MOTORCYCLE TYRE MANUFACTURING
[CODE NO. 2011]
Motorcycle tyres are the only contact between the motorcycle vehicle and the ground. The contact surface of a motorcycle tyre is generally very small compared to a tyre used for larger vehicles such as cars, lorries and trucks. Hence, it is particularly vital for the motorcycle tyre to have good traction performance, good rolling and abrasion resistance and high wear resistance. It is impossible to have all the preceding ideal physical properties in a rubber compound. However, with the right combination of rubber components and suitable amounts of additives, a good compromise between each of the desired physical properties can be achieved.
Conventional motorcycle tyres are generally manufactured from synthetic rubber such as styrene-butadiene rubber (SBR) and polybutadiene rubber (PBR), which are derived from fossil fuels such as crude oil. The rubber compound is usually reinforced with carbon black and further comprises fatty acid additives (cure aid) and vulcanization aids. Synthetic rubber produced in this manner exhibits high abrasion resistance, good wet grip and low rolling resistance.
Motorcycle tires are critical to rider safety and bike performance. The casual rider probably cares little and thinks even less about how tire companies turn raw materials into high-performance tires. During a recent press introduction at Bridgestone’s Japanese home base, Motorcycle-USA got an eyewitness account of the tire-making process during a tour of the company’s Nasu Plant.
The real beginning of the tire-making process is in the company’s engineering labs where designers use the latest technology to develop new compounds and tread patterns. After rigorous testing at the company’s nearby Bridgestone Proving Grounds, prototypes go into production at the Nasu facility. The 49-year-old plant, located in the Tochigi prefecture, is the sole motorcycle tire production plant for Bridgestone (with the company retaining 190 plants worldwide, 49 of them producing tires).
Nasu gets raw materials in the front door and delivers finished tires out the back, with Bridgestone tire reps claiming 6300 motorcycle tires produced daily. Bridgestone keeps a tight rein on its process.
Today, one cannot imagine a world without automobiles even though India has a large network of railway lines, considering the vastnes of the country and the thrust given for balanced development, road transport would have decisine role to play in the coming years. Vehicle would become more and more part of not only the commercial like but even the personal like.
The Indian tyre and tube industry has been continuously in the process of up gradation of product quality to satisfy the requirements of Indian automotive manufactures, users of automobiles and the road conditions prevailing in the country. Various developments have taken place in design of tyres especially for passenger cars, light trucks, trucks and buses involving tyre construction, strength, sizes, tread design, rubber compounding etc. The pace of development of tyres in the country has also been hastened by the requirements of new passenger car and light truck manufactures and for export, which require higher accuracies, better uniformity longer life etc.
COST ESTIMATION
Plant Capacity 3333.33 Tyres/day
Land & Building (14000 Sq.Mtr) Rs.7.55 Cr
Plant & Machinery Rs.100.00 Cr
W.C. for 3 Months Rs. 26.00 Cr
Total Capital Investment Rs. 135.00 Cr
Rate of Return 20%
Break Even Point 68%
INTRODUCTION
BUREAU OF INDIAN STANDARDS
LABORATORY TESTING OF TIRE COMPOUND
COMPONENTS OF TYRES
DETAILS OF INGREDIENT USED IN TYRE MANUFACTURE
RAW MATERIALS
RAW MATERIALS AND COMPONENTS FOR THREE WHEELER TYRES
RAW MATERIALS TEST FOR THREE WHEELER TYRES
DETAILS OF COMPONENTS IN TYRE BUILDING
OVERVIEW OF TYRE INDUSTRY IN INDIA
MARKET SURVEY
OVERVIEW OF TYRE INDUSTRY IN SRI LANKA
GLOBAL MARKET POSITION OF PNEUMATIC TYRES
TECHNICAL KNOW - HOW
FOREIGN COLLABORATIONS
TYRE SIZES FOR THREE WHEELERS
FORMULATION OF THREE WHEELER TYRE
MANUFACTURING PROCESS OF THREE WHEELER TYRES
PROCESS IN DETAILS
PROCESS FLOW DIAGRAM
MACHINERY DESCRIPTION AND PROCESS FOR THREE WHEELER TYRES
WATER CONSUMPTION, WASTE WATER GENERATION AND CHARACTERIZATION IN TYRE MANUFACTURING
FORMULATION OF TYRES COMPOUNDS
RECIPIES FOR AUTOMOBILE BEAD WIRE
SUPPLIERS OF PLANT AND EQUIPMENTS (GLOBAL)
SUPPLIERS OF PLANT AND EQUIPMENTS
SUPPLIERS OF RAW MATERIALS
TECHNOLOGY SUPPLIERS OF TYRE MAKING
SPECIFICATION OF TYRE MANUFACTURING MACHINERIES
DETAILS OF MACHINERY
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
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