ORIENTAL INSTITUTE OF SCIENCE AND TECHNOLOGY (Bhopal)

Project Report submitted in partial fulfillment of the requirements for the

Training programme in production of bias and radial tyres in J K TYRE plant (banmore) by Akshay sharma

ACKNOWLEDGEMENT
I owe a great many thanks to a great many people who helped and supported me during this project.My deepest thanks to MR. T D NARVEKAR SIR the Guide of the project for guiding and correcting various documents of mine with attention and care. He has taken pain to go through the project and make necessary correction asand when needed. My deep sense of gratitude to J.K.TYRE supportand guidance. Thanks and appreciation to the helpful people at J.K.TYRE BANMORE, for their support.I would also thank my Institution and my faculty members without whom this project would have been a distant reality. I also extend my heartfelt thanks to my family and well wishers.

ORIENTAL INSTITUTE OF SCIENCE AND TECHNOLOGY (Bhopal)

CERTIFICATE
This is to certify that Akshay sharma student of Bachelor of Engineering (AUTOMOBILE ENGINEERING) submitted his project report file of TYRE MANUFACTURING IN J.K TYRE PLANT BANMORE for the partial fulfillment of the requirement of Bachelor of Engineering in mechanical engineering under my guidance. I wish him success in the future.

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INDEX

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

About Manufacturing unit DIP unit 4 Roll DUAL Extruder Mixing procedure Specification of DIP sol Power plant Tyre types Summery

JK TYRE

They Run More to Earn More JK Tyre is the leader in the Truck/Bus segment. With its customer oriented state-of-the-art product offerings, it has outpaced the industry growth rate and surged ahead of its competitors. Our tyres are specifically designed in accordance to the different loading and application requirements of our valued customers. The "Unique SEV System" in its Truck/Bus and LCV range of tyres ensures a highly efficient and uniform tyre curve - the best option for a wide variation of road and load conditions under which trucks operate in our country. The SEV System offers the outstanding advantages of Super Mileage, Greater Strength and Higher Retreadability.

DIP UNIT

BENBURY UNIT

4 ROLL CALENDER

BIAS CUTTER LET OFF

SPLICING TABLE

2 ROLL CALENDER (squezee compound is applied on ply)

STICHER ROLL (bands are made by applying plies)

TREAD PAN (bands,beeds,breaker,chafer,trede and side wall are applied and now tyre is ready to mould)

MOULDING BOX (tyre is put in in moulding box around the bladder where moulding take place with steam and grooves are made as directed by moulder)

LET OFF STAND

LET OFF ACCUMULATOR

TENSION STAND 1

DIP TANK (D-5 solution)

1st DRYING ZONE (steam heating at 125C)

2nd DRYING ZONE (steam heating at 145C)

TENSION STAND 2

HEAT SET ZONE (oil heating at 208C)

TENSION STAND 3

NORMALIZING ZONE (oil heating at 211C)

WIND UP ACCUMULATOR

WIND UP STAND...

LET OFF STATION

JOINT PRESS

LET OFF ACCUMULATOR

4 ROLL CALENDER (wire is sorrounded by compound (B-127 for truck radial and B-460 for car radial and so on...)came from benbury unit which is a mixure of natural rubber,chemical and carbon.tempreture of roller is controlled by temp control unit.)

COOLING DRUM (temp of fabric is maintained at nearly 40C)

WIND UP ACCUMULATOR

WIND UP STAND

R&C-2 (CRECKER MILL) (cap compound)

R&C-1(CRECKER MILL) (base compound)

WARM UP MILL

FEED MILL

FEED MILL

10 EXTRUDER

8.5 EXTRUDER

SUB BASE CONVEYOR

PULL OUT CONVEYOR (cushion compound is applied)

SHRINKAGE CONVEYOR

WEIGHING CONVEYOR

CODE MAKER CONVEYOR

INCLINED CONVEYOR

COOLING CONVEYORS

DECLINE CONVEYOR

TABLE CONVEYOR

SKIVER CONVEYOR

BOOKING CONVEYOR (trede or side wall are taken and discharged to trede pan)

MD-2 (MASTER SOLUTION)

Take code 420 from condensate water storage tank. Start chiller and TCV Start stirrer Bring down the temp of code 420 to 22-23C Add code 395 & dissolve Add code 426 7 dissolve Add code 427 Keep stirrer on Inform lab imidietly about date shift and time of mixing

D-5
Take code 39 into final batch tank Rinse each drum with 5 litre of 420 Transfer code MD-2 into final batch tank Add code 420 in final batch tank Add code 129 Stirr for 5mins in each 30 mins

MIXING INSTRUCTION Water temp at the time of starting master solution =23 max Master solution (MD-2) temp (during reaction) =23 +/-2C Final solution D-5 storage temp =23+/-5C

SPECIAL INSTRUCTION Storage final dip solution =23+/-5C Age limit for dip unit=min 6 hr/max 72 hr.

MD-2
INGREDIENT CODE 420 395 426 427 TOTAL ELIOKEM lvp106 1103.00 1.40 49.61 73.14 1227.15 OMNOVA JUBILANT ORGANOSYS 1103.00 1.40 49.61 73.14 1227.15 HYUNDAI KORIA 1003.00 1.27 45.10 66.49 1115.86 1023.00 1.29 46.00 67.80 1138.09

D-5
39 420 MD-2 179 1100.00 471 1227.15 50 1020 437 1138.09 50 1100 471 1227.15 50 1000 428 1115.86 50

TOLERENCE SPECIFICATION
CODE 426 395 427 QUANTITY +/- 400gm +/- 20gm +/- 100gm

 Nurawat river Ventury clarifllacculator(bleeching powder allum and electrolyte dozing) reservoir feed pump house pressure filter dm plant or water for softning or to effluent treatment plant................. DM PLANTBOILER Activated carbon filter (chlorine is removed)=softner or cationic unit Cationic unit(hcl bed is present ph is regulated to 3-4) degasser (from nozzle arrengement co2 & o2 are removed) anionic unit(naoh resin is present ph is regulated to 7-8) mixed bed unit(silic is removed ph=6.5-7) storage tank pump deaerator(o2 is removed by same nozzle mechanism) feed pump ecconomiser steam drum(300-350) mud drum or desuperheater superheater distributing header

JET XTRA

Truck Type Vehicle Type Position Size Load Features

Truck Bias 10 WHEELER TRUCK/TANKER DUMMY 10.00-20 16 PR Heavy Load

High tread depth with wider center rib Most optimum groove angles with a step Most optimum footprint pressure distribution Tough nylon casing

Benefits

Premium mileage Extra tread rubber with increasing wear Smooth and even wear High reliability

JET ONE

Truck Type Vehicle Type Position Size Load Features

Truck Bias 10 WHEELER TRUCK/TANKER DUMMY 10.00-20 16 PR Medium- Normal Load

High NSD of 25 mm Connecting reinforcement at the shoulder Computer designed twin lugs Most optimum footprint pressure distribution

Benefits

Ultimate mileage Less flexing and lesser heat development Very strong shoulders and better contact Smooth and even wear

JET ONE

Truck Type Vehicle Type Position Size Load Features

Truck Bias TRACTOR-TRAILER DRIVE 10.00-20 16 PR Medium- Normal Load

High NSD of 25 mm Connecting reinforcement at the shoulder Computer designed twin lugs Most optimum footprint pressure distribution

Benefits

Ultimate mileage Less flexing and lesser heat development Very strong shoulders and better contact Smooth and even wear

JET XTRA

Truck Type Vehicle Type Position Size Load Features

Truck Bias TRACTOR-TRAILER DRIVE 10.00-20 16 PR Heavy Load

High tread depth with wider center rib Most optimum groove angles with a step Most optimum footprint pressure distribution Tough nylon casing

Benefits

Premium mileage Extra tread rubber with increasing wear Smooth and even wear High reliability

JET ONE

Truck Type Vehicle Type Position Size Load Features

Truck Bias TRACTOR-TRAILER DUMMY 10.00-20 16 PR Medium- Normal Load

High NSD of 25 mm Connecting reinforcement at the shoulder Computer designed twin lugs Most optimum footprint pressure distribution

Benefits

Ultimate mileage Less flexing and lesser heat development Very strong shoulders and better contact Smooth and even wear

JET ONE

Truck Type Vehicle Type Position Size Load Features

Truck Bias 10 WHEELER TRUCK/TANKER DRIVE 10.00-20 16 PR Medium- Normal Load

High NSD of 25 mm Connecting reinforcement at the shoulder Computer designed twin lugs Most optimum footprint pressure distribution

Benefits

Ultimate mileage Less flexing and lesser heat development Very strong shoulders and better contact Smooth and even wear

JET ONE

Truck Type Vehicle Type Position Size Load Features

Truck Bias 6 WHEELER TRUCK/TANKER DRIVE 10.00-20 16 PR Medium- Normal Load

High NSD of 25 mm Connecting reinforcement at the shoulder Computer designed twin lugs Most optimum footprint pressure distribution

Benefits

Ultimate mileage Less flexing and lesser heat development Very strong shoulders and better contact Smooth and even wear

JET R PLUS

Truck Type Vehicle Type Position Size Load Features

Truck Bias 6 WHEELER TRUCK/TANKER FRONT 10.00-20 16 PR Heavy Load

Super high NSD Unique rib geometry with extra stiff tread region in a sinusoidal pattern Smooth like a thumb buttress design

Benefits

Ultimate mileage Less flexing of ribs leading to lesser heat development with smoth wear. Smooth casing that allows multiple retread

JET XTRA

Truck Type Vehicle Type Position Size Load Features

Truck Bias TRACTOR-TRAILER DUMMY 10.00-20 16 PR Heavy Load

High tread depth with wider center rib Most optimum groove angles with a step Most optimum footprint pressure distribution Tough nylon casing

Benefits

Premium mileage Extra tread rubber with increasing wear Smooth and even wear High reliability

JET TRAK

Truck Type Vehicle Type Position Size Load Features

Truck Bias 10 WHEELER TRUCK/TANKER DUMMY 10.00-20 16 PR Heavy Load

Broad pyramid type lugs Strong rubber matrix Strong and clean casing

Benefits

Excellent support while carrying load High mileage Good casing resale value

JET-TRAK 39 DX

Truck Type Vehicle Type Position Size Load Features

Truck Bias TRACTOR-TRAILER DRIVE 10.00-20 18 PR Super Heavy

Super strong nylon casing Super strong beads Dual tread compound with unique lug geometry Customer friendly warranty policy

Benefits

Excellent load carrying capability and casing reliability Excellent anchorage Cooler running Assurance

JET KING-10

Truck Type Vehicle Type Position Size Load Features

Truck Bias TRACTOR-TRAILER DUMMY 10.00-20 16 PR Medium- Normal Load

Wide center rib Superior nylon casing Strong pyramid lug design

Benefits

Very good mileage Very good retreads Excellent support resulting into very good overall performance

JET R MILES

Truck Type Vehicle Type Position Size Load Features

Truck Bias TRACTOR-TRAILER FRONT 10.00-20 16 PR Medium- Normal Load

Super high NSD Unique rib geometry with extra stiff tread region in a sinusoidal pattern Smooth like a thumb buttress design

Benefits

Ultimate mileage Less flexing of ribs leading to lesser heat development with smoth wear. Smooth casing that allows multiple retread

T-LUG

Truck Type Vehicle Type Position Size Load Features

Truck Bias 10 WHEELER TRUCK/TANKER DUMMY 10.00-20 16 PR Medium- Normal Load

Optimized tread design and depth Strong nylong casing and less fatigue. Unique casing compound

Benefits

Lower heat buildups on high-speed applications such as tankers,buses, trailers etc. Multiple retreads Better casing reliability

JET-TRAK DX

Truck Type Vehicle Type Position Size Load Features

Truck Bias 10 WHEELER TRUCK/TANKER DUMMY 10.00-20 18 PR Super Heavy

Supper strong nylon casing Super strong beads Pyramid lugs design

Benefits

Good load carrying capability and reliability Better anchorage, high beads area reliability Free from lug chipping & tearing, better part worn appearance

STAR LUG

Truck Type Vehicle Type Position Size Load Features

Truck Bias TRACTOR-TRAILER DRIVE 10.00-20 16 PR Heavy Load

Wide center rib, big & broad lugs Strong nylon casing Strong bead construction

Benefits

Good mileage High casing reliability Good bead area performance

JET-TRAK DX

Truck Type Vehicle Type Position Size Load Features

Truck Bias 6 WHEELER TRUCK/TANKER DRIVE 10.00-20 18 PR Super Heavy

Supper strong nylon casing Super strong beads Pyramid lugs design

Benefits

Good load carrying capability and reliability Better anchorage, high beads area reliability Free from lug chipping & tearing, better part worn appearance

12.4-28 SONA Vehicle Type Vehicle Make Vehicle Model Tyre Type Product Name Features

Farm EICHER EICHER 241 STAR Rear Tyre 12.4-28 SONA

Unique MUD-SHAKER between lugs dislodges caked mud from the tyre surface and improves field performance. 20 lugs (in 12.4 / 28 size) with overlapping centre provide better stability, fuel efficiency and road grip. Special lug angle for excellent traction.

Benefits

Application for farming and haulage on road. Higher skid depth, which enhances initial tyre life. Strong Casing Higher retreadability. High self cleaning property.

6.00-16 SONA Vehicle Type Vehicle Make Vehicle Model Tyre Type Product Name Features
Special 3 rib tread design which performs very well in muddy and loosely cultivated soil & gives improved floatation and easy steering.

Farm EICHER EICHER 241 STAR Front Tyre 6.00-16 SONA

Benefits
Wider ribs provide more mileage during road haulage. Slotted shoulder ribs give excellent traction. Wide tread ensures resistance to side slippage on unlevelled field conditions. Strong casing. Better retreadability.

VEM AS E3 Vehicle Type OTR Type Tyre Size Brand Name Features

Off the Road LOADER 14.00-25 24 PR VEM AS E3

Directional pattern with good overlap at center. Tapered lugs at successfully tested lug angles & open space at shoulder. Heavy nylon carcass construction. Exclusively simulated bead construction for pressure distribution.

Benefits

Excellent road leveling, clearing and removal properties. Self cleaning and excellent directional stability as it digs through the terrains. Along with the distinctive tread pattern , tough nylon casing gives good resistance to buckling , tearing & cracking.