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Tire Production Process

Rubber & Tyre Machinery World
Rubber & Tyre Machinery World
Rubber & Tyre Machinery WorldConsultant at Rubber & Tyre Machinery World

The tire production process is a very meticulous and complex affair. This single page explains the complete process well.

Tire Production Process

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Process Output
Components
(illustration)
1
Extrusion - Process of applying
heat and pressure on the
compound and additional mixing
of the compound.
Tread; Improve wear and
traction in any environment.
Sidewall; Provide good
abrasion and environmental
resistance for the sides of tires.
2
Calendaring - Process of
squeezing the compound into
a thin sheet, Fabric calendars
produce an upper and lower
rubber sheet with a layer
of fabric in between. Steel
calendars produce the same with
steel cords. Calendars utilize
downstream equipment for
shearing and slicing calendared
components.
Belt package; Give the tire
strength while allowing it to
remain flexible in its structure.
Body ply; Provide tire structure
and strength.
Inner liner; Assure that tires
will hold high-pressure inside
without the air gradually
diffusing through.
3
Bead building - Shaped like
a hoop, it has coated high-tensile
wires forming its backbone. The
strands are aligned into a ribbon
coated with rubber adhesion.
Bead; Provide the mechanical
strength to fit the tire to the
wheel.
CURING4
The tire production process is a very meticulous and complex
Compounding is the operation
of bringing together natural
rubber, process oil, carbon black,
accelerator and other additives,
each of which contributes certain
properties to what is called a
‘compound’.
To obtain a homogeneous
mixture, they are mixed at high
temperatures in a massive mixer.
Output of compounding & mixing:
Cooled rubber slabs
RAW MATERIALS
The main materials
to produce tires are:
The tire building machine pre-shapes
radial tires into a form very close to their
final dimensions to make sure the many
components are in their proper positions
before the tire goes into the mold.
Ensure all components are
in their proper positions
One part of the
pre-shaping process
Another part of the
pre-shaping process
First radial tire forms, very
close to their final dimension,
before they are molded
Tires are ready to be cured at over
100 degrees Celsius for 12 or 25
minutes depending or their size
Press swings open, tires are popped
from their mold with engraved tread
patterns and sidewall markings
Tire surfaces being
checked by trained
inspectors
Checking uniformity
on balance and force
variation
Tires being sampled from
the production line and
X-rayed to detect any
hidden weaknesses or
internal failures
Components preparation falls into three classes: The curing press is where tires attain their final
shape and tread pattern. Hot molds like giant waffle
irons shape and vulcanize the tire. The molds are
then engraved with the tread pattern and sidewall
marking.
Tires are cured at over 100 degrees Celsius for 12 to
25 minutes, depending on their size. As the press
swings open, the tires are popped from their molds
onto a long conveyor that carries them to final finish
and inspection.
Professional visual inspector’s and automated inspection
machines detect the slightest defect on the final product.
Inspection does not just stop at the surfaces. Some tires are
sampled from the production line and X-rayed to detect
any hidden weaknesses or internal failures. In addition,
quality control engineers regularly perform cut sections
and study details of the tire construction that affects
performance, ride or safety.
COMPONENT
PREPARATION
TIRE BUILDING TIRE INSPECTION
COMPOUNDING &
MIXING1 2 3 5
A B
C D
Method:
- Reception inspection
- Quality guideline
- Supplier evaluation and
approval
Tools:
Raw material testing
equipment
Goal:
Ensure raw material quality
and consistency.
Method:
Monitor raw material formulas,
mixing parameters, first batch output
as well as material production dates.
Goal:
Analysis and comparison with final
product performance for further
quality improvement as well as
backward traceability in the event of
quality issues.
Method:
Online tolerance measurement of tread
extrusion.
Tools:
Terminal tread-weight equipment for
100% tread check. Automatically rejects
unqualified weight.
Goal:
Ensure high precision and consistency
of extruded components.
Method:
Curing auto-control.
Tools:
Host computer to monitor
temperatures, time &
pressure of curing machines.
Issues detected will sound
alarms.
Goal:
Produce the best final tires.
Method:
Oversee and record component
production dates, machine numbers,
techniques and parameters.
Goal:
Analysis and comparison with final
product performance for further quality
improvement as well as backward
tracing in the event of quality issues.
Alarms are  sounded
when unqualified treads
are detected. They are
sprayed white for identification,
and rejected immediately
Raw material QA
Compound & Mixer QA Extrusion QA Overall Tire Building QA Curing QA Overall Curing QAOverall Component
Preparation QA
Giti’s relentless desire for improvement ensures consistent quality
Method:
Oversee and record production dates,
machine numbers, operators, component
part numbers, techniques and parameters.
Goal:
Analysis and comparison with final product
performance for further quality improvement
as well as backward tracing in the event of
quality issues.
Method:
Oversee and record production
dates, machine numbers,
operators, techniques and
parameters
Goal:
Analysis and comparison with
final product performance for
further quality improvement as
well as backward tracing in the
event of quality issues.
Every finished tire comes
with unique barcodes
where we can perform
backward tracing
along every step of the
manufacturing process for
quick response and provide
precise solutions when
we spot issues that affect
performance, ride and
safety.
Barcode
The Finished Tire
Natural Rubber
& Chemicalsl
Fabric
Steel
Ad

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Tire Production Process

  • 1. Process Output Components (illustration) 1 Extrusion - Process of applying heat and pressure on the compound and additional mixing of the compound. Tread; Improve wear and traction in any environment. Sidewall; Provide good abrasion and environmental resistance for the sides of tires. 2 Calendaring - Process of squeezing the compound into a thin sheet, Fabric calendars produce an upper and lower rubber sheet with a layer of fabric in between. Steel calendars produce the same with steel cords. Calendars utilize downstream equipment for shearing and slicing calendared components. Belt package; Give the tire strength while allowing it to remain flexible in its structure. Body ply; Provide tire structure and strength. Inner liner; Assure that tires will hold high-pressure inside without the air gradually diffusing through. 3 Bead building - Shaped like a hoop, it has coated high-tensile wires forming its backbone. The strands are aligned into a ribbon coated with rubber adhesion. Bead; Provide the mechanical strength to fit the tire to the wheel. CURING4 The tire production process is a very meticulous and complex Compounding is the operation of bringing together natural rubber, process oil, carbon black, accelerator and other additives, each of which contributes certain properties to what is called a ‘compound’. To obtain a homogeneous mixture, they are mixed at high temperatures in a massive mixer. Output of compounding & mixing: Cooled rubber slabs RAW MATERIALS The main materials to produce tires are: The tire building machine pre-shapes radial tires into a form very close to their final dimensions to make sure the many components are in their proper positions before the tire goes into the mold. Ensure all components are in their proper positions One part of the pre-shaping process Another part of the pre-shaping process First radial tire forms, very close to their final dimension, before they are molded Tires are ready to be cured at over 100 degrees Celsius for 12 or 25 minutes depending or their size Press swings open, tires are popped from their mold with engraved tread patterns and sidewall markings Tire surfaces being checked by trained inspectors Checking uniformity on balance and force variation Tires being sampled from the production line and X-rayed to detect any hidden weaknesses or internal failures Components preparation falls into three classes: The curing press is where tires attain their final shape and tread pattern. Hot molds like giant waffle irons shape and vulcanize the tire. The molds are then engraved with the tread pattern and sidewall marking. Tires are cured at over 100 degrees Celsius for 12 to 25 minutes, depending on their size. As the press swings open, the tires are popped from their molds onto a long conveyor that carries them to final finish and inspection. Professional visual inspector’s and automated inspection machines detect the slightest defect on the final product. Inspection does not just stop at the surfaces. Some tires are sampled from the production line and X-rayed to detect any hidden weaknesses or internal failures. In addition, quality control engineers regularly perform cut sections and study details of the tire construction that affects performance, ride or safety. COMPONENT PREPARATION TIRE BUILDING TIRE INSPECTION COMPOUNDING & MIXING1 2 3 5 A B C D Method: - Reception inspection - Quality guideline - Supplier evaluation and approval Tools: Raw material testing equipment Goal: Ensure raw material quality and consistency. Method: Monitor raw material formulas, mixing parameters, first batch output as well as material production dates. Goal: Analysis and comparison with final product performance for further quality improvement as well as backward traceability in the event of quality issues. Method: Online tolerance measurement of tread extrusion. Tools: Terminal tread-weight equipment for 100% tread check. Automatically rejects unqualified weight. Goal: Ensure high precision and consistency of extruded components. Method: Curing auto-control. Tools: Host computer to monitor temperatures, time & pressure of curing machines. Issues detected will sound alarms. Goal: Produce the best final tires. Method: Oversee and record component production dates, machine numbers, techniques and parameters. Goal: Analysis and comparison with final product performance for further quality improvement as well as backward tracing in the event of quality issues. Alarms are  sounded when unqualified treads are detected. They are sprayed white for identification, and rejected immediately Raw material QA Compound & Mixer QA Extrusion QA Overall Tire Building QA Curing QA Overall Curing QAOverall Component Preparation QA Giti’s relentless desire for improvement ensures consistent quality Method: Oversee and record production dates, machine numbers, operators, component part numbers, techniques and parameters. Goal: Analysis and comparison with final product performance for further quality improvement as well as backward tracing in the event of quality issues. Method: Oversee and record production dates, machine numbers, operators, techniques and parameters Goal: Analysis and comparison with final product performance for further quality improvement as well as backward tracing in the event of quality issues. Every finished tire comes with unique barcodes where we can perform backward tracing along every step of the manufacturing process for quick response and provide precise solutions when we spot issues that affect performance, ride and safety. Barcode The Finished Tire Natural Rubber & Chemicalsl Fabric Steel