rotating drum.
Components assembling sequence is; inner liner, body ply, bead and sidewall. Carcass is formed and
transported to green tyre building machine.

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GREEN TYRE:
4Components assembling sequence for making green tyre is; two
steel belt, cap ply and tread. This assembly is picked up by
transferred ring to the carcass. Expanding by exerting pressure to
expand and green tyre is formed.

 STEELASTIC AREA:

In steelastic area steel belts for radial tyre have been manufactured. It is a belt in which steel wire which
is brass coated let off from different bobbin passes over a pulley for tension, rubber compound through
extruder adhere on steel wires and make a strong bonding, the steel belt passing through a cooling line
in which 5 stainless steel cooling drum installed containing cold water inside, the steel belt cutting
carried out at specific angle and wind up in a fabric roll to prevent sticking to each other and transported
radial tyre building to assemble. This is the part of radial tyre which providing puncture resistance to
tyre.

 TYRE CURING:
Curing of tyre, is to provide a heat in closed press to start a vulcanization process, to give tyre a final
shape with the help of mold installed inside the press machine. In vulcanization crosslinking of sulfur
with rubber takes place, which improving the rubber physical properties.

There are two types of press machines used for tyre curing, Platen type and Dome type.

The mold installed inside the press is of two types, Segmented and two piece mold.

Curing is also of two types, All steam curing and Hot water curing.

There is a bladder installed inside the press machine required a high pressure for expanding a green tyre
and make a contact of green tyre with mold.

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PLATEN TYPE:

Platen type curing is all steam curing process, high pressure and temperature steam used in this press
for heating, it is used to cure radial tyres, green tyre placed in a press machine and closed, steam supply
into the bladder for interna heating, steam supply in the mold for external heating, cold water
circulating for temperature control, temperature required for curing is 175°C, and curing is complete in
12-14 minutes, when curing is complete the steam inside bladder is drain out and vacumm is applied to
collapse the bladder, cured tyre transferred to conveyer system installed at the back of press machine.

Two types of mold used in this press, segmented mold and two piece mold.

SEGMENTED MOLD:

It is latest equipment. The mold divided into parts which provide good
uniformity to radial tyres.

TWO PIECE MOLD:

It is an old designed equipment, the mold divided into two parts upper and
lower part, lower part is fixed while upper part is moveable in up and down
direction, there is a risk of uniformity disturbance of radial tyre.

DOME TYPE PRESS:

This press used for bias tyre curing, It takes 75 minute for curing, time mostly depending on tyre size, it
is hot water curing process required temperature is 160°C, high temperature and pressure water used to
provide heat internally in bladder, steam used in mold for external heating, cold water circulates to
control temperature, when curing is complete hot water in bladder drain out , vacumm applied to
collapse the bladder, cured tyre transferred to conveyer system installed at the back of press machine.

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 MOTORCYCLE TYRE BUILDING:

The motorcycle tyre building area contains seven machines for green tyre building, motorcycle tyre
components are assembled on a rotating drum to make a green tyre the sequence of assembling
components are; 1st ply, 2nd ply; breaker, bead and tread, ply are assembled in crisscross pattern to
provide strength to tire. The green tyre through conveyer sent to the motorcycle curing department.

MOTORCYCLE TYRE CURING:

In motorcycle curing department a perforation and lubrication on green tyre is carried out and then
place in a curing press. It is all steam curing process. Two piece mold used in curing press. Tire cured in
14-15 minutes required temperature is 160°C. the cured tyre inspect by QC and transported to finish
goods warehouse for packing.

MOTORCYCLE AND AUTO TUBE MANUFACTURING:

The process of tubes manufacturing for motorcycle and auto vehicles are same. The compound used in
tube manufacturing is butyl rubber. The process of tube manufacturing is as follow:

The rubber compound first charged to mill to heat up the compound, a cutter at bottom installed to cut
a compound in strip and through conveyer transfer to feed mill from where the compound feed to
strainer which consist of sieve mesh to separate any metal or hard particle from compound, the
compound from strainer through conveyer transfer to blending mill where compound blend and
transfer to stock mill, this mill stock the compound and feed the compound to extruder, the extruder
consist of die in a cone shape which provide a hollow shape to compound of required guage, the talcum
powder inside tube is aplly to prevent sticking, the tube pass through a cooling line to decrease the
temperature of tube, blowers are installed for drying, valve applicator is installed to apply valveon tube
for air inflation, the talcum poeder apply at outside of the tube , and by automatic cutter cut at desired
length, the tube stored in sheffer truck for 4 hours , after 4 hours tube transported to splicing unit
where bud joint on tube to give a circular shape to tube, the joint kept chilling unit to make joint strong
for 5 minute, the tube placed in curing machine, curing of tube takes place in 3 minute, two piece mold
used in this press machine. After curing tube is inspect by QC inspector by air inflation that any hole is
present which causes air loss, if no hole found the tube is passed by QC inspector and fit in a motorcycle
tyre and transported for packing.

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BLADDER:

It is a component installed in a curing machine. The purpose of bladder is to provide a shape to ture
according to mold installed in curing machine, the bladder required high pressure to expand. The
bladder production is less GTR mostly used imported bladder, due to short life time the GTR starts to
manufacture bladder to save a cost, the bladder life is, to cured 200 tyres, due to high pressure and
temperature it burst. The machine for bladder manufacturing imported from china and cure a bladder in
30 minutes at a temperature of 200°C.

FLAPPER:

It is a rubber material installed between rim and tube to protect the tube from metal surface, which
increases a life of tube.

 UTILITY DEPARTMENT:

This department provides all those parameters which are used in the manufacturing of tyres for
example Hot water, Cold water, Steam, electricity etc.

Utility department consist of following plants;

STANDBY GENERATOR

LPG BOUSER

ULTRA FILTRATION PLANT

REVERSE OSMOSIS PLANT

DEAERATOR

BOILER

VACUMM PUMP

COMPRESSOR

GENERATOR:

There are three standby generators each of 1200 KVA in genera tyre.

Page 19 of 27
Two generators of CAT company.

One generator of cummins company.

Diesel as a fuel used in these generators, consumed 185-200L/h diesel.

Oil change after 3000 hours CAT SAE 40.

ULTRA FILTRATION PLANT:

Ultrafiltration (UF) is a membrane filtration process similar to Reverse Osmosis, using hydrostatic
pressure to force water through a semi-permeable membrane. Suspended solids and solutes of high
molecular weight are retained, while water and low molecular weight solutes pass through the
membrane. This plant used to filter the KDA water, to remove sand particles from water for RO plant
efficiency.

REVERSE OSMOSIS PLANT:

Reverse Osmosis (RO) is a water treatment process that removes contaminants from water by using
pressure to force water molecules through a semipermeable membrane. RO plant used to make a water
low TDS for boiler efficiency.

DEAERATOR:

A deaerator is a device that removes oxygen and other dissolved gases from
liquids. Deaerators are commonly used to remove dissolved gases in feed
water for steam-generating boilers. Dissolved oxygen in feed water will cause
serious corrosion damage in a boiler by attaching to the walls of metal piping
and other equipment and forming oxides (like rust).

BOILERS:

A boiler is basically a closed vessel into which water is heated until the water is converted into steam at
required pressure. Boilers used for making high pressure steam for heating purpose in different
machines of tyre manufacturing. There are three boilers of two types (water tube and fire tube) utilized
by general tyre having different capacity of steam making.

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WATER TUBE BOILERS:

In water tube boiler the water is heated inside tubes and hot gasses surround these tubes. There are
two water tube boilers utilized in general tyre;

DESCON and TRAINE

DESCON BOILER:

CAPACITY : 22 ton/hr

TEMPERATURE : 216°C

PRESSURE : 20 bar g

TRAINE BOILER:

CAPACITY : 16 ton/hr

TEMPERATURE : 208°C

PRESSURE : 16-18 bar g

FIRE TUBE BOILER:

In fire tube boiler, there are numbers of tubes through which hot gases are passed and water surrounds
these tubes.There is only one fire tube boiler utilized in general tyre;

BOSCH BOILER. It produce 35 ton/hr steam.

FUEL FOR BOILER:

Natural gas and LPG are as a fuel utilized in boiler. LPG backup in two 30metric ton bouser kept, if
natural gas pressure decrease, so they must have a backup to run a boiler for steam making.

VACUMM PUMP AND AIR COMPRESSOR:

There are nine compressors utilized to compress the air for pneumatic valve.

There are 3 vacumm pumps utilized.

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 RAW MATERIAL WARE HOUSE:

All the raw materials are stock in the warehouse. All raw materials are imported. This department
dispatching the raw material to production department and maintaining the stock of raw material to
prevent any raw material shortage. The raw material used in production are listed below:

Natural Rubber.

Synthetic Rubber.

Rubber Process Oil.

Carbon Black.

Sulfur.

Talcum Powder.

Nylon Fabric Roll.

Polyester Fabric Roll.

Steel Wire.

Additives.

the raw material ware house is well maintained, and for safety purpose there is no use of electricity to
prevent fire risk.

 FINISH GOODS WARE HOUSE:

When tyres passed by QC department, tyres are transported in this area for packing. There are 8
machines for packing of tyre. After packing, tyres transported to warehouse located at port qasim. Three
warehouse located at port qasim. For further delieveries according to orders with a proper
documentation.

 QUALITY ASSURANCE:

This department ensure that an organistion should follow ISO standards. They assuring quality of tyres,
claim tyres issues resolved by QA, if manufacturing defect is found then tyre should be replaced.

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 HEALTH SAFETY ENVIRONMENT:

This department monitoring the worker health and safety during operation.Make sure that no fatality
during operation. Providing PPEs to worker to work safely. Monitoring fire safety .They providing the
well maintained fire safety equipment, alarm installed in every department and fire extinguisher more
than 800. 27 high pressure hydrant system installed for firefighting. Lectures conducted for workers to
prepare a team for firefighting.

 QUALITY CONTROL:

Quality of product is the most important factor for an organization success. Quality is basically a
customer satisfaction. The product should meet the requirement that customer wants. Tyre is a major
component of any vehicle, to maintain a good quality of tyre is to save a customer life. The general tyre
is equipped with latest technology for checking tyre quality. The quality of tyre is inspected after curing
by; visual inspection, high speed test, endurance test, X-Ray machine, tyre uniformity test. The
parameters labeled on tyre is either meeting the standard or not. This is the physical testing of tyre.

 MATERIAL TESTING LAB:

In material testing lab, testing of raw material according to standards is carried out by different
apparatus, raw material they import should meet the standards, the apparatus used in material testing
lab are; Surface area analyzer, universal tensile tester, plasticity meter, distillation unit, oil extraction
assembly, water testing, oil absorption meter, mixing grader, iodine number testing, sieve shaker,
sabolt viscometer, melting point tester, fabric twist counter, fabric shrinkage and abrasion tester.

Moving disk rheometer are installed to check viscosity of compound for curing process.

 PRODUCTION PLANNING AND CONTROL:

This department planning a schedule for production, the sales and marketing department contact to
PPC, this department first check feasibility of raw material stock, and make a production plan,
monitoring the production on daily basis to achieve the target on time.

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 PRODUCT INDUSTRIALIZATION:

This department providing specifications, that in what way and the sequence of tyre components are
assembled. This department designed a tyre and mold, and labeled a tyre like; tyre size, rim diameter,
speed range, load range, ply rating, air pressure, product name, tyre type and company name & logo.
Manufacturing of die and mold is also carried out by this department.

 COMPOUNDING:

Compounding, a term that has evolved within the tire and rubber industry, is the materials science of
modifying a rubber or elastomer or a blend of polymers and other materials to optimize properties to
meet a given requirement.

The ingredients available to the scientist for formulating a rubber compound are; natural rubber,
synthetic rubber, Carbon black, clay, silica, antioxidants, antiozonants, waxes, vulcanizing agent Sulfur,
accelerators, activators and oils. Scientist use the unit of measure of "parts per hundred" (PHR) for their
formulation. This is a unit of weight for the relationship between the elastomer system and the other
systems.

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FINDINGS:
General tyre company is equipped with latest technology.

Raw material ware house is well maintained and no electric supply in warehouse which lowers the risk
of catching fire.

Firefighting system is well maintained, fire extinguisher and hydrant available in every department for
firefighting.

The conveyer system in curing department is very efficient.

SCADA system was installed in curing department to control temperature and pressure of curing press
machine.

Cameras were fitted in plant to save labor cost.

Safety wires were installed to shut off machinery in emergency situation.

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SUGGESTION:
One ply cutter machine is obsolete in stock preparation area, it should be replaced with new machine .

Lubrication of bias green tyre is manually carried out, they must approach to automatic lubrication
equipment for bias green tyre.

Advanced machinery should be use to assembling the components of truck and tractor tyre.

Scrap material kept in manufacturing area since one month, it should be transported to scrap storage
area.

Calendared fabric (ply) rolls are kept in orderless way it should be kept in proper way to maintain good
housekeeping.

Apparatus for surface area analyser in material testing lab is obsolete, it must be replaced with new
apparatus.

A smoking area near the bias tyre building area, it is not the right place for smoking, become hazardous
to plant.

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CONCLUSION:

As you can see the contents of this report that how raw materials are tested in material testing lab and
then mixed in a mixer to form a rubber compound for different components manufacturing for tyre,
tread and sidewall from extrusion, ply reinforcing material from 4 roll calender, how ply stock prepared
by cutting, making band of ply, bead building, steel belt manufacturing for radial tyres, and all these
parts are assembled in green tyre building area, lubrication of green tyre takes place, and finally curing
of tyre carried out to give tyre a finish shape, physical testing of tyre is being done by QC and
transported to finish goods ware house for packing ready for assembling in vehicles. In this way a tyre is
manufactured.

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