Tyre requirement ? CLICK Here to send enquiry now !

Send Email Send Email  |  Send SMS Send SMS

Salsons Impex Pvt. Ltd.

HomeAbout UsProductsManufacturingTyre KnowledgeContact Us

Salsons Impex Pvt. Ltd.Salsons Impex Pvt. Ltd.Salsons Impex Pvt. Ltd.

Home » Manufacturing

Product Range

Radial Truck Tyres

Bias LCV & Truck Tyres

Radial Car & Light Commercial Vehicle Tyres

Agricultural Tyres

Off The Road Tyres

Three Wheeler Tyres

Motorcycle Tyres

Industrial Tyre

Manufacturing

Plant Setup

State-of-the-art Manufacturing Machinery

Mixing Mill - (Used in Process of Compounding & Mixing)
Our modern mixing mill consists of twin counter-rotating rolls, one serrated, that provide additional mechanical working to the rubber, and produce a thick rubber sheet. This mill is used to mix a batch of rubber compound in the manufacturing process of ‘Compounding & Mixing’ after all the required ingredients are brought together through the operation of compounding.

Mixing Mill

Extruder Machine - (Used in Process of Component Preparation)
The extruder machine consists of a screw and barrel, screw drive, heaters and a die. The extruder applies two conditions to the compound – heat and pressure. Extrusion is also used for sidewall profiles and inner liners.

Calendar - (Used in Process of Component Preparation)
The calender is a set of multiple large-diameter rolls that squeeze rubber compound into a thin sheet. Calenders are used to produce body plies and belts.

Tyre Building Machine - (Used in Process of Tyre Building)
Typical TBM operations include the first stage operation, where inner liner, body plies, and sidewalls are wrapped around the drum, the beads are placed, and the assembly turned-up over the bead. In the second stage operation the belt package and tread are applied and the green tyre is inflated and shaped. The final product of the TBM process is called a green tyre.

Manual & Hydraulic Press - (Used in Process of Curing)
Mechanical presses hold the mold closed via toggle linkages, while hydraulic presses use hydraulic oil as the prime mover for machine motion, and locks the mold with a breech-lock mechanism. Hydraulic presses have emerged as more cost effective.

During and post manufacturing, there are several sophisticated tests conducted by our Quality Assurance & Quality Control departments such as tyre balance & uniformity measurements as well as endurance, plunger and X-ray tests, to ensure high quality tyres to our esteemed customers.

Tyre Manufacturing Process
A tyre is an assembly of numerous components that are built up on a drum and then cured in a press under heat and pressure. Heat facilitates a polymerization reaction that cross-links rubber monomers to create long elastic molecules. These polymers create the elastic quality that permits the tyre to be compressed in the area where the tyre contacts the road surface and spring back to its original shape under high frequency cycles.

Tyre Manufacturing Process

Click Here to Enlarge View  Click here to enlarge view

Raw materials
The main raw materials of a tyre are natural rubber, synthetic rubber, carbon black and oil. The share of rubber compounds in the total weight of a tyre is more than 80%. The rest consists of various kinds of reinforcing materials.

Approximately half of the rubber is natural rubber from a rubber tree. Rubber trees are grown in the tropics, in countries like Malaysia, India and Indonesia. Most of the synthetic, oil-based rubbers come from European manufacturers.

Approximately one-third of the compound consists of filler substances. The most important of these is carbon black which makes the tyres black in colour. Important filler is oil which is used as a plasticiser in the compound. Furthermore, hardening or vulcanising agents, various booster chemicals and protective agents are used in the rubber compounds.

Our manufacturing facility is divided into five main departments that perform the following respective functions –
Compounding & Mixing
In the mixing stage, the raw materials are mixed together and heated at a temperature of approximately 120 degrees Celsius.

The consistency of the rubber compounds used in different parts of a tyre varies, and the consistency also varies depending on the intended use and model of the tyre. The rubber compound used in a summer tyre for a passenger car is different from that of a winter tyre, and there are very few similarities between the rubber compound of a bicycle tyre and that of a forestry tyre.  

Developing and adjusting the recipes is an important part of the tyre development work.

Component manufacturing
The compounds are used in rubberising various components, such as steel cord, Bead wire, Tread, Side wall etc. A tyre is manufactured from 10–30 different components.

Steel cord
Steel wire cord quality is based on tensile strength, elongation, and stiffness. It is manufactured from steel rod with high carbon content; and while the steel wires used have different configurations, all are brass-coated strands twisted together into cords. If the wire is used in a multi-ply tire rather than a belted tire, the fatigue performance will be important. If used in belted tires, then stiffness is of primary concern. Since the steel wire is brass coated, storage conditions are important to maintain the steel wire to rubber bonding properties. Therefore, the steel wires are also kept in a temperature and humidity controlled room once they arrive at the factory.

Steel Cord

Belt and Ply Calendering
To produce fabric or steel belts, the fabric or steel cord must go through a calendering process—an operation in which the rubber compound is pressed on and into cords. Because the bonding of fabric to rubber or steel to rubber is critical to performance, the calendering process is an important step.

The calender is a heavy-duty machine equipped with three or more chrome-plated steel rolls which revolve in opposite directions. The roller temperature is controlled via steam and water. In this process, the rubber compound is applied to the cords.

First, a pre-set number of fabric or steel cords under proper tension are continuously pressed through two steel rollers, and rubber compound is added to the opening area between the rollers. Then the rubber compound is pressed into, on top of and on the bottom of the fabric or steel cords. A continuous sheet of cord-rubber composite goes through several more rollers to ensure good penetration and bonding between the rubber and cords. Quality is measured by the thickness of the sheet, spacing between cords, the number of cords and the penetration of rubber into the composite sheet. The composite sheet is then cut into appropriate sizes, shapes, and angles depending on the desired contour of the tire. 

Inner liner Calendering
The inner liner is just what it sounds like -- the inner-most layer of the tire. Its main functions are to retain the compressed air inside the tire and maintain tire pressure. Due to its low air permeability, butyl rubber—or halogenated butyl rubber compound—is the primary rubber compound used. Because this is a thin layer, it is also produced using the calender. The gauge control and no-defect surface finish are critical to retaining air pressure. Inner liner calendering is also a continuous operation. The proper length of inner liner sheet is pre-cut to be ready for the tire building process. 

Bead Component Preparation
The bead component of the tire is a non-extensible composite loop that anchors the body plies and locks the tire onto the wheel assembly so that it will not slip or rock the rim. The tire bead component includes the steel wire loop, apex or bead filler; the chafer, which protects the wire bead components; the chipper, which protects the lower sidewall; and the flipper, which helps hold the bead in place. The bead wire loop is made from a continuous steel wire covered by rubber and wound around with several continuous loops. The bead filler is made from a very hard rubber compound, which is extruded so as to form a wedge. The bead wire loop and bead filler are assembled on a sophisticated machine. The precision of the bead circumference is critical. If too small, tire mounting can be a problem; but if too loose, the tire can come off the rim too easily under loading and cornering conditions. After the circumference is checked, the bead component is ready for the tire building operation.

Bead Component Preparation

Tire Tread and Sidewall Extrusion Operations
Extrusion is one of the most important operations in the tire manufacturing process because it processes most of the rubber compounds produced from the mixing operation and then prepares various components for the ultimate tire building operation. The extruder in a tire manufacturing process is a screw-type system, consisting primarily of an extruder barrel and extruder head. First, the rubber compound is fed into the extruder barrel where it goes through a heating, blending, and pressurizing process. Then, the rubber compound flows to the extruder head where it is shaped under pressure. The modern cold-feed extruder is computer-controlled for accuracy. 

Tire Tread Extrusion
Tire tread, or the portion of the tire that comes in contact with the road, consists of tread itself, tread shoulder, and tread base. Since there are at least three different rubber compounds used in forming this complex tread profile, the extruder system consists of three different extruders sharing an extruder head. Three rubber compounds are extruded simultaneously from different extruders and are then merged into a shared extruder head. The next move is to a die plate where the shape and dimensions are formed, and then through a long cooling line—from 100 to 200 feet long—to further control and stabilize the dimensions. At the end of the line, the tread is cut according to a specific length and weight for the tire being built. 

Tire Tread Extrusion

Tire Sidewall Extrusion
The tire sidewall is extruded in a way similar to the tire tread component; however, its structure and the compound used are quite different from tread. Sometimes the sidewall extrusion process can be more complicated, and four extruders may be needed; for example, when building a tire with white sidewalls or with white lettering on the sidewalls. 

Tyre Building
Most of the components are various kinds of reinforcements. Tyre makers assemble the components into green tyres using assembly machinery.

Tyre Building

When the components have been drawn onto the belt drum of an assembly machine and the frame of a tyre has been set on the bulkheads of the stretching machine, the machine’s loading wheel transfers the unity formed by the surface and the belt onto the frame.

The frame is then pressurised and stretched to fuse with the above-mentioned unity. This is how a green tyre is manufactured.

Vulcanizing
Green tyres are vulcanized in curing presses. The high steam pressure conducted into the curing pad inside the curing press presses the elastic green tyre against the tread pattern and side texts inside the moulds, giving the tyre its final appearance.

Vulcanizing

Final Finish & Inspection
Tire inspection is the last step in the tire manufacturing process—an important step in ensuring quality in both performance and safety. The tire inspection includes:
Each tyre is inspected both visually and by a machine. Attention is paid to any faults and defects with the appearance of the tyre in the visual inspection. The machine measures the pattern as well as radial throw and lateral force variation of the tyre.

When a tyre has been inspected, it will be tested, labelled and transferred to the warehouse for delivery.

Packing
We have a sophisticated process of packing for all categories of our tyres. There is an automatic wrapping machine to wrap the tyre in an efficient and ergonomic way, for the ease of our customers. Protection from sunlight, dust and other foreign materials is ensured throughout each process in our manufacturing facility.

Packing

Quality & Certifications
We follow stringent quality inspection standards to ensure durability and dependability of our products and business relationships. Our modern laboratory equipped with latest equipments assists us in ensuring the high quality products. Various tests are conducted at pre and post production stages to check consistency, physical strength, size accuracy etc. of the tyres. Quality controllers regularly and randomly check various production stages to assure that components are in conformation with International quality standards.

All our tyres are produced in the framework of our Quality Control Policy and under the most stringent guidelines. To facilitate measurable checks, the factory is constantly subject to internal and external quality inspections.

Certificate

Tubes
Tubes are manufactured from high grade butyl rubber with enhanced elasticity for better tube life.

Tubes

Flaps
Flaps are designed and manufactured so as to protect the tyre and tubes for a longer time.

Flaps



Product Range
Radial Truck Tyres   ||  Bias LCV & Truck Tyres   ||  Radial Car & Light Commercial Vehicle Tyres  ||  Agricultural Tyres  ||  Off The Road Tyres
Three Wheeler Tyres  ||   Motorcycle Tyres  ||  Industrial Tyre


Home   |  About Us   |  Manufacturing   |  Tyre Knowledge   |  Contact Us
Member IndiaMART.com© Salsons Impex Pvt. Ltd.. All Rights Reserved (Terms of Use)
Developed and Managed by IndiaMART InterMESH Limited