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

Testimonials

We have tested IDE vEdge from last one month and got the detailed reports along with FFT spectrum, this system seems to be effectively triggering the alarms of impending failure as promised by Infinite Uptime. It is very useful and now we are planning to fix this in our multi-spindle Gang head gearbox.

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

Infinite Uptime has measured high on our expectations of quality, flexibility, and in-depth industry knowledge and has continuously raised the bar. I must say vEdge is an outstanding product, I'll recommend vEdge as an optimum cost solution.

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

We worked carefully with all our equipment that helped us for our living. We maintained them as and when required but still faced production losses and high downtime. Thank you Infinite Uptime for installing the IDE, to monitor gearboxes, motors, bearings and other critical mechanical rotating parts at real-time. We are so happy, we could save our maintenance cost, spares, wear and tear, and the million dollar life of the operator.

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

Thanks to Infinite Uptime for providing insights into our critical equipment. The plug and play real time monitoring IOT 4.0 solution, avoided unexpected breakdowns and detected large savings capabilities. We are so happy, we could save our maintenance cost, spares, wear and tear, and the million dollar life of the operator.

Mr. Bhide/Mokashi, Maintenance Manager - Bharat Forge

As promised by Infinite Uptime, the IDE sensor provided valuable data to find the root cause of abnormal vibration of the helical gearbox. With scheduled maintenance, vibration levels are normal now. We found the IDE sensor useful to avoid the breakdown.

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

Thank You very much to everyone for installing the IU devices, integrating them with PLC in optimal time. We are now able to have an insight into tool life monitoring and can schedule predictive maintenance for the machines.
We look forward to continue work with you. We appreciate your dedicated time and efforts invested to achieve our goals.

Mr. Rahul Nalawade, Maintenance & Automation Head - Hirschvogel Components India Ltd.

We are monitoring our state of art machines with Infinite Uptime’s vEdge. It is providing insights into our critical equipment thereby transforming our maintenance to predictive. The plug and play real-time industrial 4.0 vEdge help 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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