1. 1
A Report of In-Plant Training
At
CEAT Tyre Ltd
Submitted by
Youraj G. Talwekar
in partial fulfilment for the award of the degree
of
Bachelor of Engineering
in
Mechanical Department
G H Raisoni College of Engineering
July 2021
2. 2
CERTIFICATE
Certified that this Report of In-Plant Training at
“CEAT Tyre Ltd”
Being submitted herewith to the
G H Raisoni College of Engineering
is the Bonafide work of
“Youraj Gajanan Talwekar”
who carried out the project work under our guidance and supervision?
Prof. A K Khan
Guide
Dr R S Shelke
Head of the
Department
Dr S Unthavle
Principal
Mechanical Engineering
G H Raisoni College of Engineering
NAME OF UNIVERSITY
3. 3
ACKNOWLEDGEMENT
I would like to express my special thanks of gratitude to my In-Plant Training
guide Prof. AK Khan, Head ofthe Department Dr R S Shelke as well as ourprincipal
Dr S Unthavle who gave me the excellent opportunity to do this wonderful in-Plant
Training at CEAT LIMITED which provided me with an opportunity explore the
new horizons.
I express my gratitude towards CEAT LIMITED for providing this
opportunity.
I should also to all those people who have helped me directly or indirectly in
making this project report.
Date: Youraj G. Talwekar
Place: Nagpur Roll No.: 56
Class: B
4. 4
TABLE OF CONTENTS
TITLE Page
No.
Cover Page I
Certificate ii
Acknowledgement iii
Table of Content iv
List of Tables vi
List of Figures vii
List of symbols and abbreviations viii
1.0 INTRODUCTION 1
1.1 Company Overview
1.2 History
1.3 Products
1.4 CEAT TYRE NAGPUR
1.5 Products manufactured in CEAT Tyre
1.6 Objective
1
2
2
3
4
4
2.0 TYRE MANUFACTURING PROCESS 5
2.1 Parts of Tyres
2.2 Materials
2.3 components and mixtures
2.4 The Tyre Manufacturing process
2.5 Tyre Making Machinery and Equipment
2.6 quality control
5
5
6
6
9
10
5. 5
3.0 DEPARTMENT PROFILE 3
3.1 Subsection 3
3.2 Subsection 3
4.0 PROJECT WORK 4
4.1 Subsection 4
4.2 Subsection 4
5.0 CASE STUDY 5
5.1 Subsection 5
5.2 Subsection 5
6.0 CONCLUSION 6
REFERENCES 7
6. 6
LIST OF TABLES
Table No. Title Page No.
Table 1.1 Bike and Scooter
Tyres
4
Table 2.1 Name of the table
Table 3.1 Name of the table
7. 7
LIST OF FIGURES
Figure No. Title Page No.
Figure 1.1
Figure 1.2
Figure 1.3
Figure 1.4
Figure 2.1
Figure 2.2
Figure 2.3
Figure 2.4
Figure 2.5
Figure 3.1
Figure 3.2
Figure 3.3
Figure 3.4
Figure 3.5
Figure 3.6
CEAT Tyre
Motorcycle, Scooter Tyres and Tyres for
Trucks & Buses
The manufacturing process of Tyre
Testing process of Tyre
Blending
Milling
Building
Curing
Manufacturing processes
CEAT Layout
CEAT Plant
Compounding and Banbury mixing
Workshop
MIXING Plant
Tyre Building Plant
Tubes And Flaps Plant
1
2
3
3
7
7
8
8
9
11
12
13
14
14
15
9. 1
1.0 INTRODUCTION
1.1 Company Overview
CEAT Tyre Limited is a part of the RPG Goenka group. It is the second-largest Tyre manufacturer
in the country after MRF. It manufactures over 10 billion Tyres every year & enjoys a major market
share in a light truck and truck Tyre market.
CEAT Tyre Limited offers the widest range of Tyres to all user segments and manufacture world-
class radial for all Indian vehicles including heavy-duty trucks and buses, light commercial
vehicles, earthmovers, forklifts, tractors, trailers, cars, motorcycles, scooters, and auto rickshaws.
Figure 1.1 CEAT Tyre
CEAT – Cavi Electrici Affini Torino
Industry: CEAT LTD.
Type: Public
Founded On: 1958
Headquarter: Mumbai, India
Key People: H.V.Goenka, Paras K. Chowdhary, Managing Director
Chairperson: R.P. Goenka.
Products: Tyres & tubes
Revenue: ₹ 63,302.5 million
Net Income: 2787.2 million.
10. 2
Total equity: 404.5 million
1.2 History
CEAT Limited is a Tyre manufacturing company founded in Italy CEAT Tyre by Virginio Bruni
Tedeschi. The company established its manufacturing in India in 1958 and was sold to Pirelli in
1970. The company's Indian division was then taken over by RPG enterprise in the year 1982,
which also got the rights to CEAT brand and renamed the company CEAT Limited.
In India, CEAT Tyre has 6 manufacturing plants and 17 outsourcing units. The Production
Capacity of the company is 140000 Tyre per day.
They have two manufacturing plants in Maharashtra, and they plan to invest in a new Tyre plant
in Butibori, Nagpur in 2016.
1.3 Products
● Motorcycle & Scooter Tyres
● Auto-Rickshaw Tyres
● Heavy Duty Tyres for Trucks & Buses
● Inner Tubes
● Tyre Flaps
Figure 1.2 Motorcycle, Scooter Tyres and Tyres for Trucks & Buses
11. 3
1.4 CEAT TYRE NAGPUR
CEAT Tyre invested Rs 400 crore in a new plant in Butibori, Nagpur in 2016. The Chief Minister
of Maharashtra Devendra Fadnavis laid the foundation. The company manufactures 1.2 million
Tyres. The Nagpur plant manufactures two types of Tyres are bikes Tyre and scooter Tyres.
Figure 1.3 Manufacturing process of Tyre Figure 1.4 Testing process of Tyre
12. 4
1.5 Products manufactured in CEAT Tyre
In CEAT plant Nagpur, the bikes Tyres and scooter Tyres are manufactured, and their
classification is
Table 1.1 Bike and Scooter Tyres
Bike Tyres Scooter Tyres
Bike Tyre Size Scooter Tyre Size
Puncture Safe Tyre Honda Activa Tyre
Hero Splendor Tyre Suzuki Access Tyre
Hero Passion Tyre TVS Jupiter Tyre
Honda Shine Tyre Hero EZ Tyre
Honda Dream Tyre Hero Pleasure Tyre
Honda Unicorn Tyre Honda Dio Tyre
TVS Apache Tyre TVS Wego Tyre
Yamaha FZ Tyre Honda Aviator Tyre
Royal Enfield Tyre Yamaha Ray Tyre
Bajaj CT 100/110 Tyre Hero Destini Tyre
Bajaj Platina Tyre Hero Maestro Edge Tyre
Bajaj KTM 250 Tyre Yamaha Alpha Tyre
Bajaj Pulsar Tyre Mahindra Duro Tyre
Bajaj KTM 200 Tyre Yamaha Fascino Tyre
Bajaj Dominar Tyre
1.6 Objective:
To analyze the external and internal factors which influence the strategic planning of CEAT
LIMITED company.
To determine the challenges faced and study the production and manufacturing processes. To
analyze the past performance and current position, and to overview the profitability, operational
efficiency, and growth prospects of the CEAT Tyre Ltd plant butibori, Nagpur
13. 5
2.0 The sequence of operations followed
2.1 Parts of Tyres
● Belt - Steel belts are fixed around a Tyre, to give them strength and rigidity. These are
woven sheets of steel wires, coated in rubber.
● Bead - A bead is made of multiple ring-shaped steel wires and has a rubber coating. It
serves as an airtight seal between the Tyre and the rim.
● Ply - The plies are your tires skeleton, made up of multiple layers of fabric. Usually, these
are created using fiber cords woven together and have a rubber coating around them. These
plies are used to add flexibility to the Tyre. To ensure the strength of the Tyre, a layer
called 'carcass ply' is placed right above the tire's inner liner.
● Tread - The soft area on the outer side of the Tyre where the rubber meets the road is the
tread. It is responsible for both grip and cushioning. The compound and design of the tread
define its performance capabilities.
● Sidewall - It is an extra-thick rubber that stretches between bead and tread. It aids in the
lateral stability of the vehicle. All the information about the Tyre manufacturer is inscribed
on the sidewall in case you want to refer to it sometime.
● Shoulder - It is the small slant edge of a Tyre where the tread and the sidewall meet. The
design and construction of the shoulder play an essential role in delivering proper
performance on the corners.
● Sipe and groove - The evacuation of water, mud, and snow from the Tyres happens
through the deep grooves that separate the tread blocks. Along with the deep grooves, the
tread blocks also have smaller grooves or cuts to provide extra grip to the vehicle. These
smaller grooves are known as sipes.
2.2 Materials
● Natural rubber or polyisoprene is the basic elastomer used in tire making Styrene-
butadiene.
● polymer (SBR) is a synthetic rubber that is often substituted in part for natural rubber based
on the comparative raw materials cost.
● Polybutadiene is used in combination with other rubbers because of its low heat-buildup
properties.
14. 6
● Halo-butyl rubber is used for the tubeless inner liner compounds, because of its low air
permeability. The halogen atoms provide a bond with the carcass compounds which are
natural rubber. Bromo-butyl is superior to chloro-butyl but is more expensive.
● Carbon black (soot) forms a high percentage of the rubber compound. This gives
reinforcement and abrasion resistance.
● Silica, used together with carbon black in high-performance tires, as a low heat buildup
reinforcement.
● Sulphur cross links the rubber molecules in the vulcanization process.
● Vulcanizing accelerators are complex organic compounds that speed up vulcanization.
● Activators assist the vulcanization. The main one is zinc oxide.
● Antioxidants and antiozonants prevent sidewall cracking due to the action of sunlight and
ozone.
● Textile fabric reinforces the carcass of the tire.
2.3 Components and mixtures
SBR rubber compound to with chemicals formulations
● SB Rubber 100 kg (about the weight of a professional basketball player)
● carbon 220 150 kg (about half the weight of a large motorcycle)
● zinc oxide 20.5 kg
● stearic acid 13.5 kg
● accelerator 11.2 kg
● Oil 33.5 kg
● Al2O3 10.23 kg
2.4 The Tyre Manufacturing Process
Let us take a ‘factory tour’ to understand how Tyres are made. To begin with, these are the five
stages of Tyre manufacturing:
● Blending
● Milling
● Building
● Curing
● Inspection
15. 7
Let us check out each of these in detail:
2.4.1. Blending
● The process of Tyre manufacturing starts with blending. Around 30 unusual types of
rubber, fillers and other ingredients are utilized to create the Tyre rubber.
● All the ingredients are sent for blending, where they are mixed in blending machines
(blenders). After the mixing of these ingredients, a black, sticky compound is made, which
is then sent for milling.
Figure 2.1 Blending
2.4.2. Milling
● Once the rubber cools, it is then sent for cutting wherein the basic structure of the Tyre is
processed.
● The milling stage also includes the preparation of other Tyre elements. Some of these
elements are coated in a different type of rubber.
Figure 2.2 Milling
Blending Milling Buildin
g
Curing
Inspection
16. 8
2.4.3. Building
● In the building process, the Tyre is made from the inner side. Various components,
including steel belts, textile elements, ply, beads, and tread, are placed in a Tyre building
machine
● During this process, the Tyre gains proper form and is called a 'green Tyre.'
Figure 2.3 Building
2.4.4. Curing
● In this stage, the 'green Tyre' is processed for vulcanization with hot moulds in a curing
machine. All the parts of the Tyre are compressed together, giving it a final shape.
● Post vulcanization, the Tyre is furnished with the tread pattern and the manufacturer’s
sidewall markings.
Figure 2.4 Curing
17. 9
2.4.5. Inspection
● In the final inspection stage, the quality team of the Tyre manufacturer inspects each Tyre
through special machinery.
● They check for defects or imperfections before the Tyre is shipped out to the sellers.
● CEAT quality team ensures that only exceptional quality Tyres come out of their
manufacturing facilities. The entire product range thus adheres to the company's standards.
● And there you have it, folks. This is how the Tyres that roll your vehicle back and forth are
made. If you are looking for new Tyres.
Figure 2.5 manufacturing processes
2.5 TYRE MAKING MACHINERY AND EQUIPMENT
● Cutting machines for textile or metal fabrics, Tyre manufacture
● Forming machines for rubber Tyres
● Hand tools, rubber Tyre making
● Moulds, inner tube
● Moulds for pneumatic Tyres
● Presses, rubber Tyre manufacturing
● Rubber Tyre bead making machine
● Rubber Tyre building machines
● Rubber Tyre debearding machines
● Rubber Tyre retreading machines
● Rubber Tyre stock feeders
● Tyre inner tube machines
● Tyre vulcanizers
18. 10
2.6 Quality control
● Each stage of production – from the inspection of raw materials to delivery of finished tires
– is subject to ongoing quality control.
● A multi-layered process ensures Continental tires are thoroughly checked for quality.
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3.0 The layout of various workshop
3.1 CEAT LTD. Plant Layout
CEAT Tyre invested Rs 400 crore in a new plant in Butibori, Nagpur in 2016. The Chief Minister
of Maharashtra Devendra Fadnavis laid the foundation. The company manufactures 1.2 million
Tyres. The Nagpur plant manufactures two types of Tyres are bikes Tyre and scooter Tyres. Spread
over an area of 60 acres, it is expected to have an annual capacity of 1.2 million Tyres, allowing
the company to double its total capacity within two years, which in turn would directly increase
their market share. CEAT already commissioned a capacity of 39 MT/day by the end of March.
Figure 3.1 Plant Layout
20. 12
Figure 3.2 CEAT Plant
Size: 5001-10000 Employees
Turnover: 2500-5000 Crores
TYPE: -There are five forms of organization.
(1) Sole proprietorship (2) Partnership firm (3) Private limited (4) Public limited
(5) Joint stock company
CEAT Ltd. is private limited company.
21. 13
3.2 CEAT Plant Workshops: -
3.2.1 Compounding and Banbury mixing Workshop: - 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 ingredients are
generally provided to the plant in reweighed packages or are prepared and weighed by the Banbury
operator from bulk quantities. Measured ingredients are placed onto a conveyor system, and the
Banbury is charged to initiate the mixing process. Hundreds of components are combined to form
rubber utilized for Tyre manufacturing. The components include compounds which act as
accelerators, anti-oxidants, anti-ozonate, extenders, vulcanizers, pigments, plasticizers, reinforcing
agents and resins. Most constituents are unregulated and may not have had extensive toxicological
evaluations. Generally speaking, the Banbury operators' occupational exposures to the raw
materials have been reduced by improvements in administrative and engineering controls.
Figure 3.3 Compounding and Banbury mixing Workshop
22. 14
3.2.2 Mixing Plant: - Shaping of rubber begins in the milling process. At the completion of the
Banbury mixing cycle, rubber is placed onto a drop mill. The milling process shapes the rubber
into flat, long strips by forcing it through two set rolls rotating in different directions at different
speeds. Mill operators are generally concerned with safety hazards associated with the open
operation of the turning rolls.
Figure 3.4 Mixing Plant
3.2.3 Tyre Building Plant: -
Most of the components are various kinds of reinforcements. Tyre makers assemble the
components into green Tyres using assembly machinery.
Figure 3.5 Tyre Building Plant
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
pressurized and stretched to fuse with the above-mentioned unity. This is how a green Tyre is
manufactured.
23. 15
3.2.4 Tubes and flaps plant: -
Tubes are manufactured from high grade butyl rubber with enhanced elasticity for better tube life.
Flaps are designed and manufactured so as to protect the Tyre and tubes for a longer time.
Figure 3.6 Tubes and flaps plant
