The document summarizes the manufacturing process of solid tires at Camso Loadstar in Sri Lanka. It provides an overview of the company, which was established in 1984 as a joint venture to manufacture solid tires. It then describes the basic manufacturing process, which involves mixing and milling raw materials, component assembly, curing, and finishing. Key steps include inner heel building, heel rolling and bonding, molding, and curing. The document also lists the raw materials used and their country of origin, and discusses future requirements such as improved tire design and non-pneumatic tires.

1. Group Presentation
Production & Operations
Management
Presenters:
R.A.H.B. Ranawaka MBM/05/30
Chaturanga Attanayaka MBM/05/02
K.D. Hasitha Lakmal
MBM/05/17
G.R.C.R. Gunasekara MBM/05/07
S.P.B. Samarawickrama MBM/05/32
W.M.M A Weerasekara MBM/05/39
Date: 16/ 12 /2017

2. Manufacturing Process of
Solid Tyre
Camso Loadstar (Pvt) Ltd
Ekala

3. Company Profile
• In 1984, Pierre Pringiers and Philippe Danneels
found Solideal and a Belgian company has
expanded their business operations by
venturing into international market.
• In year 1984, the company named Loadstar, as
a joint venture with Solideal and Jinasena
Group, was commenced to manufacture solid
tyres in Sri Lanka. At present, Loadstar is one of
the world’s largest manufacturers of solid
rubber tyres.

4. • The company manufactures exclusively for
Solideal, one of the world’s leading industrial
tyre distributors, which has a 20-25% share of
the industrial solid rubber tyre market and
operates within a network spanning 90
countries.
• In addition to solid tyres, Loadstar
manufactures pneumatic tyres, rims and
rubber tracks and supplies about 90% of
Solideals product requirement.

5. Global Manufacturing
Casmo operates production facilities in 10 countries to
better serve their customers.

6. • Casmo has more than 7,500 dedicated employees
spread over 26 countries around the world, with
close to 200 people working in R&D, including a
dedicated “advanced technology” group. They
operate 3 advanced R&D centres and have 22
manufacturing plants in 10 countries through North
and South America, Europe and Asia.

7. Raw Material Used qty Country of Origins
Natural Rubber 1000 MT Sri Lanka
Carbon Black 500 MT China, India, Thailand
Metal 60 MT India
Textile 50 MT China, Hong Kong
Zinc Oxide 40 MT China
Sulphar 20 MT China
Additives 10 MT Singapore
Synthetic Rubber 5MT USA
Supply Chain & Raw Material Used

8. Global Distribution
To be closer to their customers, they are present in
more than 100 countries, including 20 where they
have own footprint.

9. Camso 2015 9
OEM’s Industrial Equipment Partners

10. Camso 2015 10

12. A tyre is a ring-shaped component that surrounds a wheel's rim to transfer a
vehicle's load from the axle through the wheel to the ground and to provide
traction on the surface traveled over.
From the Beginning to Now
Tyre

13. Mainly tires can be divided into main 02 categories
Pneumatic Tires
Solid Tires
Tires
Press On Tire
Resilient Tire
Cured On Tire
Radial Tire
Bias Tires
Industrial Tires
Passenger Vehicle
Tires
Industrial Tires
Tyre

14. Resilient Press On Cured On
Solid Tyres
A tyre is a ring-shaped component that surrounds a wheel's rim to transfer a
vehicle's load from the axle through the wheel to the ground and to provide
traction on the surface traveled over.

15. 2 Layer
Steel Reinforcement
Heel Layer
Tread Layer
3 Layer
Steel Reinforcement
MiddleLayer
Heel Layer
Tread Layer
3 Layer
High Heel
Steel Reinforcement
Middle Layer
Heel Layer
Tread Layer
Resilient Tyres

16. Features
• Reduce the down time period due to
absolute puncture resistance.
• Less maintenance cost and high durability.
• Stability to control highest speeding of the
vehicles due to reduce nature of tyre
heating.
• Less maintenance cost & other charges of
the vehicles due to less vibrations and
shocks.
• Low percentage of cost / hour.

17. Usage of Resilient Tyres
•Forklifts
•Ground Support Equipment
•Port Trailers
•Industrial Trailers
•Access / Warehouse Equipment
•Platform Trucks
•Reach Stackers
•Empty Container Handlers
•Other Material Handling applications

18. Types
Xtreme
Magnum
Ecomatic
RIB,HT,ZZRIB,
Mag 2

19. 1 Layer 2 Layer
Steel Band
Tread Layer
Steel Band
Tread Layer
Middle Layer
Press On Tyres

20. Features
• Reduce the down time period
due to absolute puncture
resistance.
• High Stability in better vehicle
control by the operator.
• Low rolling resistance.
• Low percentage of cost / hour.

21. Usage of Press On Tyres
• Forklifts
• Ground Support Equipment
• Access / Warehouse Equipment
• Platform Trucks
• Reach Stackers
• Empty Container Handlers
• Other Material Handling applications

22. Types
PON 775+Magnum + SM FL
SD HT + SM
SD Ecomatic ETR + ESM

23. 2 Layer1 Layer
WheelTread Layer
Wheel
Heel
Tread Layer
Cured On Tyres

24. Features
• Low Operating cost due to non
mounting process required
• Less maintenance cost and high
durability.
• Stability to control highest speeding of
the vehicles due to reduce nature of tyre
heating.
• Less maintenance cost & other charges of
the vehicles due to less vibrations and
shocks.

25. Usage of Press On Tyres
• Scissor Lifts
• Articulating Booms
• Telescopic Booms
• Light weight self propelled Booms
• Vertical Masts
• Push arounds
• Trailer Mounted Booms
• Other Arial Work Platforms

26. • Compounding and Banbury mixing
• Milling
• Extruding and Calendering
• Component Assembly and Building
• Curing and Vulcanizing
• Inspection and Finishing
Basic Tyre Manufacturing Process

28. Inner Heel
Building
Heel Rolling Bonding
Soft Rolling
Molding Tread Rolling
Curing
Finishing
Manufacturing Process of Resilient Tyres

29. Camso 2015 29
Process Flow Chart - Resilient Tyre
Manufacturing Process
245 s245 s
275 s275 s
130 s130 s
127 s127 s 200 s200 s
207 s207 s
115 s115 s
195 s195 s 95 s95 s
120 s120 s
160 s160 s
85 s85 s
Traceability
flow chart
Traceability
flow chart

31. Inner Heel Building
• Roll I.H. Compound on
Collapsible core
• Insert Bead
• Expand Collapsible Core
• Tree types of beads are used
1. Cable Beads
2. Bead Grommet
3. Steel Rods
•Spaces between Beads
should be equal.
•No of compound rolling should be
according to the specification

32. Heel Rolling & Bonding
Inner heel is transferred
to a expandable core
 To obtain good bonding
Between Heel and
Middle(Soft)
 An overlap should be applied
• Trapped air should be
removed using a wrinkle
Bonding
layer
Overlap

33. Soft Rolling & Tread Rolling
•Only for 3L tires
Characteristics of Soft
Compound
•Ability to absorb
pressure
•Ability to rebound
Characteristics of Tread
Compound
•Withstand tearing
•Withstand cracking
•Endure high temperature
•Survive in rough climatic
conditions
•Resist oils, grease etc.

34. Molding & Curing
•Cured tire should be
de-molded on correct
time
•Green tire should be
centered on mold
•bumping should be applied
•Clamps should be tied
properly

35. Tyre trimming and Final inspection
• After the tyre de-moulding skilled operators trim extra
flash of the tyre and identify visual defects and if tyre is ok
send FQC and if not ok send to the re work area.
• Inspection is to be done as some irregularities are
generated on and around the tyre after the curing process.
• It is done manually by some skilled workers.
• It includes 3 types of inspection
1. Visual
2. Hardness
3. Ultra Sonic (US)
• After the inspection details enter the
SAP system for the traceability.

36. Future Requirements
• Constant improvements in rubber chemistry and tire
design are creating exciting new tires that offer
greater mileage and improved performance in
extreme weather conditions. Manufacturers now
offer tires estimated to last up to 80,000 miles.
• Treads, designed and tested by computer, now
feature unique asymmetrical bands for improved
traction and safety on wet or snowy roads.

37. • Tire design engineers are also experimenting
with non-pneumatic tires that can never go
flat because they don't contain air under
pressure. One such non-pneumatic tire is
simply one slab of thick plastic attached to the
wheel rim. The plastic curves out from the rim
to a point where a rubber tread is secured to
the plastic for contact with the road. Such a
tire offers lower rolling resistance for greater
fuel economy and superior handling because
of a greater area of contact between tread
and road.

38. Productivity Performance
•Extremely shorter Mixing &
Curing cycles that will lead to
lowest Over Head.
•Faster Filler incorporation
•(Functionalized
Polymer/Filler)
•Faster Curing
•(Thermal Conductivity)
•No failures even under
severe/continuous
applications.
- Thermal explosions
- Chunking/Chipping
•Low HBU
•Longer Life
•Good Thermal
•Properties
(Hot Tear Resistance )