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Manufacturing Process

Manufacturing Process

Plant Setup State-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.

Tyre Manufacturing Process
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
Manufacturing Process

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Salsons Impex Pvt. Ltd.