Tyre

Tyre

Tyres are manufactured according to relatively standardised processes and machinery available worldwide in around 455 tyre factories. With over 1 billion tyres manufactured worldwide annually, the tyre industry is a significant consumer of natural rubber. Tyre factories start with bulk raw materials such as synthetic rubber, carbon black, and chemicals and produce numerous specialised components assembled and cured.

The tyre is an assembly of numerous components built upon a drum and then cured in a press under heat and pressure. Heat facilitates a polymerisation reaction that crosslinks rubber monomers to create long elastic molecules.

In India, there are many tyre manufacturing plants of different companies, including Yokohama Rubber Company, Apollo Tyre, Ceat Tyres, J.K. Tyres, MRF and TVS Tyres and many others.

Many different parts go into the making of a tyre as follows.

  • Beads
  • Belt
  • Ply
  • Sidewall
  • Sipe and Groove
  • Shoulder
  • Tread

Preparation

Raw materials for the preparation of the Tyre are Rubber – Natural + Synthetic, Polythene, Carbon Black, Silica, Sulphur, Zinc Oxide, Stearic Acid, Accelerators and Retarder – Catalysts & Fabric.

The Banbury mixer is a sophisticated piece of heavy equipment with a mixing chamber with two rotors inside. The rotor is named BANBURY ROTOR, and the chamber is BANBURY CHAMBER. There are two rotors; both the rotors rotate in opposite directions at a certain speed. The mixing occurs between the rotor tip and the chamber and not between the two rotors. Needling takes place between the two rotors. Each element added in mixing has its importance, i.e. Sulphur acts as a curing agent, Zinc Oxide and Steric Acid increase the speed of the curing time, and accelerators and retarders provide dispersive mixing. The batch is injected at a temperature of 135°C, and batch damping occurs at 165°C.

Applications

The function of the Banbury rotor is to mix the basic raw materials of the tyre. The lead time of the new Banbury Chamber is approximate 8-9 months, and in the case of Extruder Screw, it takes around 3-4 months from the date of order.

It mixes Rubber and other raw materials in Banbury Mixture. Pair of rotors rotate in opposite directions.

The function of the Banbury rotor is to mix the basic raw material of the tyre. Lead time of the new Banbury Rotor is approx. 8-9 months and in the case of Extruder Screw, it takes around 3-4 months from the date of order.

The function of the Extruder screw is to extrude rubber for the Left and right-side walls of the tyre for further process.

Solutions

The recommended solution is EWAC special welding alloys with high toughness, strength, ductility, and which is an all-position unique electrode for applications subjected to abrasion, erosion, and corrosion combined with impact.

The recommended solution would be EWAC’s new generation Cobalt base alloy with excellent resistance to Wear, Galling and Corrosion, even at elevated temperatures.

The function of the Banbury rotor is to mix the primary raw material of the tyre. The lead time of the new Banbury Rotor is approximate 8-9 months, and in the case of Extruder Screw, it takes around 3-4 months from the date of order.

The recommended solution is EWAC’S unique electrode for application subjected to abrasion, erosion, and corrosion combined with impact.

Experience of EWAC

  • We have experience in the reclamation of Banbury Rotor, Chamber and Extruder screw.
  • We take this job, as a turnkey project and deliver the reclaimed component saving time and costing.