Plant SetupState-of-the-art Manufacturing Machinery
Mixing Mill - (Used in Process of Compounding & Mixing)
Our modern mixing mill consists of twin counter-rotating rolls, one serrated, that provide additional mechanical working to the rubber, and produce a thick rubber sheet. This mill is used to mix a batch of rubber compound in the manufacturing process of ‘Compounding & Mixing’ after all the required ingredients are brought together through the operation of compounding.

Extruder Machine - (Used in Process of Component Preparation)
The extruder machine consists of a screw and barrel, screw drive, heaters and a die. The extruder applies two conditions to the compound – heat and pressure. Extrusion is also used for sidewall profiles and inner liners.

Calendar - (Used in Process of Component Preparation)
The calender is a set of multiple large-diameter rolls that squeeze rubber compound into a thin sheet. Calenders are used to produce body plies and belts.

Tyre Building Machine - (Used in Process of Tyre Building)
Typical TBM operations include the first stage operation, where inner liner, body plies, and sidewalls are wrapped around the drum, the beads are placed, and the assembly turned-up over the bead. In the second stage operation the belt package and tread are applied and the green tyre is inflated and shaped. The final product of the TBM process is called a green tyre.

Manual & Hydraulic Press - (Used in Process of Curing)
Mechanical presses hold the mold closed via toggle linkages, while hydraulic presses use hydraulic oil as the prime mover for machine motion, and locks the mold with a breech-lock mechanism. Hydraulic presses have emerged as more cost effective.

During and post manufacturing, there are several sophisticated tests conducted by our Quality Assurance & Quality Control departments such as tyre balance & uniformity measurements as well as endurance, plunger and X-ray tests, to ensure high quality tyres to our esteemed customers.

A tyre is an assembly of numerous components that are built up on a drum and then cured in a press under heat and pressure. Heat facilitates a polymerization reaction that cross-links rubber monomers to create long elastic molecules. These polymers create the elastic quality that permits the tyre to be compressed in the area where the tyre contacts the road surface and spring back to its original shape under high frequency cycles.
Raw materials
The main raw materials of a tyre are natural rubber, synthetic rubber, carbon black and oil. The share of rubber compounds in the total weight of a tyre is more than 80%. The rest consists of various kinds of reinforcing materials. Approximately half of the rubber is natural rubber from a rubber tree. Rubber trees are grown in the tropics, in countries like Malaysia, India and Indonesia. Most of the synthetic, oil-based rubbers come from European manufacturers. Approximately one-third of the compound consists of filler substances. The most important of these is carbon black which makes the tyres black in colour. Important filler is oil which is used as a plasticiser in the compound. Furthermore, hardening or vulcanising agents, various booster chemicals and protective agents are used in the rubber compounds. Our manufacturing facility is divided into five main departments that perform the following respective functions –

• Compounding & Mixing
• Component preparation
• Tyre building
• Curing/Vulcanising
• Final finish & Inspection

Compounding & Mixing
In the mixing stage, the raw materials are mixed together and heated at a temperature of approximately 120 degrees Celsius.
The consistency of the rubber compounds used in different parts of a tyre varies, and the consistency also varies depending on the intended use and model of the tyre. The rubber compound used in a summer tyre for a passenger car is different from that of a winter tyre, and there are very few similarities between the rubber compound of a bicycle tyre and that of a forestry tyre. Developing and adjusting the recipes is an important part of the tyre development work.
Component manufacturing
The compounds are used in rubberising various components, such as steel cord, Bead wire, Tread, Side wall etc. A tyre is manufactured from 10–30 different components.
Steel cord
Steel wire cord quality is based on tensile strength, elongation, and stiffness. It is manufactured from steel rod with high carbon content; and while the steel wires used have different configurations, all are brass-coated strands twisted together into cords. If the wire is used in a multi-ply tire rather than a belted tire, the fatigue performance will be important. If used in belted tires, then stiffness is of primary concern. Since the steel wire is brass coated, storage conditions are important to maintain the steel wire to rubber bonding properties. Therefore, the steel wires are also kept in a temperature and humidity controlled room once they arrive at the factory. 
Belt and Ply Calendering
To produce fabric or steel belts, the fabric or steel cord must go through a calendering process—an operation in which the rubber compound is pressed on and into cords. Because the bonding of fabric to rubber or steel to rubber is critical to performance, the calendering process is an important step.

The calender is a heavy-duty machine equipped with three or more chrome-plated steel rolls which revolve in opposite directions. The roller temperature is controlled via steam and water. In this process, the rubber compound is applied to the cords.