JK Tyre & Industries is a major Indian tire manufacturer whose sales have doubled in the last 10 years. The document describes JK Tyre's production process, which involves mixing rubber compounds, extruding sidewalls and treads, building tires layer-by-layer on a drum, curing the green tires in presses, inspecting and testing the finished tires, and supporting centralized activities through five service units. The detailed description covers the functions and components of key machines like banbury mixers and curing presses used to manufacture tires from raw materials to the final product.

1. JK TYRE & INDUSTRIES, KANKROLI
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2. ABOUT JK TYRE
JK Tyre & Industries is the flagship company of
JK Organization Group. In the last 10 years the
sales turnover of the company has increased
two-fold and it’s expected to touch Rs. 6550
crore by 2013-14. The company is headed by Dr.
Raghupati Singhania, Vice Chairman &
Managing Director. In 1977 the company set us a
modern Automotive Tyres & Tubes Plant at
Jaykaygram, Kankroli in technical collaboration
with General Tire Co., USA and another plant in
1991 at Banmore near Gwalior in M.P. In 1997
the company has acquired two plants of Vikrant
Tyres Ltd. at Mysore.
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3. COMPANY VISION
J.K. Tyre has installed sophisticated Plant &
Machinery and used state of the Art Technology to
constantly deliver products of high standard to its
customers. It has continuously upgraded Plant &
Machinery in order to stay ahead of its competitors
and has many technological firsts to its credit viz:
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4.  A precisely engineered assembly of rubber,
chemicals, fabric and material designed to
provide traction, cushions road shock and
carry a load under the varying conditions.
 Geometrically: a tyre is torous
 Mechanically : it is a flexible membrane
pressure container.
 Structurally : it is a high performance
composite.
 Chemically : it is a material of long chain
molecular.
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5.  Load carrying capacity
 Transmit driving/breaking torque.
 It should provide flotation
In addition tyre must process:
 High durability strength
 Good appearance
 Low rolling resistance
 Heat resistance
 Riding comfortment
 Low noise level
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6.  Components of tyre :
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7.  TREAD : That portion of tyre that comes into contact with the
road.it is distinguished by the design of grooves and ribs.it
provide traction
 BREAKER : a rubber coated layer of cords that is located
between the plies and the tread it helps bonding between tread and
ply and protect road shock.
 CARCASS : Two to at cross plied nylon fabric reinforced rubber
sheet structure forming the skeleton of the tyre.
 PLY : A rubber coated layer fabric usually nylon connecting cods
that runs at opposite angle of each other.
 SIDE WALL : That portion of a tyre between a tread and the bead
which flexes in service all the tyre related information is written
of this part of tyre rotate the plies from getting damaged from
external cut.
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8.  BEAD ASSEMBLY : It consist of three parts- bead wire
, filler & flipper.
BEAD WIRE – A round hoop of steel wire , wrapped or reinforced
by ply cords , that is shaped to fit the rim.
FILLER – A solid rubber placed over bead in the absence of
filler air entrapped and causes bead separation.
FLIPPER – It covers the bead and filler assembly without any
air gap , it also provide stiffness and modules
gradation to the bead area.
 CHAFER : Rubber coated nylon cross woven fabric. It protects
bead from chafing action of rim.
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9.  BUSINEES UNIT-I
 BUSINESS UNIT-II
 BUSINESS UNIT-III
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10.  BUSINESS UNIT – I :
 Raw material of rubber is mixed in a banbury mixer like
mixing with polymers , oil , carbon.
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11.  The banbury mixer is an internal, intensive, batch mixer
capable of mixing viscous materials in very short time. The
following definitions will enhance understanding of this
product.
 BATCH indicates that machines mix a fixed volume of
material during each mixing cycle.
 There are 4 banburies in the whole plant.
 Banbury 1: Situated in BU1. It is mostly used for final batch
mixing.
 Banbury 2: Situated in BU1. It is mostly used for master batch
mixing.
 Banbury 3: Situated in BU1. It is mostly used for butyl tube
and bladder compound mixing.
 Banbury 4&5: Situated in plant 3. It is mostly used for master
as well as final batch mixing of NR/SR and butyl rubber based
compound.
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12.  FUNCTION:
 Mixing of raw material to form homogenous rubber
compound in sheet form.
 Input material:
Rubber, carbon black, oil & chemicals.
 Output material:
Mixed compound in sheet form.
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13.  MAIN PARTS OF THE BANBURRY MIXER:
 HOPPER ASSEMBLY
Hopper consists of two sub assemblies . Hopper
itself, for loading the raw stock and the compounding
ingredients
 MIXER BODY
A mixing chamber
 Rotor: The place where the actual mixing is taking place.
 Hydraulically operated discharge door: it forms the bottom
of the chamber and allows batch discharging.
 Dust stops: There are four dust stops on each mixer Their
function is to prevent material leaking out of the mixing
chamber around the rotor shafts. Proper lubrication is
necessary for satisfactory operation of dust stops.
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14.  Process:The polymer and master or remill compounds are
Weighed on weighing conveyor for correct weighment and
transferred to charging conveyor to charge into the mixer
through hopper to maintain continuity in operation.
 The carbon blacks are stored in large silos. From the
silos, they are they are transported in to daybins of
blowing air. From daybins, carbon black is directly fed to
the banbury by electronic weighing system. which is
specified by the operator.
PRE MASTER OR MASTER
REMILL
FINAL
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15.  Now further sidewalls and fillers are made from the mixed rubber
in an extruder machine and also treads which is made in an MP-
Extruder machine.
 Also nylon is inserted in between two rubber plies in 4-calendaring
machine , called as three ply rubber.
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16.  BUSINESS UNIT-II:
 In this unit breaker , chafer , flipper are made in bias
cutter machine.
 Also beads are made in bead winding machine.
 Now tyre building is done by overlapping the layer of
3-ply rubber, flipper, chafer, breaker one by one over a
rotating collapsible drum.
 Now bead is attached from the either sides of drum.
 Further side wall and tread is again layered over the
curved surface of the collapsible drum.
 By this tyre building process green tyre is obtained.
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17. BEAD WINDING MACHINE TYRE BUILDING MACHINE
GREEN TYRE
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18. BUSINESS UNIT-III :
JAMMING:
Jamming is done at the tread splice area because there is a chance for spliced area of
the tread to get separated either during curing or during service conditions. Jamming
is done to prevent the separation. Jamming is a mechanical operation where a
pressure is applied using knurled rolls rotating at constant speed. The applied
pressure is 3-5 kg/cm2 for truck tyres and 1-3 kg/ cm2 for light truck and passenger
tyres.
AWLING:
Awling is the complete penetration of an awl through the carcass and inner liner
Awling is designed to remove the air built in to the carcass that is not eliminated
during stitching and building operation. Awling is done manually as well as by
awling needle of the hardened steel on the awling machine.
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19. PAINTING:
Inner painting is mica and naphtha based paint. This prevents bladder sticking to
the inner liner and ensures easy removal of bladder from tyre Outer painting is NR
based paint along with lampblack with naphtha as solvent. It is applied on the side
wall area alone. This ensures good flow of the compound.
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20.  CURING:
Curing is a process where in a green tyre is molded
in to a proper size, shape and vulcanized. This is done
in a curing press under high temperature and pressure.
 TYPES OF TYRE CURING PRESSES:
 Bag-o-matic presses: These are most modern and are widely used.
Bladder is open-ended cylindrical shaped. Tyre is ejected from bladder
by applying vacuum.
 NRM presses: Bladder is pot shaped with its upper end closed. Bladder
is sunk in bag well by ram and lifts the tyre from mould.
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21.  Bladder:
Bladder is butyl rubber product, which is used for tyre curing. The
requirements of a bladder are-
 Good air impermeability
 High steam, hot water resistance
 High heat resistance
 High flex resistance
CURING PRESS(Before curing) CURING PRESS(After curing) 21

22.  post cure inflation (PCI):
Vacuum is applied at the end of the cycle to ensure that the pressure inside
the bladder is drained so that the press does not open under pressure. Nylon
tyre as soon as removed from the press, post cure inflation is done.
 Trimming:
After receiving tyres from curing, it will go for trimming on vertical
trimming machine. Venttrimming is done by nine-channel knife whereas
the bead flash trimming is done by using a hexa blade knife.
Post Cue inflation (PCI) Trimming 22

23.  INSPECTION:
 The tyres after trimming are passed to inspection section where the visual
abnormalities such as blisters, cracks, etc and if any are marked with a
marking crayon and send to tyre rework area. OK tyre is accepted which is
not having any abnormalities, the inspector would mark with yellow stamp
near serial number and will send to ware house for lot re-inspection.
 R&D Department:
 A small piece of the rubber produced is checked by grinding such as
checking of the distance between the threads in ply and cracks.
 Further point load is applied over the whole tyre so as to check the load
bearing capacity of the tyre.
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24.  SERVICE SUPPORT UNITS
To take care of the centralized activities service support units have
been formed. There are 5 service support units taking care of the
specialized activities.
 SERVICE SUPPORT UNIT 1(SSU1)
ENGEENERING SERVICES
 SERVICE SUPPORT UNIT 2(SSU 2)
COMMERCIAL SERVICES
 SERVICE SUPPORT UNIT 3(SSU 3)
PEOPLE SERVICES
 SERVICE SUPPORT UNIT 4(SSU 4)
KNOWLEDGE SERVICES
 SERVICE SUPPORT UNIT 5(SSU 5)
FACTORY MANAGEMENT
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25. ANY QUERY…???
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