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An Internship Report in On Tyr Mechanical Engineering Department

Internship Report A.Y.2022-23

Technical Report · June 2023

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 An
Internship
Report in

K.K. Wagh Institute of

Engineering Education &
Research, Nashik
On
Tyr Mechanical Engineering Department
Internship Report A.Y.2022-23

Name: Himanshu Hitendra Mahajan

Department: Mechanical Engineering

Institute Guides: - Prof. Dr. Sanjay D. Barahate

Prof. Bhushan G. Patil
Industry Guide: - Mr. Pradeep Subedarpage

[1]
 ACKNOWLEDGEMENT

I am very thankful to Mr. Prasad Nayak Sir (HR Manager) for giving me the opportunity to undertake
my 4 - Week Internship at CEAT Ltd. Nashik Plant. It was a very good learning experience for me to
have worked at your company.

I would like to convey my heartiest thanks to Mr. Uday Kansara Sir (General Manager Finance) & Mr.
Avinash Wagh (Safety Officer) for giving me this wonderful opportunity to do an internship at your
company.

I would also like to give my heartfelt thanks to Mr. Pradeep Subedarpage Sir (Sr. Manager
Maintenance), who heartily welcomed me for the internship, and for guiding and assisting me in my
entire internship program.

I would like to thank all the department heads of CEAT Ltd., for giving their precious time and valuable
guidance during my internship program.

I am extremely thankful to Prof. Prashant Kushare Sir (Head of Department, Mechanical Engineering)
of K. K. Wagh Institute of Engineering Education & Research, Nashik, for providing me with facilities
to work in, without which this work would not have been possible. And also, I want to thank Prof. Dr.
Sanjay D. Barahate and Prof. Bhushan G. Patil (Internship Guides - Dept. of Mechanical Engineering),
for guiding me in this whole internship Program at every stage.

Last but not the least; I would like to thank all the staff of CEAT Ltd., for being so helpful during this 4-
week internship training.

[2]
CERTIFICATE OF COMPLETION

[3]
 PREFACE

Every student of Bachelor of Engineering in Mechanical Engineering, has an essential

requirement to do 4 Week of internship in any of the well reputed organization. The purpose
of this program is to acquaint the students with practical applications of theoretical concepts
taught to them during conduct of their course.

We are grateful for having a chance to do an internship in CEAT Tyres Nashik. Really, it was
a nice opportunity to have a close comparison of theoretical concept in practical field. This
report may depict deficiencies on my part but still it is an output of a student's efforts, for
which we beg pardon.
The output of my analysis is summarized in a shape of Internship the contents of the report
Shows the detail of sequence of these.

[4]
 ABSTRACT
This report provides an overview of the experiences and observations gained during a
one-month internship at the CEAT Tyres Manufacturing Plant. Industrial internship is one of
the main courses in Mechanical Engineering Programme. The period of the training was
minimum 4 weeks started at 25th January to the 25th February 2022.
The report begins with introduction to CEAT Tyres and tyre manufacturing process.
I studied the process and flow of tyre manufacturing from mixing, curing to finishing of the
tyre. The report includes information about all the departments of the company along with,
information and specifications of the machineries that I gathered by observation of the process
and interaction with employees and officers. The main point of focus was Banbury Mixer, Four
Roll Calender and Curing Press. Construction and Working of the machineries along with their
significance, assembly of parts, types of motors and gearboxes used are studied and included
in the report. I got to participate in maintenance activities of Banbury and Curing press.
Along with the study core tyre manufacturing process, I also visited departments like
Tyre test centre, engineering stores, Utility department. I studied specifications, usage and
structure of boilers and compressors in utility department. Used the SAP system used in
engineering stores and learned about the process of inventory management.
In conclusion, the internship at CEAT Tyres Manufacturing Plant provided valuable
insights into the intricacies of tyre production, Maintenance of industrial machineries and
Industrial Environment. The experience not only enhanced technical knowledge but also
fostered an understanding of the challenges and opportunities in the tyre manufacturing
industry. This report serves as a reflection on the internship experience, highlighting key
learnings, recommendations, and areas for further exploration in the field of tyre
manufacturing.

[5]
 TABLE OF CONTENTS
CHAPTER
DESCRIPTION PAGE NO.
NO.

ACKNOWLEGEMENT 2

CERTIFICATE OF COMPLETION 3

PREFACE 4

ABSTRACT 5

TABLE OF CONTENT 6

LIST OF FIGURES 8

1 Objective of Internship 9

2 Methodology of Internship 10

Introduction 11

3.1 Introduction of the company 11

3
3.2 Introduction to tyre manufacturing process 12

3.3 Importance of tyres 13

4 Raw Material Stores 15

5 Mixing Department 16

5 5.1 Banbury Mixer 16

5.2 Twin Screw Sheeter 18

5.3 Two Roll Rubber Mill 19

6
6.1 Four Roll Calender 21

6.2 Pre-Calendering Process 23

[6]
 6.3 Main Calender 23
• Construction
• Working
6.4 25
Post Calendaring Process

6.5 26
Truck Tyre Bias Cutter

7 27
Extruders

7.1 27
8” * 6” Extruder
7
7.2 28
Slug Extruder

7.3 3&1⁄2 Extruder 29

8 30
3 Roll Calender

9 Bead Department 32

10.1 Pocking and Jamming 35

10.2 Curing 36

10 10.3 Truck Tyre Curing Cycle 40

10.4 Non-Truck Tyre Curing Cycle 41

10.5 Post Curing Inflation 42

11.1 Engineering Stores 43

11 11.2 Tyre Test Centre 44

11.3 Tyre Notations 44

Boilers
12.1 46
• Types of Boilers
12
• Specifications of Boilers
12.2 49
Compressors

13 Conclusion 50

[7]
 LIST OF FIGURES

FIG. NO. FIGURE NAME PAGE NO.

Fig. 3.1 Flow of Tyre Manufacturing Process 12
Fig. 3.2 Departments in the Plant 14
Fig. 5.1 Banbury Mixer 17
Fig. 5.2 Rotors of Banbury 18
Fig. 5.3 TSS 19
Fig. 5.4 Rubber Mill 20
Fig. 6.1 Four Roll Calendar 21
Fig. 6.2 Hydraulic Fabric Storage Unit 23
Fig. 6.3 Working of 4 Roll Calendar 24
Fig. 6.4 Truck Tyre Bias Cutter 26
Fig. 7.1 Types of Extruders 27
Fig. 7.2 Simplex Extruder 29
Fig. 8.1 Working of 3 Roll Calendar 30
Fig. 9.1 Cross Section of Bias Tyre 32
Fig. 9.2 Bead Making Machine 32
Fig. 9.3 Bead Department 33
Fig. 9.4 Flow of Bead Making 34
Fig. 10.1 Poking and Jamming Machine 35
Fig. 10.2 Tyre Curing Setup 37
Fig. 10.3 Dashboard For Process Monitoring 39
Fig. 10.4 Tyre Curing Press 41
Fig. 10.5 PCI Stand 42
Fig. 12.1 Fire Tube Boiler 46
Fig. 12.2 Water Tube Boiler 47

[8]
1. Internship Objective

1. To integrate theory of engineering and practical industrial practices.

2. To develop work habits and attitudes necessary for job success.
3. To study the practical use of different mechanical components in the
industry.
4. To study the workflow of the manufacturing process.
5. To learn and understand real life/industrial situations.
6. To get familiar with various tools and technologies used in industries and
their applications.
7. To study the organizational structure of an integrated.
8. To study the equipment and machineries installed.
9. To build a record of work experience.
10. To find innovative ideas that shall optimize the processes.

[9]
 2. Methodology of Internship

1. Observing the overall workflow in the industry.

2. Understanding the tyre manufacturing process from raw material to the finished goods.
3. Understanding the various machineries used in different departments in tyre
manufacturing process.
4. Study of the principles, construction and working of the machineries.
5. Analyse and observation of data to identify opportunities for improvement.

Week 1 – Safety measures, Understanding the work flow, Visited all the departments and met
with officers including RMS, Mixing, Curing, Warehouse, Testing center and Engineering
Stores.
Week 2 – Study of Banbury Mixer, Twin Screw Sheeter and Four Roll Calender,
Maintenance of Banbury Mixer
Week 3 – Study of Extruders, Bead and Band Department
Week 4 – Curing and Post curing process, Boilers and compressors in utility, FPS

[10]
3. Introduction
3.1 Introduction of the Company
CEAT Ltd.
CEAT Tyres is a renowned Indian tire manufacturing company that has established
itself as a prominent player in the global automotive industry. With a legacy spanning several
decades, CEAT Tyres has garnered a reputation for producing high-quality tires known for
their performance, durability, and safety.
CEAT Tyres was founded in 1958 by the RPG Group, under the leadership of Mr. R.P.
Goenka, with its headquarters in Mumbai, India. The company initially began as a joint venture
with the Italian tire manufacturer, Cavi Elettrici e Affini Torino (CEAT), hence the name
"CEAT Tyres."
The CEAT Tyres Manufacturing Plant in Nashik, Maharashtra, is one of the flagship
production facilities of CEAT Tyres. In 1993, CEAT entered into a collaboration with the
Yokohama Rubber Company to manufacture radial tires at their Nashik unit. It serves as a hub
for manufacturing a wide range of high-quality tires catering to various vehicles, including
cars, two-wheelers, and commercial vehicles. It stands located at 82, MIDC, Satpur Colony,
Nashik, Maharashtra 422007 is a prominent landmark in the area and this establishment is in
close proximity to the same.

[11]
3.2 Introduction to tyre manufacturing:
Tyre manufacturing is the process of creating tyres, which are the rubber coverings that are
fitted around the wheels of vehicles. Tyres is an essential component of any vehicle and are
responsible for providing grip, stability, and safety on the road.
The process of tyre manufacturing is complex and involves a number of different stages. It
typically begins with the preparation of the rubber compounds that will be used to create the
tyre. These compounds are created by mixing together various ingredients, including natural
and synthetic rubber, carbon black, and other chemicals.
Once the rubber compounds have been prepared, they are shaped and cured into various
components of the tyre, such as the tread, sidewalls, and beads. These components are then
assembled together with other parts, such as the inner liner and steel belts, to create the final
tyre.
The tyre manufacturing process requires specialized machinery and equipment, including
mixers, extruders, calendars, and tire-building machines. It also requires skilled technicians
and engineers who are responsible for overseeing the various stages of production and ensuring
that the tyres meet strict quality standards.
Overall, tyre manufacturing is an important and complex process that requires a combination
of advanced technology, skilled labour, and quality control measures to produce safe and
reliable tyres that can withstand the demands of everyday use on the road.

Fig. 3.1 Flow of tyre manufacturing process

[12]
3.3 Importance of tyres:
The quality of tyres is essential for ensuring the safety and performance of a vehicle. Here are
some reasons why:
1. Safety: Tyres are the only contact point between a vehicle and the road. High-quality
tyres ensure better grip, handling, and control, which translates to better safety on the
road.
2. Fuel efficiency: Tyres with good quality treads and designs can reduce rolling
resistance, which in turn, enhances fuel efficiency. This can save you money on fuel
costs over the long run.
3. Longevity: High-quality tyres are made from durable materials that can withstand wear
and tear, leading to longer-lasting tyres. This can save you money on frequent tyre
replacements.
4. Performance: High-quality tyres are designed to provide better performance, including
improved acceleration, braking, and handling. This can enhance the overall driving
experience.
5. Environmental impact: Quality tyres can reduce the amount of CO2 emissions
produced by a vehicle. This can contribute to a cleaner environment and reduce your
carbon footprint.
In summary, the quality of tyres is crucial for safety, performance, fuel efficiency, longevity,
and environmental impact. It is always recommended to invest in high-quality tyres for your
vehicle.

[13]
Fig. 3.2 Flow Chart – Departments in the plant

[14]
4. Raw Material Stores (RMS)
As we know, the first step towards manufacturing of tyres is receiving correct
raw material as per quality requirements with correct physical and chemical properties.
The raw material store is the main storage location for all of the material used in tyre
manufacturing process. All type of material required are purchased from different vendors and
stored in raw material stores. The raw material stores of the company have a large capacity of
maintaining stock that production cannot stop for at least 15 days in case of breakdown of raw
material supply chain.
The material is ordered in economic order quantity and considering lead time. The received
material is firstly called as restricted material and the samples are sent to quality assurance
department for quality checking of the material. After the quality checking of the material by
quality assurance department, if the material is found good for production, then it is called as
unrestricted material and it is then supplied to Banbury for mixing and further operations. The
RMS supply the material to CEAT tyres manufacturing plant Nashik and also some outsourcing
vendors.
The RMS is mainly divided in five areas:
1. Rubber storage area: - All the various types of polymers required for tyre are stored here
such as Natural Rubber, Compound Rubber, Styrene Butadiene Rubber, Crumb Rubber.
Along with rubber various chemicals required such as Silica, Sulphur Powder, Wooden
Resin etc are also stored. Each of these variety of material has given a specific code for
easier handling and identification.
Natural Rubber – RSS4 (Sheets)
Compound Rubber – M330 (Blocks of 35 kg)
Chloro Butyl Rubber – R2160
Silica – R122
Etc.
2. Carbon storage area: - Carbon black is critical to strength, wear and durability on any
rubber of tyre. The required carbon is stored here and supplied to Banbury with the help of
carbon black conveying system. Carbons of grade N660, N550, N330 etc
3. Fabric storage area: - The dip fabric nylon required in calendaring process is stored in
fabric storage area. It is a 2000 meters and 900 kg roll.
4. Bead wire storage area: - The copper wires required in production of beads are stored.
5. Oil tanks.

[15]
5. Mixing Department
The first step in commencement of manufacturing of a finished goods from
raw material is mixing of the polymers, oils & chemicals according to the requirement of tyre
material. Mixing is the most critical stage of rubber processing. The aim of mixing is to produce
a product that has the ingredients dispersed and distributed sufficiently thoroughly that will
process satisfactory in the next process, cure efficiently and give the required properties for the
end application. The mixing of raw material is specifically done in two stages, the first stage
involves shearing of polymers and the molecules are broken down to give easier flow. This is
known as mastication. The compound formed at this stage is called as Master compound.
Second stage involves incorporation of additives in the master compound, this compound is
called as final compound. The samples are taken out from each batch of compound, that are
tested in research laboratory. After the approval the final compound is sent to subsequent
departments for further process.

5.1 Banbury Mixer

1. The raw material polymer which is in form of blocks or sheets along with chemicals (e.g.,
silica) is weighted on a weighing scale and then transferred at the door of Banbury mixer
through a chain driven conveyor. The data about the weight and composition of each batch
is recorded and stored with the help of SCADA System.

2. The raw material enters into the Banbury mixer through the hooper door from the top of
Banbury directly from conveyor. The extra ingredients required are collected in a bag using
chemical weighment machine according to required weight of each material.

3. The raw material is mixed with the help of Banbury Mixer. The Banbury mixer is the
machine with a pair of rotors of helical shape and relative rotation, which blends and mixes
the polymer material with adjustable temperature and pressure. Rubber is mixed with oil
and then heated with hot air, causing it to melt and fuse together. It is a highly efficient tool
for the mixing operation. Along with the rubber compound oil and carbon is mixed in
Banbury mixer. It has a hydraulic ram at the top of the rotors for maintaining pressure inside
the chamber.

4. There are total five Banbury in the mixing department.

[16]
 Out of which, Banbury No. 1, 2 & 3 are for making Master compound. Banbury No. 4 &
5, are for processing of Master compound and making of Final compound. The Banbury
No. 5 is driven by a twin output parallel shaft gearbox having speed reduction ratio 31.5:1
which is driven by a 450-kW motor at the mixing temperature 142 ֯ C

5. The rotors of Banbury mixer are driven by 450 kW AC motor by a gear shaft transmission
having twin output parallel shaft gearbox. The hydraulic ram pressurizes the chamber and
helps mixing at high pressure.
The process parameters are: -
Ram pressure = 45 kg/cm2
Ram down time = 56 sec
Mixing power = 13.6 kW
Mixing time = 92 sec
Mixing Temperature = 192 ֯ C
Mixing speed = 57 rpm

Hydraulic Ram

Hooper Door

Rotors

Casing

Fig. 5.1 Banbury Mixer

[17]
5.2 Twin Screw Sheeter
1. After mixing in Banbury, the compound directly comes in the Twin Screw Sheeter or
TSS Extruder though the hooper door at the top of twin screw casing. This machine
converts the mixed compound high temperature pulp in sheet plane continuous sheet.
TSS Extruder is having twin screw mechanism followed by a external two roll calendar.
The tapered, Intermeshing and counter rotating extruder screw are supported by bearing
in their casing. One screw is driven by a directly mounted motor and parallel shaft
reduction gear box. The second screw is driven by the first screw by connecting gears.
The counter rotation of the screws ensures the continuous discharge to the two-roll
calendar. Both the rolls of calendar are driven by a single motor having twin output
parallel shaft gear box.

Fig. 5.2 Rotors of Banbury

2. The sheet extruded in Twin Screw Extruder are dipped in soap/coolant water through
take off belt conveyor which is driven by chain mechanism. The sheet of compound
further passes through a colling conveyor where, sheet is cooled with the help of 18
air blowers or fans.

3. The sheets are then collected on trolley from the wig wag. The compound formed at
this stage is called as known as Master compound. The Master compound again is
sent to next Banbury line, where further additives like silica or oils are added to the
mixer.

[18]
 Fig. 5.3 TSS

5.3 Two Roll Rubber Mill

1. The compound is then dropped in the 84ʺ two roll mill through the hooper door bottom
of the Banbury, which further processes the compound to give a uniformly mixed
compound. Two rolls of the mill are assembled horizontally one after another. The mill
is a steel roll, shell type construction which allow heat transfer to the compound from
hot water inside the rolls through their steel body.
The rear roll is driven by a 185-kW & 985 rpm motor through 3 step parallel shaft gear
box of gear ratio 58.6:1. And the second roll is driven from the first roll by connecting
gears.

2. The sheet made from this mill goes to 60ʺ two roll mill. Two rolls of 60ʺ mill are
situated one on the top of another, of which the bottom roll is fixed and the top roll can
be adjusted by pneumatic pressure. The rolls are driven 112-kW, 988rpm motor and a
twin output parallel shaft gear box of gear ratio 63:1. This mill extrudes the compound
again in continuous sheet.

[19]
3. A small sample of compound is taken at this stage for chemical testing of compound in
research chemical lab from each batch of compound. The sheets produced are called as
final compound. After the quality checking of compound, it is sent to the subsequent
department for further process.

Fig. 5.4 Rubber Mill

[20]
6. Four Roll Calender
Calendering is a process in tire manufacturing where fabric is coated with rubber. It
works by pulling (sandwiching) fabric between two large rubber-coated rollers that press into
the top and bottom of the material. As it moves through the rollers, the pressure forces the
rubber to permeate and adhere to the fabric.

4 Roll Calender consist of following steps:

Let Off ( Fabric Unwinder)

Splicing Press

Final Hydraullic Storage Area

Compound for Fabric

Cracker Mill Hot Can

Warm up Mill Pre Compensator

(Blender)

Centering Unit
Feed Mill

Main Calender

Colling Drum

Post Compensator

Hydraullic Storage Area

Rewinder (Liner
Storage)

Fig. 6.1 Flow chart – Four Roll Calender

[21]
6.1 Pre-Calendering process
1. Let Off : -
The Dipped Fabric Roll is un-winded for the further calendaring process
with the help of Chain-sprocket mechanism which is driven by a 15kW, 1750
RPM DC Motor through a gear box having reduction ratio 10.85 :1.
In the Let Off Section, two set ups of the unwinding mechanism are provided
to reduce the time lag in between roll changing process.

2. Splicing Press: -
The Splicing Press is the hydraulic press which is used to join the two
rolls at the time of changing the fabric rolls. The two ends of fabrics (i.e., one end of
the roll which is about to finish and other end of the new roll) are joined in the press
with the help of a rubber material called V4 (60*0.5mm) at 182 ֯ C temperature for
30 seconds at the 50 kg/cm2 pressure.
The web tension at this stage is 48 daN.

3. Fabric Storage Unit: -

At the time of fabric roll changing and the splicing press time, the main
calendar should be stopped because continuous supply of fabric is stopped at the time
of roll changing and splicing press operation. To overcome this lag due the supply of
the fabric storage, this hydraulic storage mechanism is used. It Consist of 23 rollers.
12 at lower side and 11 at upper side. The hydraulically activated chain sprocket
mechanism lifts the upper rolls high from the lower at 60 kg/cm2 pressure, so that
more fabric gets accumulated in it. And it comes down slowly so that the fabric is
supplied to the main calendar without any interruption in the process.

[22]
 Fig. 6.2 Hydraulic Fabric Storage Unit
4. Hot Can: -
The un-winded fabric the passes on from the 10 rolls having continuous flow
hot water through them. These hot cans remove the moisture from the fabric and
make it ready for calendaring process. The temperature of water in the hot can is set
at 105 ֯ C.
Before the hot can, the fabric line passes from the Banana roll situated at various
location in the fabric line. These Banana rolls helps the fabric to remain in uniform
tension, even width and remove folds is any.

6.2 Main Calendar: -

The main calendar consists of four roller mills in which fabric cords are coated
with rubber stock. Hence, thin sheets of the calendared rubber are formed in this roller
mills.
• Construction: - The main calendar consists of four roller mills each of 1840mm in
length and 700mm diameter. Three rolls are arranged one upon another and the fourth
roller is placed at the back side of the top roll as shown in fig.

[23]
 Fig. 6.3 Working of 4 Roll Calendar

• Working: -
The final compound previously mixed in the Banbury is again well mixed and blended
with the help of two mills namely mixing mill and bending mill having hot water supply
through them. The rubber is heated with the help of hot water inside the rollers of mills or say
it is baked in these mills, to ease the calendaring process. Hot rubber is easy to mould and
reshape. After the well mixing and blending the rubber compound is transported to feed mill
with the help of conveyor belt and the feed mill again distribute the compound to conveyor 1
(upper) and conveyor 2 (lower). Conveyor 1 supplies compound to the back roll and top roll
and second conveyor supply compound at the joint of fixed roll and bottom roll. The fabric
coming from the back side from pre compensate and the rubber compound came from both the
conveyors passes through the joint between top roll and fixed roll. And hence, the fabric is
coated with the rubber compound and the thin sheet of this calendared rubber sheet is formed.

[24]
6.3 Post Calendering Process:

1. Cooling Drum: -
The sheets are then cooled with the help of 10 cooling drums having continuous
water supply through them. The water is at room temperature. This helps the sheet to
dissipate the heat to the water through metal drums. Water is supplied at pressure of
1.8 kg/cm2. The cooling drums are rotated at speed of 15 rpm. All the ten drums
simultaneously with the help of chain sprocket mechanism. The sprocket chain is
driven by 25 kW DC motor having a gearbox having reduction ratio 100:1.

2. Rewinder: -
After the cooling of the sheet, it is re winded on the liner storage. The rubber
sheet is rested on the liner are simultaneously re winded in the roll called as calendar
roll. The rewinder works with the help of Chain-sprocket mechanism which is driven
by a 15kW, 1750 RPM DC Motor through a gear box having reduction ratio 10.85:1
. The calendar roll is stored in four roll calendar storage area. And then supplied to
the Truck Tyre Bias Cutter.

• Cracker Mill: - 84ʺ * 26ʺ mill with speed 30mpm (front roll). Driven by
260kW, 990 rpm motor through a four-shaft parallel gear box with gear ratio
56:1.
• Warm Up Mill: - 79ʺ * 26* mill with speed 25mpm of front roll, driven by
180kW, 990 rpm motor through a four-shaft parallel gear box with gear ratio
56:1.
• Feed Mill: - 79ʺ * 26* mill, driven by 180kW, 990 rpm motor through a three-
shaft parallel gear box with gear ratio 12:1. Hot water temperature inside the
mill 88 ֯C

[25]
6.4 Truck Tyre Bias Cutter: -

The calendared fabric is cut into specified width at the specified angle using
Bias Cutter machine. The pieces are used for making bands of the tyre. The calendared
roll is un-winded by a chain drive having right angle gear box mechanism and cut using
oscillating chain mechanism on a belt conveyor in a rhombus like shape called bias.
The bias angle is approx.
Passenger: 32֯ -38֯
Truck: 35֯ - 40֯
Tractor: 34֯ - 38֯

Fig. 6.4 Truck Tyre Bias Cutter

[26]
7. Extruders: -

Extrusion is the process by which a rubber is propelled continuously along

a screw through regions of high temperature and pressure where it is softened and
compressed, and finally forced through a die. Extrusion is a primary requirement in the
process of manufacturing of tyres. Certain components of tyre like the tread and the
sidewall have specific profiles that can only be got through the process of extrusion.
There are three types of extruders.
• Simplex Extruders: - Single screw extruder (Slug extruder and Bead Extruder)
• Duplex Extruders: - Double screw extruder, used where two compounds are
needed to be mixed. (8ʺ * 10ʺ, 8ʺ * 6ʺ, 3. 5ʺ * 4.5ʺ)
• Multiplex Extruders: - More than two screws used for extruding.

Extruders

8ʺ * 10ʺ 8ʺ * 6ʺ 3.5” * 4.5” Slug Extruder

Treads Treads & sidewalls Sidewalls Fillets

Fig. 7.1 Types of Extruders

7.1 8ʺ * 6ʺ: -

1. The extruder has a 6-inch screw at bottom and 8-inch screw at top inclined towards
the extruder head. Both the screws have a hooper inlet from which the final
compounds are entered in the screws
2. The compound entered in the barrel is propelled along the screws which are at
temperature of 75 ֯ C. Due to which the compound become softened and
compressed.
3. The 6” & 8” screws are driven by parallel shaft reduction gear box at speed of 13.3
& 14.3 RPM respectively.

[27]
 4. The softened and hot compounds propelled by screw come in extruder head and
simultaneously passes through the die forming a continuous line of the tread or
sidewall.
5. Die is metal channel that impose the required cross section to the compound stream.
Dies of different cross sections are available for producing number of types of
treads.
6. The Die need to be pre heated before directly fitting it to the extruder head for
extruding to prevent cracking of tread or sidewall. Hence, the Die is heated for at
least 45 minutes at temperature between 110 ֯ C to 125 ֯ C.
7. The continuous stream of the extruded compound is shape of tread is passed
through the roller conveyor at speed of 14 RPM.
8. Then with the help of inclined belt conveyor it goes into the Dancing Cooling
conveyor, where it is cooled by spraying water on it. The walls of cooling conveyor
chamber are made up of layers of thermocol and wood. All the Conveyors are run
by DC motors and chain drives.
9. After cooling the Auto Skiver machine cuts the treads with the help of inclined
cutting wheel (Sidewalls are cut using Hot Knife). Auto Skiver is a Tread cutting
unit which cuts the tread by oscillating motion of chain sprocket mechanism which
is driven by DC motor and right-angle gear box.
10. Weighing scale measures the weight of each tread and gives signal in form of red
or green light. The length of tread is measured manually. Then they are loaded on
power jack.

7.2 Slug Extruder: -

The slug extruder produces fillets which are further used in manufacturing of beads.
Fillet is a triangular structure which is attached on the bead strip. A Screw of 3.5 inches is used
for the extrusion of fillet. A Motor of 150 kW and 1500 RPM drives the screw with a parallel
shaft gear box having gear ratio 31.5:1. Which drives screw at 45 RPM. The extruded fillet is
passed to the chain driven cooling belt conveyor which sprays water on fillet for cooling. The
heated water is cooled using 6 heat exchangers. The cooled fillet is winded with liner and sent
to bead department.

[28]
7.3 3𝟏⁄𝟐 Extruder: -
This extruder is mainly used for extruding sidewalls. It is a simplex extruder. i.e., It
has single screw which propels the rubber and extrudes sidewalls through dies. It is driven by
30 kW motor and a gear box with gear ratio 25:1. The die is preheated before fitting it to the
extruder head same as the other extruders at 110 ֯ C. The extruded sidewall line is transported
on cooling conveyor with the help of belt conveyor. Water is sprayed on the sidewalls for
cooling in cooling conveyor and afterwards they are wrapped in roll with liner.

Fig. 7.2 Simplex Extruder

[29]
8. Three Roll Calendar

A 3-roll calendar is a key component in the tire manufacturing process. The

process involves passing the rubber material through a series of rollers to create the desired
thickness and shape.
• Construction:-
In a 3-roll calendar, the rubber material is fed into a set of three rollers arranged in a
vertical stack. The top and bottom rollers are called "heating" rollers and are heated to a specific
temperature to soften the rubber. The middle roller is called the "cooling" roller and is kept at
a lower temperature to cool the rubber as it passes through.
As the rubber material passes through the calendar, it is compressed and elongated by the rollers
to create a flat sheet of rubber with a uniform thickness. The speed of the rollers can be adjusted
to control the thickness of the rubber sheet, and the shape of the rollers can be customized to
create a variety of patterns and textures on the surface of the rubber.
After passing through the 3-roll calendar, the rubber sheet is typically cut to the desired size
and shape for further processing, such as moulding and curing, to produce the final tire product.

Feed
TOP Conveyor 2

Feed
Conveyor 1
CENTRE

Final sheet
BOTTOM

Fig. 8.1 Working of 3 Roll Calender

[30]
 • Working:-
In this process the final compound is baked in 60” cracker mill which is driven by parallel
shaft bull gearbox later this final compound is passed to the 3-roll calendar by an overhead belt
conveyor. 3 roll calendar (having top, centre, bottom rolls) which is driven by parallel shaft
gearbox having gear ratio 66:1, in 3RC the centre roll is driven by motor and the top & bottom
rolls are driven by connecting gears.
The hot water in rolls have temperature:
Top roll = 84 C* centre roll= 80C* Bottom=80C*
Later the sheet is passed to the cooling station having 6 cooling drums which are driven by a
single motor by chain mechanism. (Water in the cooling drum is cooled by Temperature control
unit (TCU) having 3 heat exchangers at pressure 4.5 Kg/cm^2).
These sheets are passed to windup station by belt conveyor.

[31]
9. BEAD DEPARTMENT: -

Fig. 9.1 Cross Section of Bias Tyre

A tyre's bead is the edge of its sidewall that hooks around a metal wheel rim to secure
it tightly in place. The bead forms a seal between the tyre and the inside surface of the wheel
so that it can't be pushed off during use. The bead serves as the foundation of the tyre and
provides a secure anchoring point for the tyre to be mounted on the rim.
The tire bead component includes the copper wire loop, apex or bead filler; the chafer, which
protects the wire bead components; the chipper, which protects the lower sidewall; and the
flipper
The beading process begins with the preparation of the tyre carcass, which is made up of layers
of rubber-coated fabric and steel cords.
Next, the bead is applied to the tyre carcass using a bead application machine. The machine
places the bead onto the tyre carcass and then wraps it tightly around the carcass, ensuring that
it is properly aligned with the other components of the tyre.

Fig. 9.2 Bead making machine

[32]
After the bead has been applied, the tyre is placed into a tyre-building machine, where
additional layers of rubber and fabric are added to the tyre. The tyre is then shaped and cured
to its final form.
Overall, the beading process is an essential step in the tyre-building process, as it ensures that
the tyre is securely anchored to the rim and provides a stable base for the rest of the tyre
components to be built upon.

Fig. 9.3 Flow chart – Bead Department

[33]
 • Working:-
The 8 steel wires are un-winded from the loop & are aligned in parallel to each other later
these 8 wires are provided with tension by the tensioning unit and then passed to the extruder.
The extruder has 15kW, 1470RPM motor followed by a gear box of reduction ratio 20:1,
which revolves the extruder screw.
Screw Temperature – 55 ֯ C.
Barrel Temperature – 65 ֯ C.
The final compound is transferred to the hopper having thrust gearbox via conveyor.
The wires are passed through the extruder die having different thicknesses as per the need, (in
this the 8 wires are sandwiched between the rubber, the strips are moved to the festoner &
then to the chuck (here 8 loops of strips are combined to form bead)
The end of the loop is joined by the adhesive (c118).

Fig. 9.4 Flow of Bead making

[34]
10.1 Pocking and Jamming: -

The green tyre is pocked from axial and radial directions for
removing air bubbles and for good quality moulding at the time of curing of the green
tyre. The green tyre is pocked using a slider crank mechanism. The motor revolves the
crank and the slider is fitted with 9 sharp metal pins which pock the tyre from radial
direction at the pressure of 80 kg/cm2.
The joint of the tread is jammed with the jamming machine. It has a
arm having hot cracker roller as its end effector, the arm is operated by a pneumatic
system and the joint of tread is jammed with the help of roller at 3.5 kg/cm2.

Fig. 10.1 Poking and Jamming Machine

[35]
10.2 Curing: -
The curing process is the final step in tire manufacturing, where a green tire built
from layers of rubber compounds is formed to the required shape by curing it in a mould
in a press. The green tyre is transformed into a finished tyre having desired shape, size
and grip. Curing press has two sections LHS and RHS called as platan, the moulds of
desired shapes are placed inside the platans.
The bladder is fitted at the centre of mould. Bladders are the flexible
membrane that covers inside surface of tyre during curing process. The green tyre after
pocking and jamming, is carried to the curing press machine with the help of trollies.
The colour markings on the green tyre helps for identification of the tyre. The green
tyres are placed inside the mould in both RHS and LHS sides. The serial number of
tyres is placed in the mould. At the centre of mould and platen there is a piston cylinder
mechanism which helps the bladder to move.
The press head is closed which is operated by gear and pinion mechanism.
Various operations are performed in the closed press with the help of bladder such as
hot water supply, High pressure steam supply etc. We studied the process by observing
the following case of curing.

[36]
 Fig. 10.2 Tyre Curing Setup
Three key elements of the vulcanization process are time, temperature and
pressure. Temperature and pressure will directly affect the quality of the tire. Low
temperature does not produce enough sulphur content and the resulting tire rubber
polymer chains do not have the desired wear resistance or high elastic properties. High
temperature or high pressure produces too much sulphur, resulting in a tire with a short
life and the inability to withstand high forces. If the pressure is too low, the tire will
become soft and sponge-like. If the pressure is high, the life of the tire curing equipment
will be reduced and energy consumption increased.

A tire curing press is a specialized machine used in the tire manufacturing

industry to shape and cure rubber compounds into the final tire form. It applies heat and
pressure to the uncured rubber tire, causing it to bond and take on its final shape.

[37]
 Design of Curing Press:-

• Press Structure: Tire curing presses typically have a robust and heavy-duty frame to
withstand the high forces and pressures involved. The frame is usually made of steel
and designed to provide stability and rigidity during the curing process.

• Press Platens: The press is equipped with upper and lower platens that hold the uncured
tire during curing. The platens are made of high-strength steel and are designed to
distribute heat and pressure evenly across the tire.

• Hydraulic System: Tire curing presses utilize a hydraulic system to generate the
required force for curing. The system consists of hydraulic cylinders, valves, and pumps
that control the movement of the platens. The hydraulic system allows for precise
control over pressure, temperature, and curing time.

• Heating System: The press incorporates a heating system to raise the temperature of
the uncured tire to the desired level. Heating can be achieved through various methods,
such as steam, electric heaters, or hot oil circulation. The press may have separate
heating zones to ensure uniform heating across the tire.

• Control System: Modern tire curing presses feature advanced control systems for
precise monitoring and regulation of the curing process. These systems can include
programmable logic controllers (PLCs) and human-machine interfaces (HMIs) that
allow operators to set and adjust various curing parameters such as temperature,
pressure, and curing time. A proportional-integral-derivative controller (PID controller)
is a control loop feedback mechanism (controller) which is used in curing press. A PID
controller calculates an "error" value as the difference between a measured process
variable and a desired set point. The controller attempts to minimize the error in outputs
by adjusting the process control inputs. The curing time for the truck and tractors curing
press is nearly 57 minutes and for radial and non-truck tyres it is around 28 to 40
minutes.

[38]
• Safety Features: Tire curing presses are equipped with multiple safety features to
protect operators and prevent accidents. These may include emergency stop buttons,
safety interlocks, pressure relief valves, and temperature sensors to ensure safe and
reliable operation.
Curing or vulcanization of is divided into several steps which involves
combination of following operations.
1. HPS = High pressurised steam supply
2. HWS = Hot water supply
3. FSR = Forced steam return
4. HWR = Hot water return
5. CWS = Cold water supply
6. CWR = Cold water return
7. VAC = Vacuum assisted closure
8. MDN = Main drain
9. CDN = Closed drain
10. DBN = dome boosting supply
11. PCI = Post curing inflation

Fig. 10.3 Dashboard for process monitoring

[39]
 We observed and studied two curing press and the process to understand all the steps,
one of them is a truck tyre curing press Trench 08 press no. D05 and the other is non
truck tyre curing press Trench 01 press no. 05.

10.3 Truck tyre curing:-

(Trench 08 press no. D05)
Total cycle time is 52 minutes.
Table of Details of Curing Cycle: -
Step Operation Step Internal Dome Mould
No. Time Pressure Temperature Temperature
(kg/cm2)
1 HPS, MDN 4 min 15 127 ֯ C 200 ֯ C
2 CDN 30 sec 15 145 ֯ C 200 ֯ C
3 DMS 6.2 min 7 145 ֯ C 180 ֯ C
4 HWS, 34 min 25 145 ֯ C 130 ֯ C
MDN, DMS
5 HWS, 1.1 min 10 130 ֯ C 50 ֯ C
MDN, CWS
6 CWS, MDN 1 min 18 110 ֯ C 40 ֯ C
7 CWS, 3 min 17 120 ֯ C 40 ֯ C
CWR, MDN
8 HPS, FSR, 40 sec 9 130 ֯ C 130 ֯ C
MDN
9 CWS 20 sec - 130 ֯ C 100 ֯ C
10 CWR 30 sec - 130 ֯ C 100 ֯ C
11 VAC, 60 sec - 130 ֯ C 100 ֯ C
MDN, PCI

[40]
 Fig. 10.4 Tyre Curing Press
10.4 Non truck tyre curing:-
(Trench No. 1 press no. 05)
Total cycle time is 28.30 minutes.
Mould temperature = 170 ֯ C
Bladder Height = 470 mm
PCI Pressure = 5.8 kg/cm2

Table of Details of Curing Cycle: -

Step No. Operations Step time Internal pressure
(kg/cm2)
1 HPS, FSR, MDN 40 sec 11.5
2 HPS, MDN 7.7 min 15.1
3 HPS, MDN, CDN 40 sec 14.7
4 HPS, MDN 8 min 15.5
5 HWS, MDN 9 min 24.5
6 HWR, CWS, MDN 30 sec 12.6
7 CWS, MDN 40 sec 16.7
8 CWS, CWR, MDN 2 min 11.7
9 FSR, PCI, HPS, MDN 40 sec 11.5
10 PCI 40 sec 0.7
11 MDN, VAC, PCI 30 sec -

[41]
 10.5 Post curing inflation: -

This is the process of cooling the tyre immediately after removing the tyre
from curing press. The tyres are mounted on the special stand called PCI stand. PCI
stand has a mounting similar to rim of the tyre which is forced by a power screw, which
is driven by chain drive by DC motor. The mounted tyre is supplied with a specific air
pressure.
Post Curing Inflation PCI is important process in order to avoid the thermal
shrinkage of nylon. Nylon has unique property of shrinking when it is heated. After
removing the tyre from press, there are high chances of shrinkage in it is allowed to
cool in normal atmospheric pressure. But in PCI stand tyre is subjected to air pressure
inside it and cooled under pressure, so that shrinkage is avoided.
If PCI is not done immediately after curing, the tyre may lose shape and
resulting in small changes in dimensions and unbalanced condition. PCI pressure is
nearly equal to the normal tyre pressure. Three air compressors of 500CFM capacity in
the utility produces pressurised air for post curing inflation.

PCI Pressure
Gauge
Driver Motor

Power
Screw

Rim

Fig. 10.5 PCI Stand

[42]
11.1 Engineering Stores :-

Engineering stores are an integral part of any manufacturing industry, including

tire manufacturing. The availability of engineering stores is crucial to the smooth functioning
of the production process in the tire manufacturing industry. The tire manufacturing industry
is a complex and technologically advanced industry, and engineering stores play a vital role in
ensuring that the production process runs smoothly. SAP ERP is used in the engineering stores
for management and planning of resources. The stores have more than 500 vendors for
purchase of all engineering application tools and spares. Repurchasing orders are placed
automatically by the SAP by tracking inventory level with priorly set economic order quantity
(EOQ).
The reordering level is the inventory level at which an order for additional inventory is
triggered. It is calculated by subtracting the lead time (the time it takes for an order to be
fulfilled) from the demand during that lead time, and adding the safety stock (a buffer of extra
inventory to protect against unexpected demand).
The economic order quantity (EOQ) is the optimal order quantity that minimizes the total cost
of ordering and holding inventory. It takes into account the costs of placing an order, such as
ordering costs and setup costs, and the costs of holding inventory, such as storage costs and
opportunity costs.

• SAP: -
SAP (Systems, Applications, and Products in Data Processing) is a leading enterprise
resource planning (ERP) software. The software is designed to help organizations manage their
business operations, including financials, logistics, human resources, procurement, and
customer relations. SAP provides real-time data and insights into business operations, enabling
organizations to make informed decisions and improve their efficiency, productivity, and
profitability.

[43]
11.2 Tyre test centre: -
Mainly four types of tests are done in the tyre test centre.
1. Endurance –
Here full air is filled in tyre & then it is run on artificial load which helps to
understand the endurance limit of tyre. Here load on tyre is Gradually increased
& tested it till it blasts.
Up to 15” rim diameter a manual machine is used & above 15”
Automated.
2. High Speed –
On this test tyre is made run at its full speed for testing its high speed.
3. Plunger –
In this machine ball nipped pin is inserted on the centre of tyre. At 6 different
points it is inserted & load is applied on it to test its load carrying capacity.
4. Dimensional –
A part of tyre is being cut & all the dimensional tests are done on it which
includes bead checking, ply checking, rubber checking, distance between two
plies, RCL line check, distance between ply & tread shoulder.

11.3 Tyre Notations: –

N 0 5 2 1 8 0 6 2 3

Here,
N = Plant name (Nashik)
05218 = Plant Code
06 = Week of the current year
23 = Year of Manufacturing

Size Markings:-

1. 8.25-20

[44]
Here,
8.25 = Height is-to width ratio
20 = Rim Diameter

2. 700 R 15

Here,
700 = Height is-to width ratio
R = Radial tyre
15 = Rim Diameter

Note –
1) Tyre contains Tread- Tread Shoulder – Side Valve – RCL line – Bead.
2) Single tyre once in a year is tested to check its stability.

[45]
12. Utility

Utility department is responsible for supply of various utilities required in the

manufacturing process like steam, hot water, pressurized air, vacuum, electric power,
refrigeration, chemicals etc.

12.1 Boilers: -
Boilers play a crucial role in tyre manufacturing as they provide the necessary
heat and steam to carry out various processes involved in the production of tyres. A
Boiler is a closed vessel in which water or other suitable liquid is heated to generate
steam or vapour. The steam or vapour is then excited and is used for various purposes
in the plant such as in curing operation. It basically follows the concept of pressure
cooker but in better way.

• Types of Boilers: -

Fire-Tube Boilers:
Fire-tube boilers are the most commonly used type of boiler in the tyre
manufacturing industry. They have a simple design, and the combustion gases pass
through the tubes, heating the water that surrounds them. These boilers are relatively
small and are used for low-pressure applications.

Fig. 12.1 Fire Tube Boiler

[46]
Water-Tube Boilers: -
Water-tube boilers are another type of boiler used in the tyre
manufacturing industry. They have a more complex design compared to fire-tube
boilers, and the water circulates through the tubes while the combustion gases pass over
them. These boilers are typically used for high-pressure applications.

Fig. 12.2 Water Tube Boiler

Hybrid Boilers: -

A hybrid boiler is a type of boiler that combines two or more types of

boilers into a single system. It is designed to provide the benefits of multiple types of
boilers, while minimizing their disadvantages.

A hybrid boiler typically consists of a water-tube boiler and a fire-tube boiler, with the
water-tube boiler generating the majority of the steam and the fire-tube boiler providing
backup or additional capacity. The two boilers are integrated into a single system, with
a common steam drum and a shared combustion chamber.

[47]
 The water-tube boiler is used to produce high-pressure steam, while the fire-tube boiler
is used for low-pressure applications or as a backup system. The water-tube boiler is
more efficient and can handle higher pressures, but it is more expensive to manufacture
and requires more maintenance. The fire-tube boiler is less expensive and requires less
maintenance, but it is less efficient and cannot handle high-pressure applications.

There are four boilers in the utility out of which two are fire tube boiler, one is water tube and
one is hybrid or modified.

• Table of Specifications of these boilers:-

Sr. Parameters Boiler No. 1 Boiler No. 2 Boiler No. 3 Boiler No. 4
No.
1 Capacity of boiler (Ton 16 TPH 8 TPH 16 TPH 22 TPH
per hour-TPH)

2 Working pressure of 17 Kg/cm2 17 Kg/cm2 17 Kg/cm2 17 Kg/cm2

boiler (Kg/cm2)
3 Type Fire tube Hybrid Fire tube Water tube

4 Drum of boiler Single drum Single drum Single drum Bi drum

5 Furnace Type Oil fired Pulsating Oil fired Travelling

6 Height of chimney (m) 30 m 35m 35m 55m

7 Fuel used Light Diesel Biomass Light Diesel Biomass

Oil (briquette) Oil (briquette)
8 Specific fuel 415 Kg/Hr 150 Kg/Hr 415 Kg/Hr 4500 Kg/Hr
consumption

[48]
12.2 Compressor: -
The compressor is a machine that helps to increase the pressure of air. It does
this by compressing the air, which allows more oxygen and carbon dioxide to be added to the
air. The compressor is also used to drain excess water from an air system. This compressed air
is used at different stages in tyre manufacturing process such as in the curing process, in the
manufacturing of green tyre etc. There eleven compressors in the utility, which run continually
for the supply of compressed air.
There are total ten compressors in the compressor house. Out of ten, seven were of the capacity
1000 cubic feet per minute (CFM). One is 724 CFM and other three are 500 CFM compressors.

• Specifications of 500 CFM PCI Compressor: -

Working Pressure: - 12.5 BAR Max

Air Outlet Temperature: - 80 ֯ C Max
Motor: - 180 kW
Display Temperature: - 62 ֯ C
Display Pressure: - 10.1 BAR

[49]
 Conclusion

In this report, I have summarised my overall learning experience in the internship.

The internship at CEAT Ltd. Manufacturing Plant has been an enriching and valuable
experience. Over the course of the internship, a deep understanding of the various aspects of
tyre manufacturing and operations within CEAT Tyres has been gained.
The internship provided an opportunity to witness the tyre manufacturing process from start to
finish, including stages such as compound mixing, curing, and testing. The exposure to heavy
industrial machinery and failure situations has highlighted the precision and attention to detail
required to produce high-quality goods that meet industry standards.
Throughout the internship, there were opportunities to collaborate with professionals at various
levels within the organization. These interactions fostered a deeper understanding of the work
environment, organizational culture, and the importance of teamwork in achieving
organizational goals.
Overall, the internship at CEAT Tyres Manufacturing Plant has been a rewarding and insightful
experience. The exposure to various aspects of tyre manufacturing, quality control, and supply
chain management has deepened understanding and provided a solid foundation for future
professional growth. The internship has undoubtedly contributed to personal and professional
development, and it is with gratitude and appreciation that this internship report is concluded.

[50]

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