RUBBER & TEXTILES INDUSTRY

Facts & Figures of Rubber, Plastic, and Tire Industries

This conglomerate industry comprises of plastics and polymers, rubber and white goods, and tire industry. Plastics and rubber are used in the electronic manufacturing industries as they are light in weight, attractive and safe to handle. Though the white goods industry garners 60% of the market share at the national level, the Indian tire industry is the world’s third largest industry.

The global automotive tire market size is projected to reach $306 billion by 2022, growing at a CAGR of 7.6% from 2016 to 2022.

The tire industry provides direct employment to more than 0.15 million people, which is about 0.12 million of the organized sector.

The heavy investment driven tire industry contributes 3% of manufacturing GDP when the entire automotive sector accounts for 7.1 per cent of the GDP.

Annually about 215 million tires are manufactured in India and the Indian tire market contributes ~70% of total revenues.

Almost 60% of the global tire plants are located in Asia today.

The main processes involved in tyre manufacturing

Rubber Mixing
  • Up to 30 ingredients are used in tire’s rubber blend.
Cord Manufacturing
  • Cord is added for extra strength, puncture resistance, and durability.
Bead Manufacturing
  • Beads are made of high-strength steel coated in rubber, and create an airtight seal between the tire and the rim of the wheel.
Tire Building
  • Steel belts, beads, ply, tread, and other components are placed in a tire-building machine to obtain a green tire.
Vulcanisation
  • The green tire is vulcanized in a curing press, to give the tire its final shape, including its tread pattern.
Finishing
  • Edging, threading, inspection and quality testing is carried out.
Rubber Mixing
  • Up to 30 ingredients are used in tire’s rubber blend.
  • Huge Blenders and mixers are used. Generally, 4000 HP motors are used to drive mixers.
Cord Manufacturing
  • Cord is added for extra strength, puncture resistance, and durability.
  • Cords are steel wires, mixed with rubber and milled to provide strength to tires. Coolers with calendar rolls are used to roll rubber strips. A single truck tire ideally has 1200 cords.
Bead Manufacturing
  • Beads are made of high-strength steel coated in rubber, and create an airtight seal between the tire and the rim of the wheel.
  • Bead-setter assemblies consisting of rollers (to turn up beads) and sidewalls (to turn them down) are used. Use of steel and synthetic rubber beads facilitates in bearing pressure of 2 Pascal’s/square inch.
Tire Building
  • Steel belts, beads, ply, tread, and other components are placed in a tire-building machine to obtain a green tire.
  • Conveyor belts are used to provide at least two layers of rubber. This double-layered rubber strip is put in a big drum that rotates. It contains adhesive threads so that tires combat friction.
Vulcanisation
  • The green tire is vulcanized in a curing press, to give the tire its final shape, including its tread pattern.
  • Hydraulic Presses are used.
Finishing
  • Edging, threading, inspection and quality testing is carried out.
  • Threading machines are used to design the thread pattern.
Predictive Maintenance

Case Studies

Packaging/Motor
Packaging/Motor

Patented Vibration Monitoring System saves 7.5HP Pump and maintenance cost USD 26,000.

White Goods/Motor
White Goods/Motor

Plug and Play vEdge predicts anomaly in motor-powered blower-fan operations; assures safety of the workforce

Tire/Motor
Tire/Motor

Made in India, remote monitoring vibration sensor prevented motor breakdown on Extruder

Ceramic/Motor
Ceramic/Motor

Edge-computing based, Made in India, vEdge installed on motor powering the fan avoided fan failure in Glass Plant

Plastics/Motor
Plastics/Motor

Palm-sized Vibration Monitoring Sensor predicts chiller-failure; saves customized equipment in Plastic-pipes plant.

Packaging/Motor
Packaging/Motor

vEdge with visual indicators predicts motor-blower assembly looseness; ensures consistent reliability of equipment.

Ceramic/Pump
Ceramic/Pump

Comparative insights from pump monitoring system facilitate asset allocation in a Ceramic Plant.

Tire/Gearbox
Tire/Gearbox

vEdge on the dual extruder feed mill of a tire manufacturing plant saved 8 hours of downtime & 15 Thousand USD

Pipe/Motor
Pipe/Motor

vEdge on extruder of a pipe manufacturer saved downtime of 15 days and opportunity loss of 24 Thousand USD

Tire/Motor
Tire/Motor

Smart vEdge on a cracker mill of a tire manufacturing plant saved 8 hours and opportunity loss of 11 Thousand USD

White Goods/Fan
White Goods/Fan

Sensor installed on blower of a powder coat oven in an aluminum die-casting plant saved 3 hours of production loss

Packaging/Motor
Packaging/Motor

IDE vEdge installed on motor pump assembly of the boiler area in film packaging manufacturing saved 6 hours

Tire/Motor
Tire/Motor

IDE vEdge installed on motor driving mixer mill of a tire manufacturing plant saved 4 hours and loss of 1500 tires

White Goods/Fan
White Goods/Fan

Diagnostic services in a Paint shop prevented blower-failure saving 8 hours of production loss.

White Goods/Motor
White Goods/Motor

A real-time prognostic system saves production loss of USD 3500 and 5 hours of downtime in an FMCG Plant.

Testimonials

We have been using the real-time Diagnostic services rendered by Infinite Uptime and obtaining the customized reports along with the spectrum analysis. The System effectively triggers the alarms of impending failure, thus facilitating Predictive Maintenance in the Plant. We are now subscribing to these services in our other plants too.

Mr. E. N Patro, Maintenance Executive - Honda Motorcycle & Scooter India Pvt. Ltd., Karnataka

Infinite Uptime's Vibration Monitoring Solution for Predictive Maintenance has measured high on our expectations of quality, flexibility and in-depth knowledge and has continuously raised the bar. I must say the Diagnostic Services offered at a reasonable cost has increased the reliability of the equipment and reduced the investment in spares-inventory.

Mr. Keshav Prasanna, Senior Vice President - Reliance Industries Limited

We maintained our equipment well but still faced production losses and high downtime. Thank you Infinite Uptime for the real-time Vibration monitoring and Diagnostic services provided to monitor our gearboxes, motors, bearings and pumps. Our Maintenance Team is empowered and can now submit the history of equipment to auditors.

Mr. Sajo Paul, Plant Manager & Development Officer - TVS Motors

As promised by Infinite Uptime, the diagnostic services offered provided valuable data to find the root cause of abnormal behaviour of the helical gearbox. With the insights into the operating equipment, maintenance to prevent the breakdown turned the vibration levels to normal.

Mr. Shahikant Bhujbal, Sr. Manager - Integrated Electrical - Tata Steel Tarapur

We are monitoring our state-of-art machines using Infinite Uptime’s Diagnostic Services. The insights into critical equipment provided in real-time facilitate our maintenance to predictive. The plug and play Vibration monitoring System helps to avoid unexpected downtime and saves cost. The triggering of alarms with notifications on our mobiles has added an instantaneous rectification process increasing machine availability

Imran Hidayath, CEO - Hidayath Group of Industries, UAE

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PRINCE PIPING SYSTEMS
TRIDENT GROUP
VOLTAS
WELSPUN
UCIC
AVI GLOBAL PLAST
GARWARE
JK TYRE
ASTRAL PIPES
ASHIRVAD
TRUFLO
LARSEN & TOURBRO
PREMIER SEALS (INDIA)PVT LTD
IMDAAD, Lulu Hypermarket
IMDAAD, Lulu Hypermarket
MRF Tyres
Classic Auto Tubes
Gol Iplek
Rowad Plastics
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