RUBBER, WHITE GOODS & PLASTIC INDUSTRY

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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.

Consumers want SMART tires so that they can be remotely monitored for their safety, security, reliability, predict the wear and tear and optimize their service life.

  • Up to 30 ingredients are used in tire’s rubber blend.
  • Cord is added for extra strength, puncture resistance, and durability.
  • Beads are made of high-strength steel coated in rubber, and create an airtight seal between the tire and the rim of the wheel.
  • Steel belts, beads, ply, tread, and other components are placed in a tire-building machine to obtain a green tire.
  • The green tire is vulcanized in a curing press, to give the tire its final shape, including its tread pattern.
  • Edging, threading, inspection and quality testing is carried out.

The main processes involved in tire manufacturing

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.

Case Studies

Plastics/Motor

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

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Packaging/Motor

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

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Packaging/Motor

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

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Paper/Gearbox

Vibration Monitoring System predicts gearbox failure and extends the life of calendar-roller.

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Testimonials

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.

Sajo Paul - 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, - Bharat Forge

We installed the IDE on our helical gearbox to get a deeper understanding of the root causes of its failures and prevented them becoming catastrophic. Outstanding product and people make Infinite Uptime an awesome part of the predictive maintenance.

Mr. Shashikant Bhujbal - Tata Metaliks

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 - Hirschvogel Components India Ltd.

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