Industry visit to CEAT Ltd

1. Industry visit report on CEAT Ltd.
Submitted By:
Ketan Mokal (82)
Mridu Sharma (83)
Namish Sharma (84)
Namrata Kumar (85)
Nikhil Nagdeote (86)
Ninad Gajbe (87)
Niraj Sawarkar (88)

2. Background
• CEAT international was established in 1924 at Turino in
Italy and manufactured cables for telephones &
railways.
• In 1958, CEAT came to India, and CEAT Tyres of India
Ltd was established in collaboration with the TATA
Group.
• In 1982,the RPG Group took over CEAT Tyres of India.
• In 1990,renamed company CEAT Ltd.
• Head office in Dr Annie Besant Road, Worli, Mumbai

3. Vision and Mission
Vision:
• To be amongst the most profitable tyre companies
in India by 2016
• Leadership in 5 countries Outside India
• Market Leadership in select categories in India
• Mission:
"To nurture an exciting and challenging work
environment with fairness and transparency."

4. Current Scenario
• Manufactures over 6 million tyres every year.
• More than 3500 Cr annual turnover
• Operates from Mumbai ,Nasik & Halol plants.
• Export to 130 countries
• Segment wise revenue break-up
 Replacement market 55-60 %
 OEM 20-25 %
• Tyre range : 2 Wheelers, Car/SUV, LCV/Trucks, OTR,
Farm vehicles

5. Production Capacity
• Nashik plant established on 15th Aug, 1973
• Current employees - 1530
Product wise production rate (in Tonnage) at Nasik Plant
• Truck – 112
• RT(Radial Tyres) – 25
• Non Truck- bias – 88
• PC & LT Radial – 18
So, Total daily (Cured Tonnage) = 243 T

6. Values
• C=>Challenger
• A=>Aspiration led
• I=>Integrity
• R=>Result Obsession
• O=>Openness
• Appraisal system PRIDE

7. The Market
• Domestic Customers:
• Competitors (India and abroad)

8. The Tyre Manufacturing
Process

9. • Components of a tyre :
The tyre is an assembly of
numerous components
that are built up on a
drum and then cured in a
press under heat and
pressure.
The Tyre Manufacturing
Process

10. Typical components used in tyre assembly are listed below:
• Inner line : The inner liner is an extruded halobutyl rubber sheet compounded
with additives that result in low air permeability.
• Body ply : The body ply is a calendered sheet consisting of one layer of rubber,
one layer of reinforcing fabric, and a second layer of rubber.
• Side wall : Sidewalls are non-reinforced extruded profiles with additives to give
the sides of the tyre good abrasion resistance and environmental resistance.
• Beads : Beads are bands of high tensile-strength steel wire encased in a rubber
compound. Bead wire is coated with special alloys of bronze or brass.
• Apex : The apex is a triangular extruded profile that mates against the bead.
• Belt Package : Belts are calendered sheets consisting of a layer of rubber, a
layer of closely spaced steel cords, and a second layer of rubber. The steel
cords are oriented radially in radial tyre construction, and at opposing angles
in bias tyre construction.
• Tread : The tread is a thick extruded profile that surrounds the tyre carcass.
• Cushion gum : Many higher-performing tyres include an extruded component
between the belt package and the tread to isolate the tread from
mechanical wear from the steel belts.
The Tyre Manufacturing
Process

11. • Chemical formulation of a tyre:
Chemical % formulation
Rubber (Natural and synthetic) 38%
Fillers (Carbon black, silica, carbon chalk) 30%
Reinforcing materials (steel, rayon, nylon) 16%
Plasticizers (oils and resins) 10%
Chemicals for vulcanisation (sulphur, zinc
oxide, various chemicals)
4%
Chemicals as antioxidants to counter ozone
effects and material fatigue
1%
Miscellaneous 1%
The Tyre Manufacturing
Process

12. The tyre manufacturing process is done in following five stages:
1.Compounding and Banbury mixing:
A banbury mixer combines rubber stock, carbon black and other
chemical ingredients to create a homogeneous rubber material. Time,
heat and raw materials are factors utilized to engineer material
composition.
The Tyre Manufacturing
Process

13. 2. Component Part Constructing – Calendering
The Tyre Manufacturing
Process

14. 2.Component Part Constructing – Steel Calendering
The Tyre Manufacturing
Process

15. 2.Component Part Constructing - Extrusion
The Tyre Manufacturing
Process

16. 2.Component Part Constructing - Bead Production
The Tyre Manufacturing
Process

17. 3.Assembly of components
The components are
assembled on an automated
machine in the following
order:
Carcass Building, Inner Liner,
Body Ply: Mounting, Bead Wire
Mounting and Turn-Up,
Sidewall Mounting and
Joining, Tread package, Cap
Ply: Mounting and Joining,
Tread Mounting, First and
Second Stage Coupling and
finally Green Tyre
The Tyre Manufacturing
Process

18. 4.Curing and Vulcanizing:
The curing press utilizes heat and pressure to convert the assembly into
final tyre.
This increases rubber compound strength. In this process all tyre
components are welded onto each other and tread pattern and sidewall
graphics are engraved on the tyre.
The Tyre Manufacturing
Process

19. 5.Finishing Inspection:
Following curing, finishing operations and inspection remain to be
performed before the tyre is stored or shipped. After building the green
tyre it is transferred to the painting machine, where anti-blemish chemicals
are applied.
The Tyre Manufacturing
Process