TYRE RETREADING
[CODE NO.3954]
Tyre is made up of natural rubber or synthetic rubber .natural rubber is present as milky liquid or latex in the bark of rubber tree, HEVEA BRASILIENSIS. Natural rubber combines with carbon, oil, sulphur and the chemicals at a temperature of 100-140 °C and under goes a number of stages of processes. Synthetic rubber is any vulcanisable man made rubber like polymer.
Retreading is a process that provides tyres with a second life by giving a new tread to a worn tyre. Retreading is the generic term for tyre reconditioning which extends the useful life of a worn tyre for its original purpose by the addition of new material. In the majority of cases the tread rubber is the only part of a tyre to wear away. The structure of the tyre remains intact. As the tyre construction has been produced to be capable of more than one life, to use this potential by replacing the worn tread makes sound environmental and economic sense. Whilst a car tyre is retreaded only once, OTR tyres are often retreaded two or three times and aircraft tyres many, many times. It is essential that casings are carefully inspected before retreading, to ensure that there is no casing damage that could reduce the safety and performance of the retreaded tyre. When the casing has been approved, the worn tread is buffed away and a new tread is bonded to the tyre casing. There are two different process techniques (hot and cold), but both are similar to the manufacture of a new tyre, bonding a new tread through the application of heat and pressure for a predetermined time. Retreaded tyres are manufactured to high standards, using highly sophisticated machinery. There is no doubt that professionally-made retreads are as safe as new tyres. With lower production costs than new tyres, retreads have a purchase price that is normally between 25 % and 50% lower than comparable new tyres.
Tyre Retreading is a new technology, where the old tyres are made serviceable by removing worn out and damaged treads and replacing it with new treads. New treads are available in the market in form of rolls and inbrief, in can be put on old tyre and cured with the help of steam. Similar to the new tyres, the treated tyres can be very well used on all vehicles, irrespective of light or heavy vehicles. With a safe and new technology, which is being adopted now-a-days, it will be more easy and economical to produce tyres.
Retreading of damaged tyre is done by conventional hot matrix curing in most cases. But recently a new technology has been developed called "Pre-cured Tread Rubber Retreading Process" which is commonly known as "Cold Process Retreading". In this process, the Pre-cured Tread Rubber already has a tread pattern on it eliminating the need for a tread matrix at vulcanizing stage. Tread Rubber is pre-cured along with other raw materials and manufactured in the factory under controlled conditions and given a well-researched pattern ensuring that the transporter gets a reliable perfectly finish product. Retreading Tyre by pre-cured method gives 50% more mileage than the tyre retreaded by conventional process.
Tires that are repaired and retreaded with the help of suitable tread compounds to receive suitable mileage are known as retread tires. Tires gradually wear down due to road travel. The part of tire which wears down is known as tire tread. However, the casing of the tire does not get affected to a great extent while travelling on roads. The tread of the tire can be replaced and this replacement allows the vehicle to run with full potential. This provides economic advantage to the vehicle’s owner and also ensures that the tires are not discarded impulsively.
As a matter of fact, significant cost reduction can be attained using retread tires as the cost of a remolded tire is 30%-50% lower than that of a new tire. The retread tire market is anticipated to witness significant transitions in terms of demand. The global retread tire market is anticipated to witness increasing investments from tire manufacturers. On the other hand, fluctuations in raw material prices may act as a hampering factor and cause fluctuating market growth. Since, oil is a key raw material used for tire retreading, any fluctuations in oil prices are capable of causing fluctuations in retread tire market growth.
The functions of a tire are pretty simple – provide a smooth grip, maintain contact between the road and the vehicle, and most of all, not let the vehicle “slip” and cause accidents. It can often be noticed that new tires perform these tasks with absolutely no difficulty, however, as the vehicle gets older, the tires begin to lose their efficiency. This is because of a common problem known as wearing out of tires.
Due to excessive friction produced when the tires are in a movement against the road, components of the tire, known as threads, wear out and this causes a loss in the grip for the vehicle. Luckily, you do not have to dig a hole in your wallet every time the threads of your tire wear out. Instead, you can do something popularly known as tire retreading.
As the tyre starts to wear off, the treads on the tyres starts getting shallow. The tread pattern is essential to make the vehicle safe on wet and grimy roads. Keep these things in mind to increase tyre life.
COST ESTIMATION
Plant Capacity 18 Pcs/Day
Land & Building (500 sq.mt.) Rs. 29 Lac
Plant & Machinery Rs. 1.45 Lac
Working Capital for 1 Month Rs. 17 Lac
Total Capital Investment Rs. 53 Lac
Rate of Return 53%
Break Even Point 48%
INTRODUCTION
SIZES OF OTR TYRES RETREATED (RADIAL AND CROSS PLY):
DUMP TRUCKS:
LOADERS & GRADERS:
TYPES OF TYRES TO BE
PROJECT LOCATION-CHENNAI
MAP OF DISTRICT
CLIMATE
TRANSPORTATION
TRANSPORTATION WITHIN THE CITY
TYPES OF TYRE RETREADING
COLD RETREADING
POINTS TO NOTE:
HOT RETREADING
ARGUMENTS IN FAVOUR OF HOT RETREADING:
POINTS TO NOTE:
CONSTRUCTION OF TYRES
TYRES – THEIR CONSTRUCTION & MAINTENANCE
TIRE COMPONENTS
BASIC COMPONENTS /TYRE CONSTRUCTION
TREAD
SIDEWALL
PLIES
CARCASS OR CORD BODY
BEAD
BELTS
LINER
BREAKERS
STEEL BREAKERS
A SUBSET OF TYRE CONSTRUCTION: TYRE TREADS.
TREAD PATTERNS
TYRE DIMENSIONS
ASPECT RATIO
OVERALL DIAMETER
OVERALL WIDTH
SECTION WIDTH
TREAD WIDTH
TREAD DEPTH
SECTION HEIGHT
RIM WIDTH
NOMINAL RIM DIAMETER
STATIC LOADED RADIUS
LOADED WIDTH
MINIMUM DUAL SPACING
REVOLUTIONS PER MILE (RPM)
LOAD RATING
INFLATION PRESSURE
SPEED RATING
CONSTRUCTION
PR (PLY RATING)
TYRE USE CLASSIFICATIONS
PASSENGER AND LIGHT TRUCK
RUN-FLAT TYRE
HEAVY DUTY TRUCK TYRES
OFF-THE-ROAD (OTR)
AGRICULTURAL
RACING
INDUSTRIAL
BICYCLE
AIRCRAFT
MOTORCYCLE
BIAS/CROSSPLY & RADIAL TYPES OF TYRES
RADIAL TYRES
BIAS /CROSS PLY TYRES
THE REASONS FOR THIS LIMITED USE OF BIAS TYRES ARE:
TYRE RETREADING COMPOUND:
IN RETREADING UNIT:
HYDRAULIC HOIST:
HYDRAULIC JACK:
PRODUCT & ITS APPLICATION
B.I.S. OR OTHER INTERNATIONAL STANDARDS OF SPECIFICATION
PROPERTIES
MANUFACTURING PROCESS
RETREADING PROCESS
THERE ARE SIX KEY STAGES TO THE RETREADING PROCESS:
INITIAL INSPECTION
BUFFING
PREPARATION
BUILDING
CURING
FINAL INSPECTION
LIST OF MACHINERY
RETREAD EQUIPMENT
RETREAD CONSUMABLES
RETREADING TOOLS
REPAIR EQUIPMENT
PROS & CONS OF TIRE RETREADING
PROS OF TIRE RETREADING
CONS OF TYRE RETREADING
MARKET POSITION
TYPES OF RETREADERS
INNOVATION IS KEY TO ADVANCING THE SECTOR
MARANGONI-GRP
MAJOR PLAYERS IN THE SAME MOULD FOR EXPANSION
HANKOOK-TIRE
GLOBAL RETREAD TIRE MARKET: SEGMENTATION
ASIA-PACIFIC CONTINUES TO BE THE LARGEST MARKET
COMPETITIVE LANDSCAPE
PRESENT MANUFACTURERS
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
COMPLETE PLANT SUPPLIERS
SUPPLIERS OF OTHERS PLANT AND MACHINERIES
AIR COMPRESSORS
BOILERS
BUFFING MACHINE
SUPPLIERS OF RAW MATERIALS
TYRE RETREADING MATERIALS & SUPPLIES
MACHINERY PHOTOGRAPHS
TIRE BUFFER
TREAD BUILDER
ELECTRIC CURING CHAMBER
ENVELOPE EXPANDER
CEMENT CHURNER & CYCLONE FILTER
RAIL SYSTEM / MONORAIL
INSPECTION SPREADER
EXPANDABLE RIMS AND HUB
CURING RIMS & BEAD SEAL PLATE
RIMMING STATION
SNAP SEAL
TIRE STAND, TROLLEY AND SKIVING
NAIL HOLE DETECTOR
TREAD PREPARATION TABLE WITH ROTARY CUTTER
RETREAD CONSUMABLES
CURING BAG
ENVELOPE
RETREADING TOOLS
REPAIR EQUIPMENT
EXTRUDER GUN TIRE SPOTTER
PRODUCT PHOTOGRAPHS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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