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    Detailed Project Report on tyre retreading

    Detailed Project Report on tyre retreading
    Detailed Project Report on tyre retreading
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      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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