Inplant Traing

Ceat Ltd, Halol, Vadodara
Dept. Of PS&RT, CUSAT
IN-PLANT TRAINING REPORT

Done At
CEAT TYRE LIMITED Halol, Vadodara, Gujarat

Submitted in partial fulfilment of the requirements for the award of the degree of
Bac elor o! Tec nolo"# In Polymer Science & Engineering B# Mu$e% $u&ar Re"'No()*+*,*,De.t' o! Pol#&er /c0ence and Ru11er Tec nolo"# 2C3/AT, Coc 0-++, 4erala5
APRIL 2013

ACKNOWLEDGEMENTS
I thank to GOD almighty for giving me courage and pleasure to pursue my task successfully throughout my project work. I feel privileged to my In-plant training and Project work in Indias leading tyre manufacturing industry CEAT LTD, !alol "adodara #ujarat. I wish to e$tend my special thanks Mr T!m Th!ma" %E$ecutive director& & Mr G #$$i%ri"h$a$ %"P !ead-design and compounding '&(& and Mr &a'!( G)!rg) %"P !ead product management '&(& for giving me such great opportunity. I e$press my gratitude to Dr S*$il K N K*tty !)( Dr K E G)!rg) %Professor& Dr Ra$i &!")+h %Professor& Dr Th!ma" K*ria$ %Professor& (ept. of Polymer Science & 'u**er +echnology ,-S.+ /ochi for arranging my training and project work at ,eat ltd. +he person most thanked is MR S*,ith Nair #0 & head of compounding '&( ,eat 1td. !alol #ujarat. !is invalua*le and professional guidance personal attention e$pertise and encouragement throughout the course of this work have ena*led me to complete the same successfully. I gratefully acknowledge Mr Lalit Pa$-)y %"P production& ,eat 1td. for his e$pertise proper guidance encouragement during the work. I wish to e$tend my sincere thanks to Mr G)rg!ry A$t!$y %#0 & plant head& Mr A"h.ath %*mar %0anger tech.& and Mr /)llra, for their support and encouragement during my project work. I acknowledge at this moment the appreciations recognitions favors advices and encouragement from all 0amily m)m()r" of ,eat 1td. !alol "adodara has given to me. I once again sincerely thanks all those who have helped me directly and indirectly during my project. I take this opportunity to thank all 0a'*lty m)m()r" 1 "ta00" !0 !*r -)+artm)$t a$- my -)ar 'la""mat)" for supporting me throughout my college life. I heartily acknowledge my +ar)$t" a$- 0amily m)m()r" for their love appreciations recognitions and encouragement.
M#KES2 K#MAR
CONTENTS
13 INTROD#CTION44444444444444 44 356
23 STOCK PREPERATION4444444444444 5 78 33 T9RE :#ILDING4444444444444444 7; 5 83 63 T9RE C#RING44444444444444444 86 5 8< 73 INSPECTION =INIS2444444 AND 8> 5 ;2 =INAL 7
83 TESTING
ON
RADIAL
T9RES444444444 ;3 5 ;>
INTROD#CTION +yre is composed of fi*er reinforced ru**er matri$ .nd the main functions of a tyre is to cushion the ride and provide some means of direction to the vehicle. 2ut *oth the concepts are opposing. 3hen the cords are at an angle parallel to the circumferential direction of the tread tyre will give good directional sta*ility and steering response. 2ut riding will *e harsher. 3hen the cords are at right angel to the tread circumference the ride will *e softest and the lateral sta*ility will *e poor. +he *ias tyre was constructed in terms of a compromise in cord angle to get intermediate performance properties. 2ut the idea *ehind radial ply tyre was to eliminate this compromise in cord angle and to divide the carcass into two parts. directional 4ualities. )ne to provide the desired ride 4uality i.e. radially running plies cords and the other to provide
. radial tyre consists of a radial carcass and a sta*ili5ing *elt underneath the tread. 'adial carcass consists of reinforcement layer of
4
fa*ric cords running from one *ead to another at 67 7 to the tread ,entre line and is designed to hold the air pressure. +he sta*ili5ing *elt consist of reinforcement layer of high modulus fa*ric cords or steel running circumferentially around the carcass at an angle of 89-:: 7 to the tread ,entre line *eneath the tread and designed to transmit driving *reaking and cornering tor4ue. +he function of tread and the sidewall are separated to a great e$tent such that major shortcomings of *ias construction are eliminated. +his construction re4uires greater num*er of components than *ias tyre and very precise placement of component is also necessary. . flow diagram is drawn in ne$t page illustrating steps involved in manufacturing of passenger car radial %P,'& tyre.
Ra. ,ater"al!
&"'"$% area
.
ead !e"#"$%
Pl( a$d elt Cale$dar"$%
Co,po*$d +'tr*!"o$
ead
Rad"al pl( )*t Pl(
elt )*tt"$% 1$$er l"$er Tread - S"de .all
elt
/ree$ t(re 0*"ld"$%
C*r"$%
Tr",,"$%
2"$al "$!pe)t"o$
U$"for,"t( te!t
3are 4o*!"$%
23 STOCK PREPERATION?
C!m+!*$-i$g1 Mi@i$g?
1ike *ias compounding radial tyre compounding is normally done in three stages- master *atches repass and final. In ,E.+ tyres ltd. !alol radial compounding is done in two separate *an*uries provided with modern accessorise. )ne is for final compound and other for master *atch. 2oth *an*uries consists of two hori5ontal rotors with four wings. +hey are rotated at a synchronous speed which produce a very high shear rate during mi$ing. ;or the master *atch mi$ing 2an*ury instead of dump mill and cracker mills a twin-screw e$truder and a two-roll calendar are used for sheet out. +his will produce proper *lending with very high uniformity among the compounds. +hey are provided with a +.,.- at cham*er sides rotors and drop door to maintain highest level of shear during the mi$ing process. +he final *atch producing 2an*ury is e4uipped with a +.,.- on the ram in addition to the a*ove-mentioned places for *etter temperature control. 'am of *oth *an*uries is operated *y hydraulic mechanism for o*taining higher pressure with *etter uniformity. ;or a synchronous rotor the large wing has a heli$ angle of :<-=7 7 and proceeds to 7.:to 7.9< length fraction of the rotor and other wing has a heli$ angle of ><-<<7 with a length ratio of 7.>< to 7.?< of length of the rotor. 1arger the ratio of a$ial wing length to rotor length propelling action of the material increases in the a$ial direction along the cavity. +his *an*uries are provided with head stock loader automatic weighing conveyor automatic charging system automatic car*on and silica charging system and automatic oil charging system. +he cooling station consists of chain conveyors suspension *ars and num*er of cooling ventilation to cool the compound and dry the dip slurry.
RAW MATERIALS? +he *road classification of raw materials used for manufacturing tyres is@ .& 2& ,& 0aterials used for various ru**er compounds 0aterials used for tyre reinforcements .u$iliary materials
A3 Mat)rial" *")- 0!r tyr) '!m+!*$-" +he essential ingredients used in a ru**er compound *y its function is as given *elow 'aw ru**er .ctivators 'einforcing agents Process oils .ntidegradants "ulcani5ing agents .ccelerators Process aids Special additives 'u**er as such is a soft semisolid material which does not have any property re4uired for a tyre compound vi5. elasticity strength hardness tear end fle$ resistance 'aw ru**er when heated with vulcani5ing agents *ecomes elastic stronger and harder and this process is called vulcani5ation. !owever the ru**er is to *e heated for :=hrs for achieving full vulcani5ation. +o increa>e the speed of vulcani5ation accelerators are used. +hus with vulcani5ing agents and accelerators the vulcanising time is reduced to >7 minutes at practical vulcani5ing temperature. .ctivators are used to improve
the efficiency of accelerators and it improves the strength and elasticity of the vulcani5ates. . vulcani5ate thus made of raw ru**er vulcani5ing agents
accelerators and activators are still soft. ;or improving the strength hardness tear wear and fle$ properties suita*le for a tyre compound reinforcing agents are added. +he major reinforcing agents are car*on *lacks and silica. Incorporation of fillers is difficult and to facilitate easy incorporation process oils are added. 0ost of the ru**ers are suscepti*le to degradation when su*jected to heat fle$ and weather and to take care of this antidegradants are added. Process aids are added to the compound to improve processa*ility at e$truder calendar or to improve surface tack. )ften low cost fillers are added to reduce cost *ut this method is used only for some particular compound application. Sometimes special additives like corrosion inhi*itors *onding agents hardening agents are added for specific vulcani5ate properties. RAW RUBBERS: Nat*ral R*(()r Aatural ru**er occupies the top position as the general-purpose ru**er. It gives good strength tear wear and fle$ resistance good crack growth resistance good processa*ility and tack low heat *uild up and good a*rasion resistance. It is slightly inferior in crack initiation skid resistance and traction. It finds application in carcass compounds tread compound for heavy-duty truck tyres. 'SS-= and ISA'-:7 are the major used grades. ,repe grades are used in non-critical applications.
R)'laim R*(()r 'eclaim ru**ers are de-vulcanised ru**er manufactured from waste ru**er products. +his is however a low cost ru**er and has good processa*ility. !owever due to inferior dynamic properties it finds applications like .(" tyres and flaps Styr)$)5(*ta-i)$) R*(()r AS:R3 +his is the first synthetic ru**er developed. It offers good strength and tear good crack initiation resistance good a*rasion resistance good processa*ility. It also offers very good skid resistance and traction. 2ut it has inferior crack propagation and higher heat *uild up and poor tack. S2' is mainly used in passenger tyres *ecause of its high skid resistance and traction. It is used generally in *lends with P2( for *etter fle$ resistance and traction. S2' is also recommended for high hardness *ead compound. P!ly(*ta-i)$) R*(()r It offers the *est a*rasion resistance and fle$ resistance. It has low heat *uild up good heat resistance and good weather resistance. It is inferior in processa*ility skid resistance traction lug chip resistance and surface tack. It finds application in sidewall compound and light duty truck treads in *lends with natural ru**er. It is also used for passenger treads in *lends with S2' for *etter wear and fla$ resistance :*tyl R*(()r +he outstanding air impermea*le together with high heat resistance makes *utyl the *est ru**er for inner tu*es. Its halogenated varieties are used in tu*e less tyre interlinear. It also finds application in curing *ladders *ecause of its high heat resistance EP(0 'u**er. +his is new generation synthetic ru**er which offers e$cellent heat and weather resistance and good fle$ resistance. It finds application in tu*es
18
where it reduces the softening of *utyl tu*e in service. It is also used for radial tyre sidewallB especially in white sidewall a *lend of A' with halo *utyl is used for weather resistance and colourfastness.
:3 /#LCANISING AGENTS
SULPHUR The cross linking of rubber is generally achieved by addition of sulphur or sulphur donors. +here are two types of sulphur Solu*le sulphur Insolu*le sulphur
+he commonly used sulphur donors are +0+( %+etra methyl thiuram disulfide& (0(S %(imorphoilinyl disulfide&
+he sulphur donor system gives *etter heat resistance than sulphur system *ut inferior fle$ resistance.
ACCELERATORS .ccelerators are classified *ased on the speed of vulcani5ation. It is also classified as primary accelerator and secondaryC accelerator. Secondary accelerator is the one follow@ which is used as *ooster to a primaryaccelerator +he commonly used accelerator in tyre industry is as
T9PE Slow
C2EMICAL NAME (iphenyl guanidine

11
#SE IN T9RE Secondary accelerator in
.ccelerator
S2' compounds
-sed in *ead compounds ,yclohe$yl*en5othia5ylSulphenamide% ,2S& Primary accelerator in +ertiary *utyl S2' compound *en5othia5ylSulphenamide %+22S& 0ediumfast 0orpholinothio*en5othia5ylSulphenami accelerator 3idely used in tyre de industry %02S& (icyclohe$yl*en5othia5ylSulphenamide%( -sed mainly in retread ,2S& materials 0ercapto*en5othia5ole%022+& ;ast 2utyl tu*e accelerator ;lap compounds 0ercapto*en5thia5ole disulfide%02+S& -ltra fast 0ainly for *utyl and +etramethylthiuram disulfide%+0+(& accelerator secondary accelerator for S2' compounds +etramethylthiurammonosulfide%+0+0 Secondary accelerator in & tread *ase compounds Super ultra Dinc diethyl dithiocar*amate%D(,& fast 'epair compounds accelerator ACTI/ATORS +he general activators are 5inc o$ide and stearic acid. Instead 5inc stearate can *e used *ut a higher dosage is re4uired. C3 REIN=ORCING AGENTS? +he commonly used reinforcing agents are car*on *lack and precipitated silica. +here are three types of *lackC *ased on the manufacturing techni4ue they are ,hannel *lack +hermal *lack
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;urnace *lack In furnace *lack there are different grades characteri5ed *y the particle
diameter and structure. .s the particle diameter decreases the reinforcement increases. !igher the reinforcement higher the strength the modulus tear fle$ a*rasion resistance and higher the heat *uild up. .s the structure increases modulus increases *ut fle$ fatigue resistance decreases. +he heat *uild up increases slightly. Precipitated silica offers *etter tear resistance than car*on *lack. !owever the heat *uild up is higher and silica is not easily dispersi*le in ru**er. Particle #rade (iameter %nm& S.; IS.; !.; ;E; #P; Precipitated silica :: :9 >: 8=? ?7 >7
Structure %(2P Ao& 88< 88< ?7 8:7 67 A.
.pplication Aot used in tyre industry difficult to disperse. +read cap compounds %ri* pattern& +ruck treads cap sidewall and *ead insulation. )uter ply cushion 2reaker tread *ase ,ompound S4ueegee Inner ply inner liner for tu*eless flap 'adial tyres )+' tyre tread
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D3 PROCESS OIL +hese are used to improve car*on *lack incorporation in a ru**er compound and also to improve compound process a*ility at calendar and e$trusion. Process oils are classified *ased on the "#, ,lass .romatic Aapthenic Paraffinic "#, Staining 8 Ees !eat resistance #ood 2etter 2est ,ompati*le 'u**ers A' S2' 'eclaim -(o2utylFEP(0 -se P2 #eneral process oil 3hite sidewall +u*e 2ladder purpose
7.6 0ild 7.9 Ao
E3
ANTIDEGRADANTS Staining Ao 0ild )$ygen )5one resistance resistance 0ild #ood #ood Ail Ail Ail -se 3hite sidewall ,arcass compound ,arcass compound +read and Sidewall +read sidewall +read sidewall and and
,hemicals name Styrenated phenol (ihydrotrimethylGuinoline
.cetone amine condensate Strong (i-aryl p-Phenylenediamine Strong (imethyl*utylparaphenylen "ery ediamine 0icrocrystalline wa$ strong no
"ery good 0ild E$cellent 0ild Ail E$cellent
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=3
PROCESS AIDS
Process aids are those su*stances which are added to ru**er compound for reducing viscosity of the stock for increasing tack for improving process safety or for improving the surface finish. +he various types are given *elow@ +ype Aame Dinc Pepti5er phenol Phenol +ackifier formaldehyde +ackifier I resin ,yclohe$ylthiopth 'etarder alimide salt of ;eature -se
pentachlorothio
;aster *reakdown of A' 0astication during master mi$ing purposes Ply sidewall and ;or *etter surface tack cushion compounds Improves scorch Safety Practically added in all compounds
G3 ,lass
SPECIAL ADDITI/ES Aame '; 'esin !000 .pplication ;or *etter *ond strength In
(ry *onding
2onding agents Precipitated silica SteelFglassFaramidskim compound !ardening +hermosetting P; ;or hard compounds like *ead agents ,orrosion inhi*itor resin ,o*alt comple$es insulation filler etc ;or steel cord skim compound for 'educing corrosion
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2 2 MIBING #NIT In a ru**er industry mi$ing is the foundation step upon which every further step is dependent on. 0i$ing is the most critical component of ru**er processing. +he aim of mi$ing is to produce a product that has the ingredients dispersed and distri*uted sufficiently thoroughly that will process satisfactory in the ne$t process cure efficiently and give the re4uired properties for the end application. 0i$ing re4uires deciding the formulation what e4uipment to use and the times speeds pressures temperatures. +he aim should *e to minimi5e the la*our energy and e4uipment cost per unit volume of product. (ue to the partly elastic nature and very high viscosity of ru**er power intensive necessary. In ,E.+ +yres !alol there are two 2an*ury continuously in operation to get compounded ru**er for further processing. .mong two 2an*ury one is for master mi$ing and another one for final mi$ing. :AN:#R9? +he 2an*ury mi$er is a tangential type internal mi$ing machine in which two slightly spiralled rotors revolve side *y side toward each other within a cham*er shaped like two short cylinders lying together with adjacent sides open. +he cham*er has a top opening called hopper which can *e closed *y a pneumatic means for inserting the material and a *ottom gate which can *e hydraulically opened to drop out the contents after mi$ing. +he 2an*ury is charged *y raising the ram completely out of hopper and dropping in *ales of ru**er weighed up properly to fill the cham*er. +he ram is then lowered under pressure and the ru**er forced and held in the cham*er while it is kneaded and *lended *y the rotors. 2reakdown of ru**er is accomplished *y the shearing action *etween rotor *lade tips and rotor walls and *etween rotor-rotor with one rotor running slightly faster than the other to prevent sticking to the *lades. sturdy machinery like mi$ing mills and internal mi$ers are
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:AN:#R9 CONSTR#CTION +he physical demands upon 2an*ury mi$er are enormous. 'u**er is e$tremely tough compounds are a*rasive pressures and temperatures developed are high. ;or the purpose of description the machine parts can *e divided into following categories. A 2OPPER ASSEM:L9 RAM? 'am consists of a rod and floating weight. +he ram utili5es not only its own weight *ut also an additional e$ternal force to e$ert a certain pressure on the mi$. +raditionally the ram is operated pneumatically. .n air-operated piston in a cylinder holds it. In the raised position the ram *ottom is a*ove to the hopper door allowing the introduction of material into the mi$ing cham*er. +he ram is raised *y compressed lu*ricated air. It is lowered *y floating %no air& or *y regulated air pressure. Aormal pressure used is =.< -H.H /gFcm :. Sealing of the pneumatic piston rod is a very sensitive design element. .nother pro*lem with the pneumatic ram is the variation of ram pressure ram pressure decreases when ram goes down. "ariations in ram pressure have a *ig effect in mi$ing 4uality. +he tell-tail rod of ram indicates the position of floating weight. (uring normal mi$ing the material inside the cham*er moves the ram up and down. +he total up and down motion of the ram is directly indicated *y the tell-tail rod to the operator who can there *y assess the status of the mi$ing process. +he floating weight may have several configurations a& Single slope " *ottom. *& Single slope ;lat *ottom. c& (ou*le ga*le " *ottom. d& (ou*le ga*le ;lat *ottom. 2OPPER?
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+he hopper of the mi$er is simply a *o$ through which ingredients are fed and through which the ram weight travels. +he front of the *o$ is a hopper door through which material is fed through a conveyer. +he hopper door is air operated and hinged at the *ottom. . chute is provided near the hopper assem*ly to provide the weighed car*on from the day *ins *y means of automatic car*on discharge system. .ll hoppers are e4uipped with a method for venting gases and powders which accumulate in the hopper area *y means of air suction. +his makes the area near *y the mi$er clean and tidy. T2E PNE#MATIC S9STEM? +he floating weight or ram cylinder and the cylinder operating the hopper door are air actuated. +hese are actuated *y means of sensors fitted near to the hopper assem*ly. +he flow of air to the weight and hopper cylinders is controlled *y solenoid-operated valves which are actuated *y switches on the 2an*ury control panel. : MIBING C2AM:ER It is the section of the mi$er *elow the hopper assem*ly and a*ove the *edplate. +he important parts of mi$ing cham*er are C2AM:ER SIDES? +he portions of the mi$er that enclose the mi$ing cavity are the cham*er sides. +hese sides consist of heavy shells *ored with laterally drilled holes for the circulation of steam andFor water. +he internal surface of the cham*er is treated with satellite for wear resistance. END =RAME ASSEM:L9@ It supports the cham*er with rotors. Each end frame assem*ly consists of the frame the rotor *earing seals and the rotor end plates. +hey are made of heavy iron castings with spherical roller *earings including thermocouple for *earing temperature measurement. +here are two ends in the 2an*ury mi$er the water end and the drive end. +he water end is the area
16
through which the heating or cooling water is introduced. +he opposite is the connection point of for the machine drive arrangement. ,ooling water passes through large drilled passagesB the design used causes tur*ulence of water and good heat transfer. +he *ores are welded with hard wear resistant material clamp plates and *olts secure the sides to the end frames which ena*les the fitting on site of new sides without machining or causing serious distur*ance to end frames. ROTOR? +he two rotors perform the mi$ing action *y rotating in opposite direction and at slightly different speeds. Each rotor have *lade like projections called wings. +he edge of the rotor wings are called 'otor tip. +he rotors are set in the mi$ing cham*er so that the long wing of one rotor is opposite the short of the other. In CEAT Tyr)", 2al!lB the rotors are = winged designs. +his helps in the increase of the rotor surface area and *etter shearB intern helps effective and faster heat transfer. +he two types of rotor design are 8. :. +wo wing rotor ;our wing rotor . two-wing rotor has one short wing and one long wing. . four-wing rotor has two of each. +he rotors turn within the cham*er toward each other and at une4ual speeds. +his is done so that the relative wing-to-wing positions are constantly changing. 2ecause of the shape of the rotor wings materials are always sheared against mi$ing cham*er and then toward the other rotor. +he curvature of the rotor wings causes the materials *eing forced *ack and forth from one end of the mi$ing cham*er to the other. Since the rotors are running at une4ual speeds the mi$ is also *eing pushed from side to side in the cham*er. 'otors have varying speeds of rotation with faster *reakdown *eing o*tained as speeds go up.
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+he rotors are one piece steel castings accurately shaped on the mi$ing *lade profiles. +here are no internal joints which could cause leakage. Steam or water circulating through the centre of each shaft controls the temperature. 0ost rotors have spray cooling. Spray heads which have small enough orifices to properly *reak-up the water stream are used. D#ST STOP? +here are four dust stops on each 2an*ury one at each point where rotor shaft passes through the *ody. +heir function is to seal the mi$ing cham*er around the rotor shafts. 1u*rication is critical for the satisfactory operation of dust seal. +wo types of dust seals are in use ;E! and SS.. In the ;E! type dust seal hydraulic cylinders are used to load the sealing rings against the rotor ends they are so arranged that as the rotors move a$ially during mi$ing the sealing rings are always in contact with the rotor ends. +he frictional heat generated *y ;E! dust stops is low and heat sensitive stocks can *e mi$ed at high rotor speeds without cured particles *eing formed. +he design eliminates all areas where material could *e trapped and su*se4uently causes contamination. In the SS. type dust seal design the sealing faces are preloaded *y springs and additional sealing pressure is generated during mi$ing *y a small process oil feed which loads the *ack face of the floating ring and which cannot escape *ecause of the compound in the mi$ing cham*er. . floating metal split ring rides in a collar against the *ack of a flange on the rotor end plate. +hese two surfaces are kept flooded with light ru**er process oil and as the compound forces its way into this joint this oil traps and holds it. .ny e$cess oil enters the *atch and is harmlessly a*sor*ed. Earlier rotating 2a**itt or *ron5e sealswere usedB *oth the life and sealing of these were poor. ,ompounds and ru**ers were forced through the seals and were lost their way into *ron5e *earings on which rotors turned and damaged them and journals. ;loating rings of tin nylon and many others were tried *ut jamming of journal rings resulted in failures.
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DISC2ARGE DOOR? ;.''E1 ; :?7 2an*ury is furnished with drop type discharge door. +he drop door is mounted on a support shaft which pivots parallel to the shaft rotor. +he offset hinge arrangement allows swinging down and away from the door opening permitting the finished *atch to discharge. . hydraulic rotating device called ')+., opens and closes the door. . hydraulically operating door latch locks the door in place when the door is closed and creates a tight seal. )lder *an*uries are e4uipped with a wedge shaped doors which slide hori5ontally on a pair of rails into position. +he rails lift the door very slightly as it reaches the closed position *ut wear on rails is rapid. 1arge pistons move them and demands close original fitting and proper maintenance to prevent leakage. Proper maintenance of the piston and rails are difficult and e$pensive. .nd failures which prevent the opening with a *atch inside can *e disastrous. +heir movements are also slow. +he new drop door type is faster and thus shortens cycle times. Some pro*lems of metal lining failure and metal failure in swing arms have noted in them. +he drop door top has passages with inlet and discharge fittings for the circulation of cooling water or steam. +he door top is normally cooled to prevent the sticking of stock at the time of discharge. ,ooling or heating the door top is also effective in controlling the *atch temperature. +he discharge door profile has an ape$ to eliminate Cdead spotsC while allowing the re4uired thermocouple projection. +wo thermocouples are sometimes fitted in the door one for normal operation and one for a safety override. MIBING ACTION? It is a popular misconception that all the mi$ing in a *an*ury takes place in the gap *etween the rotor tips and the cham*er walls. .t the start of the cycle when the polymer is normally in large pieces and the powders are still loose the initial *reakdown and mi$ing takes place in the large space *etween the rotors and against the door top. .s the material softens flow over
21
the rotor tips starts to take place *ut until the viscosity of the mi$ has fallen sufficiently most of the work is done *etween rotors along the rotor heli$ angles and *etween rotors and discharge door top. +he area just in front of rotor tip is similar to the nip of a mill and causes internal shear in the material. +he mi$er should *e cooled to remove heat generated *y the mechanical energy of mi$ing. !eat transfer and cooling efficiency is dependent on the temperature differential *etween material *eing mi$ed and machine components. .t the start of the cycle when the feed material is cold and stiff most work is done *etween the rotors as the mi$ing progresses the material softens and deforms to make e$tensive and close contact with the rotor mi$ing cham*ers walls and door top at which point they all are availa*le to transfer heat from compound to the machine components and so to remove it *y the cooling water. +he material at the door top is su*jected to high pressures and a highly tur*ulent action. C 29DRA#LIC S9STEM +he discharge door the door latch dust stops and grease pumps are actuated *y hydraulic oil under pressure. +he hydraulic system consists of two major assem*lies the pumping assem*ly and the control valve assem*ly. P*m+i$g A"")m(ly? ,onsist of a motor driven vane type mounted on a reservoir tank. )il is pumped to the control assem*ly which directs high-pressure oil to various components of the system. C!$tr!l CalC)"? ,ontrol valves are electric solenoid type and are energi5ed from the 2an*ury control panel. +hese valves are providing directional control for the hydraulic fluid so that the drop door can *e opened or closed and the door latch engaged or disengaged. D ACCESSOR9 ED#IPMENTS
22
13 W)ighi$g '!$C)y!r" a$- 0))-i$g '!$C)y!r Each 2an*ury is e4uipped with electronic weighing conveyor *alance and feeding conveyor. Electronic weighing conveyor has two load cells with a capacity of <77kgs with at least count of 7.8 kg. 'u**ers masters re mill *atches are weighed in the weighing conveyor and transferred to the adjacent feeding conveyor which is leading to the hopper door of the 2an*ury. 2oth weighing and feeding conveyor are e4uipped with independent motor drives. ;oot control switches are used to move the *elt at I & II *an*uries which moves the material to the feeding conveyor and to the 2an*ury at I & II. .utomatic conveyer feeding system is worked out in the *an*uries III I"I. In this conveyer movement is stopped as soon as ru**er and chemical reach near to the hopper door. +his is made happened though a sensor connected at the hopper door which is activated when the ru**er on the conveyer cuts of the sensing path of the sensor. 2an*uries are e4uipped with overhead unfolding conveyor at weighing point of ru**er to facilitative transfer of continuous sheet on the weighing conveyor. 23 A*t!mati' 'ar(!$ -i"'harg) "y"t)m ,ar*on *lack of different categories received in jum*o *ags of 8777 /g is silted at the *ottom and collected in a cham*er. ;rom this it is fed to S," %single cham*er & valve& hopper. ;rom this *lack is mi$ed with air collected from the *lower and fluidise to convey to silos through cone valves. Silos are large storage cylindrical cham*ers erected vertical. +hese are = in num*ers. Each silo is of H7 tons capacity. Selected car*on *lack from the silo is conveyed to day *ins at each *an*ury. Each *an*ury is e4uipped with an average of <-H day *ins. Each *in is meant for each type of car*on *lack or for silica. ,ar*on *lack is conveyed to day *in through plastic piping *y air *lowing. Each silo has only one outlet. +o facilitate different car*ons to different day *ins of different *an*uries a diverter is placed at the intake system. +his is a rotary type diverter connected to 9 piping going to different *an*uries. Some car*ons are conveyed directly to the respective day *ins where as some are connected again to different diverters and then to the day *ins. 0ost of the car*on *lacks used in general and in large 4uantities are conveyed directly. .utomatic car*on discharge system is completely automated and hence the
23
day *ins automatically get filled with car*on *lack when the lower limit of the car*on level is reached. +he *lack stored in the day *in is collected to a hopper near to 2an*ury with an automatic weighing system and conveys to 2an*ury through a chute opening at the sides of the hopper assem*ly. +he parameters affecting the easy fluidisation and conveying of car*on *lack areB 0oisture content Pellet hardness Pour density ;ineness content Pellet si5e distri*ution 33 T)m+)rat*r) '!$tr!l *$it +he introduction of drilled sides improved rotor cooling and *etter water circulation in the door top coupled with rotor action has dramatically improved the cooling efficiency of *an*ury mi$er. 3hen the surface temperature of the metal in contact with ru**er is too low the ru**er slips on the cold surfaces. ;or good dispersion and *etter mi$ing it is necessary to put shear strain energy into the mi$ this can occur only when the ru**er is gripped *etween the rotor tip and cham*er wall or *etween rotors. ;or this reason it is not desira*le to have the mi$ing cham*er too cold as the frictional contact *etween ru**er and metal is influenced *y temperature. +,- assem*ly consists of a tank divided into three divisions each receiving cold water and hot water and over flow water which is corrected for temperature. 3ater from rotor cham*er and drop door is mi$ed with factory cooling water at ><7, to get a final temperature of >?->9 7,. +his mechanism of sensing and actuating the water flow is done *y sets of solenoid valves.
24
+hese temperature corrected water is then circulated *y means of > pumps with varying capacity depending upon the amount of water to *e circulated. 0i$ing of the compound should do as per timeFtemp given on the mi$ing specification card. 63 D*"t '!ll)'t!r" 2an*ury is e4uipped with dust collectorB this is to collect the fly off dusts of car*on *lack chemicals and vapours. +he car*on dust collector system is designed to return the car*on *lack into one place from all 2an*ury. 73 Oil "t!rag) ta$%" +here is a centrali5ed tank for oil storage. +his is connected to the 2an*ury through pipelines. +his oil is collected in small tanks kept near*y 2an*ury. +here are : tanks one for process oil and the other for hydraulic oil. 83 Oil +i+)li$) )il pipelines are used for delivering different oils. (ifferent oils
collected are process oil for mi$ing & for dust seals and hydraulic oil for pressure application mechanism. )il is o*tained *y operating solenoid valve which in turn operates the diaphragm valve of pipelines. )il is measured in litters in the cali*rated measuring tank. )il pipelines are connected to the measuring tank with diaphragm valve for control. +he oil pipelines are e4uipped with electric heat tracing to maintain the oil temperature at around H7 degree ;3 Oil 'harg)r 2ottom of the oil tank is connected *y a pipeline with motor driven pump which injects oil into the 2an*ury through a pipeline. )il is charged to the 2an*ury from *oth front and *ackside at side-*ottom level through oil injecting valves. +hese are non-return valves. +he measured volume of oil is taken into the oil charger from the measuring tank *y operating diaphragm valve of the tank and is held till the specified temperature %H7 7,& in the mi$ing cycle is reached. .fter each addition oil for the ne$t mi$ is collected and weighed properly and kept ready.
25
<3 Oil m)a"*r)m)$t? "olumetric oil measurement tank is provided at each 2an*ury for measuring oil *y volume. +he oil is drained to the oil charger tank *y operating diaphragm valve through solenoid valve operation.
>3 :at'h !00 mill .n 9=-inch mill has *een provided in each 2an*ury. +he *atches dumped on mill from the 2an*ury is further mi$ed and passed directly on to the *atch off unit. +he num*er of cuts given is two for master and one for final *atches. In the mill the compounded is *lended well and sheeted to the re4uired width and thickness to effectively cool the compound. 2lender *ars are provided to facilitate the cross mi$ing action there*y attaining more uniformly mi$ed compound. 103 :at'h !00 *$it ,omponents of the *atch off unit 13 Ta%) a.ay '!$C)y)r5+iC!t)- ty+)? 5 +his is e4uipped with varia*le speed drives to control the speed of *atch off.
23 Im+r)""i!$ +ri$t)r *$it? 5 +his is to print the compound code *y impression method. am*iguity in the material code. 33 Sh))t !*t mill? 5 +his is in si5e similar to that of dumping mill. +his is e4uipped with knife arrangement and correct nip gap setting to get re4uired gauge and width to the sheet. +he compound from this mill is conveyed to the dipping tank. +his
identification further helps to sent sample to the 'heo la* without any
26
63 Di+ ta$% -!*(l) '!m+artm)$t .ith "tirr)r", 'ir'*lati$g +*m+" a$'!!li$g? 5 (ip tank contains diluted soap solution to avoid sticking of ru**er compound at the lay down unit. Soap solution that overflows or moves outside the tank is collected in an underground tank. +his collected soap solution is filtered and pumped to the dipping tank to avoid the material loss. +o maintain proper concentration of soap solution and to ensure the mi$ing of pumped soap solution stirrers are also provided. 73 P*ll !*t m)"h ()lt .ith h*gg)r '!$C)y)r"? 5 +he compound after dipping is pulled *y two-mesh *elt moving together *y enclosing the compound. +his mesh provides dripping of e$cess soap solution though the holes. 83 =)"t!!$ '!!li$g ra'% .ith 0a$"? 5 +his is the longest portion of the lay down unit. +his contains moving chain *elt with *oth sides connected with *ars. 'u**er sheets from the hunger conveyer are fed to the moving *ars of the cooling rank. +hese *ars act as hangers for the ru**er sheet and maintain specific loop length. +his length is maintained to ensure proper drying of the sheet. +he entire length of the cooling rack is fitted with =-< sets of cooling fan units on *oth sides. Each fan unit contains =-9 individual fans. Sides are covered *y metallic covers to ensure the retention of the cooling air. ;3 P)$-*l*m '!$C)y)r <3 Ta%) !*t '!$C)y)r >3 Ra$-!m '!$C)y)r 103 El)'tri' '!$tr!l" 113 Wig5.ag lay -!.$? 5 +his is a moving conveyer to lay down and to pack the dried sheets. It supplies sheet and also moves with wigwag motion. .+1 !alol also
25
facilitated packer stacker system at few *an*uries. +his is a wigwag lay down system which automatically lays down the compound without any manual operation with proper laying of sheets with e$cellent consolidation. 8:& 3eighing ta*le@ -sually a skid consists of = *atches from *an*ury. +o check this parameter each skid is taken to the weighing ta*le for weightment. PROCESS? +ake off section is situated in front of dip unit with two adjusta*le knives having a cutting width of H77-677 mm. It includes a hinged take off conveyer which receives the ru**er sla* from the mill and conveys it to dip tank. +he take off conveyer is provided with an impresser type printer to imprint figures into ru**er sla*. .t the *eginning of the *atch off unit compound sheet is dipped into the anti tack solution. +he dip unit is a sheet steel reservoir mounted in a structural steel frame. .fter passage through take off the ru**er sla* is received *y a *elt this *elt conveys the strip through dip solution and thereafter to the cooling festoon rack. +he ru**er is retained on *elt and guided upwards *y hugger *elts. 2atch is carried in continuous sheet form over the chain *ars running in cooling conveyor. .t the cooling conveyor cooling fans are mounted one side of the conveyor which e$pedites cooling compound sheets on to the am*ient temperature. Stock code is em*ossed and written with crayon throughout in all *atches and compound code is tied to the last sheet of the each *atch at the point of lay down in order to distinguish *etween different *atches. 2an*ury is e4uipped with fi$ed *ar chain cooling conveyor system and the other end has *een mounted with wigwag system. +he compound sheets are passed through the wigwag and laid on the skid in continuous sheets. C!m+!*$-i$g "tag)"?
26
(epending
upon
composition
and
processing
re4uirements
compound mi$ing is done in following stages. Ma"t)r (at'h mi@i$g? .t master *atch mi$ing stage ru**er is intimately mi$ed with fillers processing aids activators antio$idants wa$es etc. 0aster *atch mi$ing is usually done at temperatures around 8>7-8H7 Jc. 0aster *atching improves the physical properties of those compounds where a high degree of car*on *lack dispersion would *e achieved. +he master *atches can *e varied depending on the compound i.e. the master *atch recipe may *e the same as the compound recipe *ut without curatives or it contains only ru**er filler sand some softeners. Since high speed and high- pressure internal mi$ers are used for master *atching it is not advisa*le to incorporate accelerators in the master *atch as the temperature of the ru**er is likely to e$ceed. +he master *atches have poor *lack dispersion so a milling operation is essential to achieve ade4uate dispersion of the car*on *lack. R)5+a"" "tag) mi@i$g? In re-pass stage master *atch is further re-mi$ed to improve dispersion ofthe compound. +his is also done at a temperature range of 8:78H7J,. (uring re-pass stage the compound viscosity is reduced according to the re4uirement of su*se4uent operations. +his is usually done for very hard compounds like high car*on loading and the car*on *lack is incorporated in two stages for getting *etter dispersion. =i$al '!m+!*$- mi@i$g? In this stage master *atches are converted into final compounds. +his is usually mi$ed around 67 7, to 877J,. In final stage mi$ing curatives like sulphur accelerator retarder etc. are added to the master *atch.
27
D#MPING CRITERIA +here are num*er of varia*les such as temperature power energy mi$ing time etc. which influence the mi$ 4uality. In a company where large production of ru**er compounds is made some optimisation has to *e set in the mi$ing parameters to get ru**er compound with ade4uate properties. +ime temperature and energy are the main dumping criteria. In 8 st and :nd 2an*ury = set points are fed in the software of the 2an*ury on those set values of energy mi$ing se4uence and dumping time are carried out during the mi$ing. ;or other *an*uries set values of temperature and energy are fed in the software. If temperature is e$ceeded from a set value dumping takes place irrespective of the set energy values. :ASIC OPERATING C9CLE? 8& Start operation -(ischarge door closed i. 'am up ii. !opper door :& 0i$ing started >& ,lose hopper door =& ,harge car*on *lack is fed <& 1ower ram %timer is started& H& 0i$ for re4uired period ?& 'am up 9& 'am down 6& 'am upFdown 87& 88& 8:& 'am float )pen discharge door Start the ne$t cycle -oil injection -'u**er K chemical powders open
38
CONTROLLA:LE =ACTORS 8. :. >. =. <. H. ?. 2atch si5e Se4uence of addition 'am cylinder pressure 'otor speed 0i$ing time +emperature of the finished mi$ cham*er rotors discharge door top Energy for mi$ing
E6TR3/ION
+'tr*!"o$ "! t4e te)4$"9*e of pre:for,"$% *$;*l)a$"#ed r*00er )o,po*$d! 0( for)"$% ,ater"al t4ro*%4 f"'ed apert*re! or d"e!, to o0ta"$ def"$"te !4ape! a$d !"#e!. A$ e'tr*der "! a ,a)4"$e de!"%$ed to prod*)e a )o$t"$*o*! le$%t4 of ,ater"al of de!"red )ro!! !e)t"o$ 0( for)"$% t4e ,ater"al t4ro*%4 a$ or"f")e or d"e *$der )o$trolled )o$d"t"o$! of te,perat*re, pre!!*re, rate a$d 4o,o%e$e"t(. 1$ r*00er e'tr*!"o$, r*00er )o,po*$d! are for)ed *$der pre!!*re t4ro*%4 a d"e to %et )o$t"$*o*! prof"le!. 1$ t(re "$d*!tr"e! t4e ,a<or part of t4e e'tr*ded art")le! are t4e tread a$d !"de.all.
E77ECT/ O7 /TOC4 PHY/ICAL VARIATION/ ON E6TR3/ION

T4e )o$trol of !to)= a$d pro)e!! d*r"$% all e'tr*der operat"o$! "! t4e o$l( 0a!"! for )o$!ta$t d",e$!"o$! fro, r*$ to r*$ "$ a$( e'tr*ded prod*)t. So,e of t4e )o,,o$ ;ar"a0le! a$d t4e"r )a*!e! follo.> :
,' +' 8' 9' <'
V0%co%0t# Te&.erature /corc M0:0n" ;ar0at0on% Poro%0t#

31
-'
/=ell
/e$erall(, !.ell "! de)rea!ed 0( a. ?o.er ;"!)o!"t( 0. H"%4er 4eat of !to)= or e9*"p,e$t ). &ore .or= perfor,ed o$ !to)= : H"%4er .ar, *p d. Add"t"o$ of re.or= e. U$der:,"'ed !to)= f. ?o. 4ead pre!!*re
S.ell "! "$)rea!ed 0(> : a. 0. ). d. H"%4 ;"!)o!"t( ?o. te,perat*re! of !to)= or e9*"p,e$t H"%4 4ead pre!!*re A$( !)or)4 "$ !to)=
Ade9*ate )o$trol! of all t4e!e ;ar"a0le! are 0*"lt "$to )o,po*$d"$% for,*lat"o$!, pro)e!!"$% !pe)"f")at"o$! a$d e9*"p,e$t de!"%$. Caref*l o0!er;a$)e of all t4e!e are fea!"0le a$d ."ll re!*lt "$ 0ot4 9*al"t( a$d 9*a$t"t( of prod*)t"o$.
Para&eter% o! E:trudate
a' THERMAL /HRIN4AGE T4e $o$:@e.to$"a$ $at*re of r*00er pol(,er! a$d e;er )4a$%"$% for,*lat"o$! *!ed "$ t4e t(re "$d*!tr( ,a=e t4e e!ta0l"!4,e$t of !4r"$=a%e e9*at"o$! ;er( d"ff")*lt. T4"! ,ea$! t4at ea)4 )o,po*$d 0e4a;e! d"ffere$tl( ."t4 re!pe)t to !4r"$=a%e. @at*ral r*00er )o,po*$d! te$d to 4a;e 4"%4er !4r"$=a%e. Var"at"o$! "$ ,"'"$% a$d .ar, *p prod*)e ,*)4 %reater ;ar"at"o$! "$ $at*ral r*00er e'tr*!"o$! t4a$ "$ t4e !($t4et") r*00er e'tr*!"o$!. T4e ;ar"a0"l"t( "$ d",e$!"o$! ."ll 0e t4e ,"$",*, .4e$ t4e e'tr*date 4a! t4e ,"$",*, e$trapped !tre!!. T4e!e !tre!!e! are )a*!ed 0( t4e 0a!") pol(,er r4eolo%")al rea!o$!, or 0( te,perat*re. /";"$% a loop of ,oderate !"#e ",,ed"atel( after t4e d"e fa)"l"tate! rel"e;"$% t4e!e !tre!!e!. A lar%e loop ."ll "$trod*)e !tre!!. Al!o, a for)ed !4r"$=a%e ."ll fa)"l"tate rel"e;"$% of !tre!!e!.
32
1' /HAPE /TABILITY

+;e$ t4o*%4 lo. ;"!)o!"t( "$)rea!e! prod*)t";"t( a$d 9*al"t( of t4e e'tr*date, t4e( !a%, )ollap!e, a$d al!o ."ll %et 0adl( defor,ed "$ !*0!e9*e$t !ta%e! of operat"o$ !*)4 a! !t"t)4"$%. +.%.> Tread !t"t)4"$% "$ T(re 0*"ld"$%
c' TAC4
/e$erall( 4"%4er e'tr*!"o$ te,perat*re fa)"l"tate! 4"%4er ta)=. Ho.e;er after a t4re!4old te,perat*re, re;er!al of "$!ol*0le "$to !ol*0le S*lp4*r ta=e! pla)e, a$d ,a( affe)t ta)="$e!!. All !to)=! te$d to 0e !t")="er "f r*$ at 4"%4er te,perat*re!A $at*ral r*00er !to)=! ;ar( ,ore t4a$ !($t4et"). S,oot4 !*rfa)e! are !t")="er t4a$ ro*%4 !*rfa)e!. Soft !to)=! are al!o ta)="er. S*rfa)e ta)= ,a( 0e affe)ted 0( )ool"$%A ;er( rap"d )ool"$% !peed! *p 0loo, a$d lo.er! ta)=. A"r )ool"$% a$d !lo. .ater:)ool"$% ,a"$ta"$! ta)="$e!!. Sto)=! .rapped 4ot "$to l"$er! ,a( lo!e ta)= 0e)a*!e of t4e rap"d ,"%rat"o$ of t4e pro)e!!"$% o"l a$d re!"$! to t4e !*rfa)e. >' E6TR3DED COMPONENT/ T4e ,a<or t(re )o,po$e$t! ,ade *!"$% e'tr*der! are t4e tread a$d !"de.all. T4e!e )o,po$e$t! are ,ade of e"t4er !"$%le or d*al )o,po*$d!. T4e d",e$!"o$!, .e"%4t a$d prof"le of t4e!e are of %reat !"%$"f")a$)e "$ t4e !*0!e9*e$t pro)e!!e! a! .ell a! "$ t4e *lt",ate perfor,a$)e of t4e prod*)t.
CROSS S+CT1O@A? V1+3 O2 S1D+3A?? 31TH R1&STR1P
S1D+ 3A??
R1& STR1P
CROSS S+CT1O@A? V1+3 O2 TR+AD 31TH 31@/ T1P
CAP 31@/ T1P CUSH1O@
33
Depe$d"$% *po$ t4e te,perat*re of feed, e'tr*der! )a$ 0e )la!!"f"ed a! 1. Hot feed e'tr*der! 2. Cold feed e'tr*der! Co,par"!o$! of ;ar"o*! a!pe)t! of 4ot a$d )old feed e'tr*der! are %";e$ 0elo..
S. @o. A 1 2 3 4 5 6
HOT 2++D +BTRUD+R D+S1/@ PARA&+T+RS S4ort 0arrel ?o.er ?-D rat"o 4>1 to 5>1 Co,pre!!"o$ rat"o appro'.1
CO?D 2++D +BTRUD+R ?o$% 0arrel H"%4er ?-D rat"o 18>1 to 15>1 Co,pre!!"o$ rat"o C1
Dept4 of t4e fl"%4t "! 1-6t4 of D"a. Dept4 of fl"%4t "! 1-6t4 to 1-18t4 of D"a. Co$!ta$t or ;ar"a0le p"t)4 Co$!ta$t fl"%4t dept4 PROC+S1@/ 2ACTORS Var"a0le p"t)4 Var"a0le fl"%4t dept4
1 2 3
Co,po*$d pre .ar,ed
Cold )o,po*$d
Te$de$)( to !)or)4 ?e!! !)or)4"$% 2eed ;ar"e! "$ te,perat*re & Co$!ta$t te,perat*re & ;"!)o!"t( ;"!)o!"t( D"ff")*lt to ,a"$ta"$ )o$!"!te$)( etter d",e$!"o$al )o$trol of e'tr*date Prod*)t"o$ e9*"l"0r"*, atta"$ed Ta=e! lo$%er t",e for e'tr*!"o$ to !ta0"l"#e ."t4"$ a !4ort t",e +CO@O&1C 2ACTORS H"%4er "$;e!t,e$t H"%4er la0o*r )o!t Re9*"re! lar%e floor area ?o.er "$;e!t,e$t ?o.er la0o*r )o!t ?e!! !pa)e re9*"red
5 C 1 2 3
4 5
?o.er fre9*e$)( of repla)e,e$t 2re9*e$t repla)e,e$t of !)re. a$d l"$er of !)re. a$d l"$er H"%4er o*tp*t ?o.er o*tp*t
34
Ceat Ltd, Halol, Vadodara +
PART/ O7 AN E6TR3DER
T4e e'tr*der )a$ 0e d";"ded "$to !"' 0a!") part! for ea!e of de!)r"pt"o$. a. T4e arrel 0. S)re. ). 2eed 4opper d. Head e. D"e. f. Dr";e a$d %. Te,perat*re )o$trol
2"%> D"a%ra, of e'tr*der
a'
BARREL
T4e 0arrel e$)lo!e! t4e !)re. a$d "! ,ade of 4arde$ed !teel. T4e "$$er l"$"$% of 0arrel "! ,ade ."t4 a ;er( 4ard allo(. 3all! ,*!t 0e 4ea;( to re!"!t t4e rad"al pre!!*re! de;eloped "$!"de. +;e$ %reater are t4e lo$%"t*d"$al pre!!*re! a! t4e !)re. %e$erate! e$or,o*! !eparat"$% for)e! "$ p*!4"$% t4e !to)= t4ro*%4 t4e re!tr")ted d"e. T4e!e for)e! are ta=e$ *p "$ t4e rear 0( t4r*!t 0ear"$%! a$d t4e ,a!!";e$e!! of t4e!e 0ear"$%! re;eal t4e ,a%$"t*de of t4e pre!!*re! de;eloped. T4e )a!t o*ter 0arrel 4a! a t4",0le or 0*!4"$% "$!ert ."t4 r"0! r*$$"$% d"a%o$all( aro*$d "t "$ t4e pre!!*re area. 34e$ t4e t4",0le "! "$!erted "$ t4e 0arrel, t4e !pa)e! 0et.ee$ t4e r"0! 35
for, t4e )4a$$el! t4ro*%4 .4")4 t4e )ool"$% .ater )"r)*late!. T4e t4",0le "$ t*r$ )o$ta"$! a$ e'tre,el( 4ard ,etal re,o;a0le l"$er, .4")4 pro;"de! a .ear re!"!ta$t !*rfa)e !*rro*$d"$% t4e !)re.. T4"! )a$ 0e repla)ed rap"dl( a$d e)o$o,")all( .4e$ .or$. T4e r*00er )o,po*$d "! !4eared 0et.ee$ t4e .all! of t4e 0arrel a$d fl"%4t! of t4e !)re. 0( t4e fr")t"o$ 0et.ee$ r*00er a$d 0arrel. 2or t4"! rea!o$, t4e 0arrel !4o*ld $ot 0e )ooled too lo., a! )o$de$!at"o$ of .ater o$ t4e .all ."ll red*)e t4e fr")t"o$ a$d )a*!e "$eff")"e$t e'tr*!"o$. Al!o t4e 0arrel ,*!t $ot 0e .ar, too 4"%4, a! t4"! ,"%4t )a*!e !)or)4"$%. T4e o*tp*t of a$ e'tr*der "! depe$de$t o$ t4e relat";e %r"p 0et.ee$ t4e !)re. a$d 0arrel, t4e 4"%4er t4e %r"p of 0arrel, 4"%4er t4e o*tp*t. 1' THE /CRE? T4e rotat"$% !p"ral !)re. "! t4e 4eart of t4e e'tr*der. 1t "! a t4readed !4aft, .4")4 l"e! )o: a'"all( a$d 4or"#o$tall( "$!"de t4e 0arrel. 1t "! )o$$e)ted ."t4 a ,otor a$d rotate! a$t": )lo)=:."!e. T4e ",porta$t para,eter t4at deter,"$e! t4e eff")"e$)( of t4e !)re. "! "t! ?-D rat"o. 1t "! %";e$ 0(, T4e le$%t4:to:d"a,eter D?-DE rat"o> : T4e rat"o prod*)ed 0( d";"d"$% t4e effe)t";e le$%t4 of t4e !)re. 0( "t! d"a,eter. +a)4 !)re. 4a! %ot a def"$"te ?-D rat"o. T4e ?-D rat"o "! a ,a<or fa)tor "$ t4e !ele)t"o$ of a$ e'tr*der to ,at)4 t4e pro)e!! re9*"re,e$t! a$d a%a"$ o$e t4at pre!e$t! pro0le, "$ 9*a$t"f("$% a )learl( def"$ed %e$eral pr"$)"ple. T4e ?-D rat"o$ )o$trol! to a lar%e e'te$t t4e pla!t")at"o$ of t4e )o,po*$d "$!"de t4e e'tr*der. T4e ,o!t )o,,o$ ?-D rat"o! *!ed toda( are 4>1 to 5>1 for 4ot feed e'tr*der! a$d 18>1 to 12>1 for )old feed e'tr*der!. &o!t r*00er !)re.! are prod*)ed fro, 4"%4 ,ol(0de$*, !teel, t*r$ed a$d %ro*$d to !4ape, fla,e 4arde$ed, a$d t4e$ )4ro,e plated. T4"! ",pro;e! t4e l"fe 0( red*)"$% t4e .ear rate a%a"$!t t4e l"$er. T4e pr",ar( p*rpo!e of t4e !)re. "! to )o$;e( ,ater"al alo$% t4e 0arrel. T4e r*00er )o,po*$d "! )o$;e(ed fro, t4e feed e$d to t4e d"e e$d 0( t4e re)"pro)at"$% ,o;e,e$t of t4e !)re. a$d 0*"ld! *p !*ff")"e$t pre!!*re !o a! to for)e t4e r*00er t4ro*%4 t4e d"e.
36
A! t4e r*00er %et! .or=ed "$!"de t4e e'tr*der, a lot of 4eat "! %e$erated. A part of t4"! 4eat "! ta=e$ o*t 0( )ool"$% t4e !)re. 0( )"r)*lat"$% .ater "$!"de t4e !)re.. T4e !)re. "! dr"lled "$ter$all( to per,"t .ater to 0e )"r)*lated o$ "t! "$!"de. C' HOPPER 1$ all e'tr*der!, t4e !)re. "! pro;"ded ."t4 a feed 4opper, .4")4 ,a( 0e of re)ta$%*lar or )"r)*lar ope$"$%, .4")4 re)e";e! )o,po*$d "$ a !tr"p for, )o$t"$*o*!l( a$d %*"de! "t do.$ "$to t4e Ffeed fl"%4t!G of t4e !)re.. T4e !4ape a$d lo)at"o$ of 4opper !e)t"o$ are ",porta$t fa)tor! "$ t4e )o$trol a$d o*tp*t of t4e e'tr*der. T4e!e ,*!t 0e !*)4 t4at t4e feed !tr"p ."ll 0e pre!e$ted to t4e !)re. 0"te ."t4 t4e lea!t "$terfere$)e a$d "$ a )o$!"!te$t a$d eff")"e$t po!"t"o$. T4e 4opper "! t4e lar%e!t )o,pat"0le ."t4 t4e !"#e, "! off!et to.ard t4e 0"te !"de of t4e !)re. a! "t re;ol;e!, a$d 4a! %e$tl( tapered !,oot4 !"de.all! to pre;e$t t4e feed !tr"p fro, 0r"d%"$% a! "t fall!. T4e 0arrel "! *$der)*t o$ t4e floor of t4e 4opper 0e$eat4 t4e !)re. H t4at "!, "t "! )*t a.a( !o t4at a )leara$)e of a 4alf:"$)4 or ,ore 0et.ee$ t4e t"p of t4e !)re. a$d t4e floor 0efore "t "! p"$)4ed off. d' HEAD T4e 4ead of a$ e'tr*der "! t4e ,ea$! of )o$!ol"dat"$% t4e roll"$% )ol*,$ of r*00er e,er%"$% fro, t4e 0arrel a$d !)re. "$to a 4o,o%e$eo*! ,a!!A of d"!tr"0*t"$% t4"! ,a!! to t4e d"e a! e;e$l( a! po!!"0leA a$d of ,o*$t"$% t4e d"e a$d a))e!!or"e!. 1t 4old! t4e )o,po*$d a! a re!er;o"r, .4")4 e$!*re! e;e$ pre!!*re at t4e e,er%"$% e$d of t4e e'tr*der "$ !p"te of ;ar"at"o$ "$ feed rate. Heat tra$!fer fro, t4e 4ead "! ;er( ",porta$t. &*)4 of t4e %e$erated 4eat 4a! 0ee$ de;eloped .4e$ t4e !to)= lea;e! t4e !)re., !o te,perat*re )o$trol!, .4")4 pro;"de a$d ,a"$ta"$ )o$!"!te$t )o$d"t"o$! .4"le t4e !to)= "! "$ t4e 4ead, are $e)e!!ar(. T4"! ,ea$! t4at t4e 4ead "! 4eated pr"or to t4e r*$ !o t4at t4e !to)= at t4e !tart of t4e r*$ doe! $ot lo!e "t! 4eat "$ .ar,"$% t4e 4ead. After !tart *p, a te,perat*re )o$troller ."ll ,a"$ta"$ opt",*, e'tr*!"o$ )o$d"t"o$!. +a)4 4ead "! )ored or )4a,0ered for !tea, a$d .ater )"r)*lat"o$. U!*all( 0ot4 pro;"!"o$! are %";e$ to 4eat t4e 4ead "$"t"all( a$d t4e$ to )ool. Alter$at";el(, te,perat*re )o$trol *$"t! are *!ed.
35
Ceat Ltd, Halol, Vadodara !' DIE
D"e de!"%$! a$d ,a$*fa)t*re "! a ,a<or part of e'tr*der operat"o$. T4e f*$)t"o$ of t4e d"e "! to %";e t4e re9*"red prof"le to t4e e'tr*date. Alt4o*%4 a !et of 0a!") r*le! %o;er$! d"e!, !o ,*)4 of t4e f"$al d"e d",e$!"o$ depe$d! *po$ t4e part")*lar e'tr*der, !to)= propert"e! a$d prof"le ."t4 .4")4 "t "! *!ed, t4at fa,"l"ar"t( ."t4 t4e!e part")*lar! "! of ,ore ;al*e t4a$ %e$eral )al)*lat"o$!. 34e$ prepar"$% t4e e'tr*!"o$ d"e, "t 4a! to 0e )o$!"dered t4at t4e e,er%"$% prof"le doe! $ot 4a;e t4e !a,e d",e$!"o$! a! t4e d"e ope$"$% 0*t t4at a )erta"$ e'tr*date !.ell o))*r!. 34e$ pa!!"$% t4ro*%4 t4e d"e, t4e )o,po*$d !4r"$=! alo$% t4e"r le$%t4 a$d !.ell! a)ro!! t4e )ro!! !e)t"o$ DD"e S.ellE. T4"! !.ell o))*r! 0ot4 "$ t4e ;ert")al a! .ell a! t4e lateral d"re)t"o$. D"e !.ell depe$d! o$> 1. 2. 3. 4. T4e !4ape of t4e 4ead a$d t4e e'tr*date. Pre!!*re "$ t4e 4ead. Head a$d )o,po*$d te,perat*re. Co,po*$dG! R4eolo%")al )4ara)ter"!t")
D"e !.ell 4a! to 0e a))o*$ted, ".e. t4e d"e 4a! to 0e ,ade for a part")*lar )o,po*$d a$d 4ead. T4"$$er re%"o$! "$ t4e e'tr*date 4a;e to 0e ,ade t4")=er a$d ;")e ;er!a .4"le de!"%$"$% t4e d"e. R*00er flo. to.ard! lar%er ope$"$%! "$ t4e d"e !4o*ld 0e re!tr")ted e"t4er 0( ,ea$! of 0affle! or 0( red*)ed or $"l taper"$%. Too !,all a d"e ."ll lead to 4"%4:pre!!*re area! a$d Fdead !pot!G "$ t4e 4ead t4at )a*!e! !ta%$at"o$ a$d !*0!e9*e$t !)or)4"$% of t4e )o,po*$d. leeder 4ole! ,a( 0e dr"lled "$ t4e d"e to rel"e;e 4"%4:pre!!*re area! or el","$ate Fdead !pot!G "$ t4e flo.. Too lar%e ope$"$% ."ll lead to "$!*ff")"e$t pre!!*re de;elop,e$t a$d *$der d",e$!"o$ of t4e e'tr*date. Al!o, "t )a$ )a*!e )a;"tat"o$! a$d !*0!e9*e$t poro!"t( "$ t4e e'tr*date. 2or a part")*lar d"e, t4e e'tr*date prof"le depe$d! to a %reat e'te$t o$ t4e ;"!)o!"t( of t4e !to)=, t4e a,o*$t of !to)= 0rea=do.$, t4e ;ol*,e of t4e feed !tr"p, t4e !to)= te,perat*re, t4e e'tr*der te,perat*re! a$d t4e !)re. !peed. 1t 0e)o,e! o0;"o*! t4at t4"! d"e ."ll prod*)e t4e !a,e e'tr*date prof"le o$l( .4e$ t4e )o$d"t"o$! *$der .4")4 "t .a! de;eloped are repeated. D"e! are 4eated pr"or to f"t,e$t o$ to t4e 4ead.
36
Ceat Ltd, Halol, Vadodara "' DRIVE
+'tr*der dr";e! ,*!t pro;"de ade9*ate tor9*e to t*r$ t4e !)re. o;er ."de ra$%e H 8 to 288 rp, H ."t4 pre)"!e !peed )o$trol. T4e rotat"o$al !peed at t4e e'tr*der e$d "! $or,all( a)4"e;ed 0( )o*pl"$% t4e e'tr*der !4aft t4ro*%4 a %ear tra"$ ."t4 t4e ,otor. T4e %ear red*)t"o$ !(!te, "! *!ed to red*)e !peed a$d ,*lt"pl( tor9*e. ' TEMPERAT3RE
CONTROL/
Te,perat*re "! to 0e )o$trolled "$ t4e 4ead, 0arrel, !)re. a$d d"e of t4e e'tr*der to prod*)e %ood 9*al"t( )ro!! !e)t"o$! a$d to ,a"$ta"$ )o$!"!te$)(. A te,perat*re )4a$%e of 18IC "$ t4e !to)= ."ll )4a$%e t4e !4ear rate 0( appro'",atel( 1.3J. T4"! ."ll affe)t t4e rate of flo. t4ro*%4 t4e d"e a! .ell a! t4e d"e !.ell )4ara)ter"!t")!. T4e )o$!"!te$)( of te,perat*re "! ,ore ",porta$t t4a$ t4e a)t*al te,perat*re, .4")4 ,a( 0e !et depe$d"$% o$ t4e pro)e!! a$d )o,po*$d )4ara)ter"!t")!. 2or pre)"!e )o$trol of e'tr*!"o$, ,*lt" H#o$e 0arrel, 4ead, !)re. a$d D"e- D"e )la,p 0lo)= te,perat*re! are !eparatel( !et a$d )o$trolled. T.o ,et4od! of te,perat*re )o$trol are "$ *!e> 1. D"re)t .4ere t4e )ool"$% ,ed"*,, !a( .ater "! d"re)tl( ad,"tted "$to t4e e'tr*der #o$e! a! re9*"red H $or,all( for 4"%4 )ro!! !e)t"o$ e'tr*!"o$! C158 !9.,, 2. 1$d"re)t !(!te,, .4ere a )"r)*lat"$% fl*"d "! pa!!ed t4ro*%4 a 4eat e')4a$%er, .4")4 re,o;e! t4e 4eat fro, t4e )"r)*lat"$% ,ed"*,
CALENDERING O= =A:RIC?
PRINCIPLE O= CALENDERING
+he majority of the calendars installed in general ru**er good companies are three roll units where as four roll calendars are normally used *y tyre manufacturers. +he advantage of >-roll calendar is its versatility and it can produce a sheet of ru**er and a friction or a skim coat on one side of a fa*ric. +he main advantage of =-roll calendar is its a*ility to top the dou*le side of a fa*ric is single operation. ,ommonly used four roll calendars are@
37
8& Th) i$C)rt)- L5'!$0ig*rati!$ +his was the first major change in the *asic vertical calendar design. It has all the versatility of the *asic three-roll calendar *ecause of the *ottom and off set rolls is keyed to provide *oth even and odd sheet. :& E5r!ll '!$0ig*rati!$ +his calendar is generally used in the tyre industry as the heart of high production cord coating line speciali5ed in e4uipment capa*le of continuous high 4uality output. +he main advantages of D-roll calendars are it eliminates the nip force interaction and roll float. +he nip force act in a plane at 67 7 to each other and roll float are minimal *ecause the direction of resultant of nip force *eing relatively insensitive to change in these force. +he main disadvantage is that it lacks some fle$i*ility for automatic gauge control. ,alendaring process can *e descri*ed *y means of com*ined drag flow and pressure flow. +he clearance *etween the rollers and viscoelastic *ehavior of the ru**er will determine the thickness of the sheet. +he counterrotating roll will drag the material in the converging region of the calendar nip through the clearance. (ue to this highly converging flow a high pressure is *uild up in the nip region. +his is also a function of compound viscosity clearance line speed and rolling *ank height. . part of dragged material is pushed *ack *y the pressure flow. +his will results in rolling *ank in the calendar nip. deflection. +he roll separating force is a calendar is given *y ;L:-"'h %8Fh-8F!& 3here -Lviscosity of the *ank "Lspeed of the roll !Lthe nip *etween the rolls 'L radius of the calendar rolls. +his nip pressure causes a nip force and therefore a roll
48
;or good 4uality product following precautions should *e taken@ ,onstant and steady nip feeding ,onstant stock temperature ,ord tension should *e as low as possi*le *ut sufficient to keep cord distri*ution ,alendar to *e e4uipped with crowned rolls e$ternal roll *ending and adjusta*le cross a$is setting +hickness control e4uipment Peak in tension to *e damped 2atch to *atch variation should *e avoided 0ajor changes in the line speed should *e avoided
41
42
C!$tr!l !0 ga*g) 8& Cr!.$i$g +he calendars are huge and designed to resist great separating force *etween their rolls. +hese forces *end the rolls and stretch side frames so much. +he rolls must *e ground to accommodate and counteract this *ending or deflection. So the rolls are grind with varying diameter from the middle to the end of the roll and it is known as crown. 3arm up of the stock on mill change in the roll temperature thickness of the skim si5e of the calendar *ank and speed of the calendar effect the separating force and thus the *end of the roll. +he deflection can *e calculated from the formula of deflection of a *eam supported at *oth ends and loaded uniformly over its length. +his produces a regular curve which is an arc of a circle. "ariation in estimates of total separating force resulted in total calculated deflection of 7.77: to 7.77<M ma$imum on a :=M N H9M calendar roll and calendar crown were ground to handle the deflection. +he crown produced on a calendar will *e always a compromise. +he crown given for a calendar used for a soft compound and a hard compound should *e different due to the difference in separating force. So the crown adjusted for a hard compound will produce a lightly thinner sheet at the center than at the edge with soft ru**er compounds. So *y choosing crown for major stock runs a sheet of ideal flatness can *e achieved. :& R!ll ()$-i$g 'oll *ending control arouse out of original effort to preload calendar roll to counter act the *ending force governed *y ru**er. +he journal of the rolls are e$tended *eyond the housing journal *o$es collars are installed on these e$tension and hydraulic cylinders linked in the collars in proper position to supply the desired force. +hey are mounted on one roll or all rolls and +he pressure operate in *oth directions. +he ma$imum deflection possi*le of achievement *y roll *ending on a :=M N H9M calendar is a*out 7.77=M. response o*tained is fast. reac4uired to achieve this is in the range of H7 777 pounds per roll ends. +he
43
>& R!ll 'r!""i$g 'oll crossing is accomplished *y tilting the plane a$is of one of the two adjacent rolls in relation to the common plane a$is of the two. +he journal *o$es of the crowning roll slide not only towards and away from their mates on the adjoining rolls *ut can *e moved at 67 7 from these latter. +his is achieved *y mechanical screw similar to roll skew downs hydraulic system and sliding wedges. 0echanism of roll crossing is complicated. T)m+)rat*r) '!$tr!l ,alendar reac4uires a uniform and well-controlled temperature profile across the surface of the roll. +he temperature control system for calendar due to the short residence time cannot compensate effectively for transient change in feed material. So the main consideration is for maintaining temperature sta*ility in calendared rolls. ;or this the *asic function of a +he calendar temperature control system is to hold inlet temperature of the roll constant and take away the heat developed *y normal calendaring. different types of roll cooling systems used in calendars are a& C!r)- r!ll ,ored rolls are mold casted with internal cores and are machined on the outer surface only. +hey have variation in wall thickness due to casting irregularities. +he walls tend to *e heavy so that heat transmission for cooling is slow and uneven. +hey can *e used at lower speeds with good accuracy. *& Drill)- r!ll" +hese rolls have a *ored center-hole a*out 9M in diameter and a concentric rings of 8F=M holes drilled from end to end a*out 8-8F:M *elow the circumference and water is circulated through this. It will improve the rate of heat transfer from roll surface and to remedy the temperature fall off at the roll edges.
44
>& =))- '!$tr!l +he supply of a material of uniform flow properties to calendar nip at constant rate is a prere4uisite for dimensional accuracy and good surface appearance for calendared sheets. . uniform roll separation fore is important and the temperature *and in which successful calendaring can take place may *e 4uite narrow. +he rolling *ank si5e influences *oth temperature and roll separating force. .s calendar speed is increased the control of flow properties and feed rate necessary for successful manufacture *ecame more critical. ;or uniform feed rate and even feed across the width of calendar nip a conveyor feed from the pre-plastici5ation machine terminating in a pendulum head which can oscillate *ack and forth across the width is used.
Cal)$-)r -)"'ri+ti!$
45
'oll si5e 'oll design 'oll crowing ,ross a$is 2ending 'oll speed 'oll temperature 'eed temperature
?: N :9M inclined D calendar (rilled 7.89 mm on I & I" th roll Ao Ees :H.9 rpm 677, 997,
+he roll ends are fitted with rotary joints for connection to the water
system. . S+))- rati! +he speed of >rd roll is specified as the speed of calendar. .ll other motors in line are synchroni5ed with motor running in > rd roll. +he speed ratio are given *y 8F: 8@8.< :F> 8@8.78 >F= 8.<@8 ;or A' compound temperature of : nd and>rd roll should *e high
*ecause of its tendency to cling on hot and low rolls.
6 2 CALENDERING #NIT In ,E.+ tyres !alol a four-roll calendar with D configuration is used for coating ru**er to fa*ric. +he important parts of calendar unit are A3 13 L)t !00 F!$) D*al l)t !00 +his unit permits continuous operation of the system *y providing active and standing *y storage of two fa*ric rolls. +his has an automatic tensioning system with pneumatically operated *reak and load sensor. +he fa*rics let off at a constant preset tension. +he roll holding chucks are crammed so that
46
they cannot *e open unless the seat in loading position and the cam will close the chuck when it is rotated. 23 S+li'i$g +r)"" . hydraulically operated splice press is used to join the successive roll ends to form a continuous we* of fa*ric supply to the calendar unit. +he press has two electrically heated platen of si5e :77 N 8H?<-mm separated *y a distance of :77m. +he temperature of the press is maintained at >H7 O:7 ; and a pressure ><-/gFcm:. . gum stock of ru**er is applied at leading end of the new fa*ric roll is placed together with the tail end of previous roll in the press and the platens are closed. +he presses will automatically open after >7 seconds. -pper plate is insulated from the press head and mounted on a stationary position on a *olster plate. +he lower platen is connected to a hydraulic cylinder for closing force. +he hydraulic unit is a separate unit to which the press is piped and each cylinder is provided with hydraulic e4uali5ing to assure a uniform pressure throughout the length of plate 33 T)$"i!$ ")tt)r +his tension setter is used to keep the fa*ric in tension in the line. Aormally the tension applied in this tension setter is a*out 8777/g. 63 L)t !00 a''*m*lat!r 0))- r!ll +his feed roller will draw the fa*ric from the let off at a steady rate and synchroni5e with the other fa*ric driving mechanism in the system. +he roll stand has one driving roll one air operated nip roll and three steel idler passing rolls. (uring the time of edge splicing nip roll will press against the feed roller and will prevent the loosing of the free ends of the ended fa*ric rolls. It will also act as a hold *ack when the following accumulator provides the fa*ric to the system towards the *eginning of a new fa*ric roll. +he pneumatic load cell which senses the fa*ric tension so that one can control the let off tension in mounted under the idle roller *earing. +his roll will have a tension of a*out <7 to :<7 /g. 73 L)t !00 a''*m*lat!r
45
It is a top floating hydraulically operated simultaneously arranged complete with entering and leaving idle reactor controller unit which provide the storage of fa*ric at the time of roll change. It can store a*out 8:7m of fa*ric in 8:7seconds. +he clearance *etween the idle rollers is >9mm. #enerally the floating carriage is in the top position having sufficient storage of fa*ric and is move down for giving time for joining of two fa*ric ends i.e. when the accumulator feed roll stops the fa*ric is fed into the system *y lowering of floating platform. +he traveling platform is carried *y a chain from the four corners. +he accumulator is provided with two control switches one for operation at the top with full accumulator and one for operating at a*out :<7mm from the *ottom with near empty accumulator. 83 Pr) 'al)$-ari$g -ryi$g -r*m +wo set of 87 steam heated drum are used to dry the fa*ric *efore enter into the calendar. +he main purpose is to remove the moisture in the fa*ric. Steam is used for heating the drum. +he steam pressure inside the cylinder is <.9/gFcm: so as to get the surface temperature is 67 7 ,. +he drums are made of stainless steel and each drum is provided with vacuum *reaker. +he drums are freewheeling with disc *reak on entering drum on each side. ;3 Pr) 'al)$-ar t)$"i!$ "ta$In order to provide a pre calendaring tension a capstan type tension stand is provided which is floor set after the drying drum. It consists of four rollers *ack geared together and driven through a totally enclosed reducer *y a (, motor. 'olls rotate in roller *earing supported on post type side frame. +he diameter of the roll s a*out :8<mm and it e$perience a tension of 8777/g. <3 Da$')r r!ll" +he main function of this stand is to a*sor* the stacks developed in the fa*rics. +his is a specially designed compensator stand consisting of a top roll capa*le of move up and down and two rollers fi$ed at *ottom. . pneumatic cylinder is used for the roll movement with a compressed air at
46
<.?/gFcm:. +ension range e$perience is a*out :77-8777/g. +wo-flow control valve are there to limit rate of roll travel on a fa*ric *reaker provided. >3 C)$t)r g*i-) It consists of pair of rollers which can move to keep the fa*ric in the centre line. +his consists of P type frame sensor that keeps the fa*ric tracking within a preset limit. +he edges of the fa*ric will travel *etween a sender and a receiver. +his will read the fa*ric location through an electronic unit and transmit the mechanical action to the roll to keep the fa*ric in center. 103 S+r)a- ma"t)r A(a$a$a r!ll3 It consists of two *owed rolls and it is hydraulically controlled. +he edge of the fa*ric is sensed *y a photocell. +hese must *e positioned for varying fa*ric width. 3hen fa*ric passes over this roll against convert *ow ness the fa*ric width reduces and when faces the concave *ow ness fa*ric width increases. 113 E-g) )@+a$-)r It consists of three finger lime rolls arranged hori5ontally at the fa*ric edges. 3hile in operation the top roll will move a*ove the fa*ric and two *ottom rollers *elow the fa*ric. +he *ottom rolls are fi$ed and the top rollers move in and out in *etween the *ottom rolls. +his help to avoid crowdedness of the cords at the edges or variation in ends per inch. 123 Cal)$-ar r!ll" +he four roll calendar has an inclined D type configuration. +he chilled cast iron rolls are mounted on the roll *earing which are attached to the main housing of the machine. +he roll si5e of this is ?: N :9Q and a roll speed of :H.9 rpm. Each roll has individual drives. surface temperature of 997,. +he rolls are maintained at a +he temperature is given *y hot water at
=/gFcm: pressure circulated through drilled holes. !ydraulic pump is used at a pressure 8< /gFcm: for roll *ending. In order to provide roll *ending higher force is to *e transmitted. So main roll *earing is arranged at a greater distance from the au$iliary *earing. +wo hydraulic cylinders are used which act on roll journal to provide uniform gauge. +he *ending force can *e preset on hydraulic cylinder on *oth sides. +he common line speed of the calendar
47
is H7mFmin. +he fa*ric is entered *etween : nd and >rd rollers. +he compounds are fed *etween I & II and III & I". 2etween the rollers I & II and III & I" a frictional ratio of 7.H is given. +he roll *ending pressure is applied *etween I &II is a*out =<7psi and that *etween III & I" is =89 psi. Ao cross a$is is given *etween the rollers. 133 P!"t 'al)$-ar -a$'ar r!ll It a*sor*s the slack formed in the ru**er-coated fa*ric as earlier in the pre calendar dancer rolls. 163 C!!li$g -r*m It consist set of 87 drums are designed to cool the calendared fa*ric to the room temperature. ,hilled cooling water of 89 7, at a pressure of = /gFcm: is circulated through the drum so as to attain surface temperature of 977,. +he design of the drum is such that water enters into the drum on *oth side and e$it on either side through the journal. . *ooster pump is used to *oost the pressure in cooling water. (rums are freewheeling and designed to withstand :777/g tension with fa*ric tack additional. . gate valve is furnished *etween each drum. 173 Pi'%)r r!ll" It involves pin type penetration of rails fitted on two rolls in line with the calendar. +he coated fa*ric is passed *etween these two rolls for perforation and hence allows the escape of air within the plies. 183 Pi'% (r)a%)r +he pick *reaker consists of two grooved rolls one a*ove and one *elow the fa*ric just like meshing of gear teeth. +hese meshing of rolls *reak the west end and hence avoid the no uniform spreading of fa*ric during *uilding. +hey are rotated on a flanged cartridge type *all *earing on a dead shaft. +he lower roll is fi$ed on a welded steel frame. +he upper end is mounted in a pivot arm attached to the pneumatic cylinder.
1;3
P!"t 'al)$-ar t)$"i!$ "ta$-
58
It consists of three rolls to provide a tension of :7-:77/g of the calendared fa*ric to keep the coated fa*ric in line. 1<3 Wi$- *+ a''*m*lat!r +his wind up accumulator is used to store the material in the line while the wind up rolls are changed. It has a storage capacity of H7 m fa*ric within H7seconds. +he tension in this 5one is <7-:<7 /g. It consists of 8> *ottom rollers and 8: top rollers with roll clearance of 877 mm. +he working of this is similar to the let off accumulator e$cept there is only one reactor and two limit switches. +he reactor is located at near *ottom of the carriage travel maintain the carriage position during normal operation. +he tension is indicated on an adjusta*le scale on the hydraulic system gauge. 1>3 203 Tri! 'a$t)r Its function is to avoid the edge crowding Wi$- *+ 0))- r!ll" +hey are used to provide the fa*ric to the winder and isolate the winder during the roll change from the rest of the line. It consists of two steel rolls and a nip rolls and it e$periences a tension of :<-:<7 /g. . selector switch is provided to engage or disengage the nip roll. . remote read out is located at the floor level with a counter having 9 digits. +he rolls are on a rigid frame mounted in such a way that any individual roller *earing can removed and repaired without distur*ing any other roll mounted overhead. 0ounted on the entry side of the wind up feed roll is offset pivot type centre guide to esta*lish constant position for winding. 213 D*al .i$- *+ a$- li$)r l)t !00 +he stand has pneumatically
+his unit consists of two separate winds up stand with a drive motor on each stand to make the process continuous. adjusta*le male chucks and are arranged to allow craw hook *etween the package and chick. +he liner let off stand oscillates on an antifriction *earing mounted to the frame of the stand through a hydraulic with response time of 8< mmFsec. +he total travel availa*le is 8<7mm on each side of the centre line of the fa*ric.
51
A'')""!ri)" 8& Warm *+ mill" 3arm up mill is a two roll mill 7f si5e :9 N 9=Q. Since the consumption of ru**er in the calendar is very high it stores the stock from the warm up mill. !old mill is provided with a stock *lender *ar. It is cooled *y passing chilled water. +he stock in the feed mill is conveyed to the feed mill via conveyor. :3 =))- mill ;eed mill supply the compound for the calendar. +he feeding of the ru**er is through a pendulum conveyer. mill is cooled *y passing chilled water. Cal)$-ari$g !+)rati!$ +he dipped fa*ric after a maturation period it is taken into the calendaring unit through ;I;) system. +he *lack cover is removed and +his gum has splicing gum is applied at the leading end of the fa*ric. in the one of the dual let off stand. .fter the ending of the feeding roll the let of accumulator will stops and synchroni5e the other operation. .t the same time two rollers near the splice press will close to hold the end of that fa*ric. +he splice gum applied leading end of the fa*ric is joined with the tail end of the old fa*ric is the splicing press. +he lower platen closes with high pressure at a temperature of >7 ;. .fter a cure time of =7 sec it will automatically open. (uring this time let off accumulator will provide fa*ric for the calendar unit. . tension stand is provided after the splice press to keep the fa*ric in line *y the application of tension. .fter let of accumulator the fa*ric will pass through a heating 5one consisting of :7 cylindrical drum of surface temperature of 677,. +his heating 5one will remove any type of moisture a*sor*ed in the fa*ric surface. It will create some pro*lem in final tyre during service. ;ollowing this a dancer roll is there to a*sor* any slack formed in the fa*ric. In order to keep the fa*ric in centerline with specified EPI fa*ric will +he mill is fitted with a knife to cut the compound to the correct width which is *eing fed to the calendar. +he
appro$imate width of H inch and 7.<mm thickness. +hese roll is then loaded
52
pass through centre guide rollers *anana rollers and trio canter *efore entering into the calendaring rolls. +he fa*ric enters into the calendar *etween second and third rollers. +he compound to *e coated is fed though a pendulum conveyer *etween I & II and III & I"
th
rollers. 2efore enter into to the calendar the compound is +he
passed through series of mill for proper *lending and *reakdown.
compound applied to the calendar will have a temperature of near 97 7, otherwise there will *e variation in the property of the fa*ric. +his skim coated compound is passed through post calendar dancing roll to the cooling drum. +he cooling drum has a surface temperature of >7 7, to cool the fa*ric to room temperature. .fter this 5one *leeder yarns are applied to the +his fa*ric then pass through calendared fa*ric for proper identification.
picker rolls pick *reaker to remove any air in the fa*ric. .fter passing through the wind up accumulator and wind up let off roll the fa*rics are wound on a wind roller with a liner. In order to keep the fa*ric in centre a centre guide is attached to the assem*ly. +his wind up rollers with identification tag is stored in the racks and taken into the *ias cutter in ;I;) manner. C!mm!$ -)0)'t" i$ th) 'al)$-ar)- 0a(ri'?5 ,old stock and rough surface Split fa*ric and crush fa*ric ;oreign matter 1umpy compound in fa*ric 3rinkles and folds 1oose cord and loose coating )ff *alance coating #um edge Improper gauge and width 0issing cords
St))l '!r- 'al)$-ari$g

53
Steel cord calendar is used for the production of steel *elt i.e. in a steel cord calendar the two sides of the steel wires are coated with a ru**er compound *y maintaining a specified ends per inch. +he important components of the machines are 1 Cr))l r!!m +he steel wires are coated with *rass material for *etter adhesion and prevent the corrosion. +o protect this the steel wires are stored and let off from a room called creel room. +he temperature is maintained at =7 7c with a relative humidity of ><R. 2 Gr!!C) r!ll +he steel cords are weft less. So in order to maintain the specified ends per inch in calendared fa*ric the groove rolls and a reed like structure is used. +hey will allow the passage of steel cords in specified path. ;or separate EPI separate groove rolls are used. 3 Cal)$-ar *$it +he calendaring unit consists of a four roll calendar rolls of inclined Dtype cooling drum let off accumulator and wind up stations. +he surface temperature of the cooling drum is maintained at :7 7c. In *etween the wind up accumulator and the wind up station a knife is provided to cut the *elt. +hey are shear cutters. 3ind up accumulator is provided for the continuous production. O+)rati!$? +he compound to *e coated is introduced into the cracker mill and feed mill. +he cords drown from the creel room is introduced in *etween the second and third roll maintained at a temperature of 97 7c through the grooved rollers. . tension of a*out >.H /gFcm: should *e maintained in the cord for getting the re4uired EPI. +he compounds are introduced *etween the first and second rolls and *etween third and fourth roll. +he compound should *e warmed up to 977c *efore introducing in the calendar. +wo side coated compound is passed through the cooling drum and wound on the liners in the wind up 5one. +he speed of the calendar is very small to o*tain good coating on *oth sides.
54
St))l .ir) '*tt)r
Steel wire cutter is used for cutting the calendared steel fa*ric into a specified degree of angle and splices the pieces to form a continuous strip. In ,E.+ tyre !alol two steel cutters are employed for cutting the calendared steel fa*ric. ;irst the fa*ric to *e cut is loaded in the let off stand. +he ply from the let off stand is passed through a let of festooner which control the tension in the fa*ric. +his festooner operation is controlled *y limit switches and actuated *y the length measuring device. .fter the festooner the fa*ric enters into a hori5ontal ta*le conveyor. +he cutter used for cutting the steel *elt consist of two rotating roller which are step off to each other. +he shearing action *etween the rotors gives the cutting. +his cutter assem*ly can *e adjusted for a specified angle. +his cut ply is transferred to the splicing ta*le *y a magnetic material and leading end is spliced with the tail end of the wound ends. 2efore winding in the liners gum strip is applied using gum strip assem*ly
Ca+ +li)" "litt)r?
,ap ply slitter used in ,E.+ +yres !alol is made *y +ech. edge (elhi. It can operate with a line speed of >7 rpm. ,ap ply slitter is used for slitting a calendared cap ply fa*ric into cap ply strip of re4uired smaller width. +he main parts of this machine are 13 =a(ri' l)t !00 +he fa*ric let off is controlled *y unwinding the liner. . constant speed is ensured *y the let off motor drive system. +his let off station is mounted over a moving *ase and tensioning device operated *y hydraulic centering system. 0ovement of the *ase is activated *y the automatic centering system which consists of a light source and receiver.
23
Slitti$g %$i0)
55
Slitting knife is pneumatically operated and distance *etween the knives can *e adjusted depends on the width of the cap ply re4uired. +he silted pieces are separated *y independently adjusta*le idle rollers which are vertically mounted. 33 Ta%) a.ay '!$C)y)r a$- .i$- *+ "tati!$
+ake away conveyor is driven *y a (,- motor. +here are four stations along with one set of each stand *y winding up for the continuous winding f slit rollers. +he winding is done *y engaging the roll with the conveyor. +he liner tension from the liner let off in wind up can *e adjusted down *y a particle *reak. .ll wind ups are provided *y air motor to ensure a positive and tight winding.
Ca+ "tri+ '*tt)r?

1 =a(ri' l)t !00
;a*ric is let off from the roll *y unwinding the liner. . constant speed is ensured *y the let of dancer system. +his will also achieve centering and proper tensioning of the ply. 2 K$i0) "y"t)m /nife fitted to a toggle shaft which are guided *y the cord direction. +he distance *etween the knife can *e independently adjusted depends on the width of the ply. Silted fa*rics are separated *y independently adjusta*le vertically mounted idle rollers. 3 Wi$-*+ "tati!$. .ll winders are provided *y a tensioner device to ensure the positive wind up tension. Some supply stations are there which can move parallel to the winder in such a way that uniform supply of fa*ric.
A"")m(ly li$)r ALi$)r +r)+arati!$3?

In order to reduce the tyre *uilding cycle time in passenger car tyresB chafer is assem*led with the inner liner in assem*ly liner preparation unit.
56
Peculiarity of this unit is it uses highly sophisticated charge code digital camera for centering the chafer and inner liner. +he different component s of this machine is 8& SG*))g)) +r)+arati!$ *$it +he s4ueegee preparation unit is com*ination of a cold feed e$truder and a two-roll calendar. +he head of the cold fed e$truder is connected to a two-roll calendar So that the s4ueegee with a very fine thickness and 4uality is o*tained. +he calendar rolls are provided with two knives adjusted a particular distance same as that of width of the s4ueegee. +his s4ueegee is pulled *y a take away conveyor. +he speed of the calendar rolls and the line speed of the conveyor are synchroni5ed. :& Cha0)r "*++ly +he cut chafer can *e placed on a let of station. +here is a let off accumulator for making the process continuous. +o place the chafer on proper position it is passed through a moving *ase whose movement can *e actuated *y the signals from ,,( camera. O+)rati!$? +he inner liner compound is introduced in the cold feed e$truder. +he e$truded inner liner is taken through the nip of the calendar and allowed to wind on it. +he cutting knifes are adjusted for the specified width and the cut s4ueegee is introduced in the take off conveyor. +he s4ueegee is then passed over the guide roller and the space of the guide roller is adjusted for proper centering. +he moving *ase assem*ly and ,,( camera do the appropriate centering of the s4ueegee. (uring this time the chafers are loaded in the chafer let off assem*ly and introduced on the inner liner through let off accumulators. +he chafers should *e properly centered using ,,( camera. +his assem*ly is then wound at the winding station. Speed of the conveyor is synchroni5ed. . guider roll is provided for proper placing of the s4ueegee on the conveyor.
55
:)a- a$- a+)@ (*il-i$g *$it?

In radial high performance tyres smooth *uilding up of stress from the rim to the carcass is necessary for *etter riding comfort and steering response. So the dimensional sta*ility of the ape$ed *ead should *e of very high 4uality. In ,E.+ +yres !alol for the preparation of *ead with very good dimensional sta*ility they are using a *ead ape$ing machine called ;0; ,onti 2ead ape$ing machine. +he machine is semi-automatic. +wo *eads can *e ape$es at a time with this machine. +he different components of the machine are@ 13 E@tr*-)r . cold fed e$truder is used for preparing predetermined profile of filer. +he e$truder used is a ?< mm e$truder. +he e$truder is provided with a temperature control system and the temperature of the e$truder is normally set at 6<7,. +he e$t=uder is provided with a head and die. +he die is designed in such a way that two fillers are joined at the top portion through a prating line. +he hot filler is e$truded on a hori5ontal moving conveyor. +he speed of the conveyor and the rate of e$trusion should *e synchroni5ed. )therwise the dimension of profile should *e changed. +he ma$imum line speed of this e$truder is :7 rpm.
2 C!!li$g -r*m +he e$truder will e$trude the filler at a temperature of 6< 7,. In order to cool this filler it is passed through a large cooling drum in order to maintain the *ooking temperature as =77,. +he surface temperature of the drum should *e not *eing more than >77,. ;actory cooling water is used for cooling the drum. +he drum is rotating at very low rpm. .fter cooling the filler is stored in an accumulator. +here are five series of accumulators arranged parallel to each other and the accumulator supplies the filler to the ne$t section. controlled *y light sensors. +he
56
3 A+)@i$g *$it .pe$ing unit consist of a servicer and a *ead placing *ladder. +his device provides the two filler in appropriate position on the drum. +his is achieved through photo sensing device. +o cut the filler at desired length a hot knife is provided. +he knife is heated at :>7, for smooth cutting. +he cutting angle is almost =<7,. . sponge roller is provided for applying pressure of filler at the time of placement of ape$ on the *ladder. *ladder. 6 :)a- ")rCi')r a"")m(ly ;or the correct placement of *ead on the drum with respect to the filler *ead servicer is used. In this unit first the *ead is placed on a collapsi*le chuck. +hese *eads are carried *y a semi arc like structure *ead servicer which can e$pand and collapse so as to take the *ead from the chuck and place e$actly on *ladder. 2ead servicer can move laterally over the length of the *ladder. 2ead servicer places the *ead in such a way that the standing faces of two *eads face each other at a particular distance. :)a- a+)@i$g +r!')""? +emperature control of the e$truder is set under specification. +he +he *ladder is supported on two rim in such a way that it can move laterally to e$pand the
specified die is inserted and the screw rpm and line speed are set as per specification. +he e$truded filler passing through the cooling drum they are stored in the accumulator. .fter the accumulator the filler is silted along the parting line *y a rotating knife. +he two separate fillers move through their corresponding path. 3hen a specified length of the filler is on the servicer the cutting knife will activate and cut the filler to separate. +he skived angle should *e free from folding damages and with straight tip. +he servicer moves towards the drum and apply the filler at correct position. +he sponge roller applies a pressure > /gFcm:for correct placement of the filler on the
57
drum. +he splicing should *e minimum and spliced portion is consolidated *y a series of needle like structure automatically. (uring this time the *ead servicer is ready with the *ead holder assem*ly. 3ound *ead should *e placed on the *ead hold assem*ly in such a way that to get a spotting of 8977*etween wound *ead splice overlap and filler splice overlap. It will move lateral to the drum containing filler and placed on the appropriate position. (uring the time drum e$pands and hold the *ead. +he distance *etween the *ead and the lip of the filler should *e > mm. +he *ead servicer moves to its original position. +hen *oth the rim come closer to each other and e$pansion of the drum take place at the position *etween the *eads in such a way that the *ead ape$ should *e placed over the *ead and *end against the holder assem*ly. .fter this the rim move away and the drum is returned to the original position. +he wound *eads are taken and placed on the rack.
2igh ta(l) (ia" '*tt)r?

!igh ta*le *ias cutter is used for cutting the plies to a re4uired width and angle from the calendared roll to produce continuous length of the fa*ric. +he cut plies are spliced manually and wound on liners. +he main parts of the machines are a let off unit and festooner a ta*le conveyor cutting knife assem*ly splicing ta*le and a wind up unit. +he let off station consist of a chuck provided with *reak for maintaining suita*le tension in the fa*ric. ;rom this the fa*ric is passed through a festoon drive which is operated *etween two limit switches. +his festooner is operated *etween limit switches. +his festooner controls the supply of the fa*ric to the other units. .fter that the fa*ric is drawn through a ta*le conveyor on which the cutting of the plies takes place. +he knife assem*ly consists of a round knife supported on a high mass to provide re4uired moment of inertia. +his knife assem*ly can *e set according to the re4uired angle. Aormally the angle is set in the range of 99 7 to 6:7. +he knife assem*ly is actuated *y a length measuring device set for specified value. +he cutting ta*le is placed at a height from the splicing ta*le. +his cut ply fall
68
down to the splicing ta*le. +his plies are spliced manually and wound in liners. +he movement of the wind up assem*ly is controlled *y photo sensors.
Cha0)r "litt)r
,hafer slitter is used for the manufacture of chafer. +his involves the cutting of calendared fa*ric from the = roll calendar and this is further silted in Sohnston slitter for further use in tyre *uilding and assem*ly liner. +he spitted calendared fa*ric is placed on the let off roll. +he fa*ric is taken and is lead through the centering roll to the knife assem*ly unit. +he liner is wound in another empty sell. +he knives are pneumatically operated and engage the cuter into the fa*ric. +he knife assem*ly is adjusted in such a way that the center distance *etween the cutters is as per the chafer width to the slit. +he station consist of five wind up stand can engage with the conveyer for uniform winding. .ll wind up stations are provided with air motor to ensure the positive tight winding. +he cut chafer is first wound on the hollow s4uare *ars and engages it with the conveyor *y the pneumatic switch. 3hen the *ar is full raise the stand the put new *ars for filling. Tyr) (*il-i$g +r!')""? :*il-i$g ma'hi$) 'adial tyres are *uilt in two stages due to the ine$tensi*le *elt package. In first stage carcass with the side wall are prepared and the *elt and tread packages are applied in the second stage. +he important components of the tyre *uilding machines are given *elow 1 I"t "tag) (*il-i$g ma'hi$) a3 :*il-i$g -r*m 2uilding drum is mounted on a shaft which is attached to an .., drive. +he *uilding drum consists of a drum surrounded *y an e$panda*le *ladder. 2ladder can *e e$panded at the time of *ead application. Some holes are
61
provided on the drum to introduce air *etween drum and *ladder. .t the time of tyre strip out the *ladder will deflate to promote the strip out operation. (3 =i$g)r +ly -!.$ a"")m(ly +his is an assem*ly of spring fingers mounted as an end to a ring. 3hen the finger arrives at the drum edge they are opened to encircle the overhanging plies. '3 D*al (la--)r t*r$ *+ a"")m(ly +hese *ladder turn up assem*ly is a pair of inflata*le ru**er tu*es one side the other. +hey are clamped *y their edges in a spiral ring which forms an air tight seal. +he ring assem*ly can move *ack and forth *y means of an air cylinder. .fter the *ead set operation the *ladder is inflated and each assumes the shape of a donut with the ply portion to *e turn up. +hen the push-can will push the inflated *ladder with plies end and stitches it around the *ead. -3 Stit'h)r *$it In order to remove the trapped air *etween the plies they are stitched well with a stitcher. +here are two types of stitchers in a first stage *uilding machine. +hey are called *ottom stitchers and swan neck switchers. +he *ottom stitchers consist of two rollers rotating at a specified rpm. It can stitch the carcass at low pressure and side wall at high pressure. Swan neck rollers are provided at *oth end of the drum. Swan neck switchers are used for final tuck in operation. +o keep the plies in position during the application on the drum a sponge roller is used. +hey can apply a small pressure. )3 Car'a"" +li)" ")rCi')r +he cassette containing carcass ply and drum s4ueegee has separate let off stations. +hey are provided with *reaking system to maintain the tension during application. +he plies are centered using light sensors and cut at specified length *y a rotating knife. 2 S)'!$- "tag) (*il-i$g ma'hi$) a3 : 1 T -r*m
62
2 & + drum consists of a dou*le conical e$pansion cone which is fitted *etween the drumCs side flanges. +he metallic flat rigid aluminum segments among them num*er of segments form-*uilding deck is filled with magnets to pick steel cord *reaker. +he drum segment with red mark on the side identifies the layup position of first ply. +he segments are attached to pressure plates which are in contact with e$pansion cone. +he segments can e$pand radially to the specified diameter *y the movement of e$pansion cone. +he movement of this e$pansion cone is controlled *y air pressure. +he ru**er retraction ring in the segments will *ring down the drum to the position. +he spacers are availa*le for changing the drum diameter for different tyre. .n .., servo geared motor drive the 2 & + drum. (3 T 5 ri$g It is a ring which can e$pand and collapse radially and used to transfer the tread and *elt assem*ly from 2 & + - ring to the carcass drum. +he inner diameter of the + - ring can *e adjusted *y means of a star handle. . pneumatic cylinder controls its movement. +he inward movement of the + ring is controlled *y a capacitative switch to prevent crashing of the 2 & + package. '3 Car'a"" -r*m? ,arcass drum is used to e$pand the carcass in the second stage *uilding at the time of 2 & + assem*ly application. It has a pair of conical *ead locking system to ensure a positive *ead lock. In carcass drum it is e$panded *y using an air circulation. +he rim can *e moved inwards up to the informing limit at the time of shaping. -3 Stit'h)r *$it Stitcher station is e4uipped with tread and side roll stitcher. It is a dynamic stitching arrangement. +he stitching pressure is applied pneumatically. +he stitcher movement is such that it stitches the centre line of the tyre to the shoulder with a specified dwell time of > second at the tread shoulder. . template governs the travel of the stitcher. )3 :)lt a$- 'a+ +ly ")rCi')r
63
2elt and cap ply containing cassette is placed *ehind the machine in line with 2 & + drum. +he first *elt is placed with the help of tip control and second does not pave the *elts are pre cut to the re4uired length automatically. +he hook knife cut the *elt from the centre to the sides. +he *elts are applied automatically. +he cap ply is pre cut to a specified length using a rotary knife and applied manually on the drum. 03 Tr)a- ")rCi')r +read servicer is always at the *ack of the operator. +he tread is applied either from top or *ottom. +he tread is guided *y an inverted C"C groove. I.e. the tread should *e placed in such a way that the tread centre groove should *e on this C"C groove
Tyr) :*il-i$g !+)rati!$?

1 =ir"t "tag) (*il-i$g A3 Pa"")$g)r ra-ial '!$"tr*'ti!$ 8 plies construction +wo *eads are placed on the *uilding drum. .fter that the outside ply cuff will closes. +he two *eads are placed on their respective *ead-placing ring. +he drumstick is applied on the drum. Aow the systems servicer will come near to the *uilding drum and ply the drum s4ueegee with chafer with the help of a head roller. .fter the application of drum s4ueegee the drum will automatically position for 8st ply application. +he spotting is 67 7with the inner liner splicing. +he servicer will move near to the drum and 8 st ply is applied on the drum. !ead rollers apply pressure to consolidate with inner liner. .fter that the *ladder on the drum will e$pand and the 2P' placer the *ead in position. +urn up *ladder is e$pand and the push-can will push the *ladder to consolidate the turn up portion with the carcass.
64
1"t"tag) (*il-i$g Ma'hi$) .fter completion the push-can will move *ack than the drum will positioned for side wall application. +he spotting is :?7 7 with the inner liner splicing. +he properly cut sidewall is applied on the drum automatically and the splicing is done manually. Ply cuff move away each other and the *ottom stitcher will start the stitching operation. +he turn down operation of chafer with rim strip operation is done *y turn around device. +hen the drum will collapse and 8st stage carcass is taken out.+his is placed on the servicer to the second stage. +he second stage is two *elt two cap ply construction. :3 Lightly tr*'% '!$"tr*'ti!$ A2*+ H1 -$3 +wo up one down construction +wo filler construction +hree *elts K : cap ply construction 0ore manual operation manual. ply and s4ueegee application is
65
2eads are inserted on the *uilding drum and placed on the resp7ective *ead placing ring. +he drumstick is applied on the *uilding *ladder. ;rom the servicer the inner liner is applied on the drum and joined *ut with minimum possi*le overlap. +he first ply is applied in such a way that it is at a distance of :=<7 with inner liner. Sponge roll apply a pressure of : /gFcm : during the application of plies. +he second ply is also applied in similar manner. +he spotting is =<7 with inner liner splicing. +he *ottom stitchers will stitch the first *and at a pressure of 8.9 /gFcm: +he second filler is placed on the carcass and stitched well with hand stitcher on *oth side. +he guide lights are provided for proper placing. +he finger disc will do the ply down operation at the same time the *ead placing is done *y the 2P'. +he turn up *ladder e$pounds and push can come closer to each other to do the turn up operation. +he turns up ply ends are stitched with the *ottom snitcher which are moving inwards at a pressure of > /gFcm:. 2 S)'!$- "tag) (*il-i$g A2: H 2C3 +he first *elt at an angle of a*out :? 7 is unwound from the cassette and automatically cut to a pieces length on a *elt ply servicer. . round edge knife heated *y ultra-sonic wave does the cutting. +his cut ply will *e automatically centered in the servicer using a photo sensor unit. +his servicer will move to the lower portion of the 2 & + drum. +he tip controller places the tip of the *elt in correct position and the drum is rotated. (ue to the magnetic field the *elt will wound on the 2 & + drum. 2y the time second *elt is cut and ready for application. +hen the 2 & + drum adjust itself for the splice location and for this and similarly applied from the *ottom of the drum. +here is no tip control for this ply application. )ver the two-*elt assem*ly cap ply or cap strip is applied. ,ap strip acts as an endless strip which will reduce the growth of the *elt. In ,E.+ +yres !alol one passenger car module is provided with cap strip. .ll others are having cap ply application only. +he machine with cap ply is provided with two 2 & + drum such that when one is used for applying cap strip other is used for tread application. +
66
wound on the *elt *y continuously rotation of the drum and moving the cap ply holder perpendicular to the rotation. .fter the application of the *elt the cap strip is similarly applied from the top. +he cap ply location is adjusted *efore the application. +he end of the cap ply is cut with a rotary *lade at an angel of =< 7. . *rush roller does the splicing. +he male and female part of the tread should *e cemented and dried properly *efore applying in the drum. +he tread is placed on the tread servicer in such away that the tread cushion side upward. +he tread servicer move towards the *ottom of the 2 & + drum and applied it from the *ottom. 2efore this drum should *e placed for specified splice location. +he tread servicer presses the tread with the drum. +he splicing and stitching is done manually. 2y this time the + - ring will come to pick up the 2 & + assem*ly. Parallel to this operation the carcass is placed manually over the shaping *ead. +he mounting of carcass shaping head is *ased of ;0 vector analysis. .fter that *oth the *ead holder will come closer and a regulated air supplies admitted into it to inflate. (uring this time the + - ring *ring the 2 & + assem*ly e$actly over the carcass position centrally over the e$panded carcass. +he inward movement of the *ead holder will stop at the informing limit which are always ?7R of *ead jump set. 3hen the carcass is in contact with the 2 & + ring then + - ring collapses outwards and release the 2 & + assem*ly on to the carcass. .fter this + - ring move to its home position. +he *ack stitcher assem*ly move forward and stitches the *elt and tread package to the carcass. +he pressure applied during stitching is a*out :.< /gFcm:. ;irst the tread roll starts stitching the tread region in such a way that *oth rings move away from each other. 3hen it reaches the shoulder area the side rolls start stitching the *uttress region from *oth sides. +his stitching will consolidate the 2 & + assem*ly to the carcass *y *leeding out the air. ;ollowing this operation tyre. the carcass drum deflates and moves outwards to release the tyre. +hen the + - ring come in position to receive the +his finished tyre is removed and kept in trolleys shall rest with its
65
shoulder area on storage trolley. +he green tyre should *e handled slowly *ecause any distortion may cause uniformity variation in the tyre.
2$- "tag) (*il-i$g ma'hi$)"

Tyr) '*ri$g 'adial curing is mainly done *y using platen type of presses. In .+1 passenger and 1," tyres are molded. ,uring press has following parts
C*ri$g )G*i+m)$t"
0old "ertical chuck loader 2ladder unit ,ured tyre unloading system Pipe lines ,ontrol panel )ther accessories
P,I .wling Pneumatic air 0old spray
66
/)rti'al 'h*'% l!a-)r +his is used to load the #+ on the mold with accurate positioning. +his helps to reduce the direct handling of #+ with hand. .lso reduces the cycle time. It essentially has two main parts. . ta*le on which the #+ is kept and other is the chuck loader. +he ta*le has = segments fitted with some space provision to make a circular appearance. +he inner contour of these segments is similar to that of the #+ placing trolley ;'P unit. It has inverted segments of pedals which can e$pand to different diameters. +he loader is operated *y using a pneumatic cylinder. Each mold is provided with a ",1. +he #+ is placed on the ta*le so that the tread splice comes at the P0". sticker. +his type of loading gives tyres with *etter uniformity. ",1 can move vertically and laterally and picks the #+ and places it e$actly on the *ottom mold half. +he segmental pedals are introduced inside the #+ and increase the diameter of the loader. .nd after #+ placing *ladder e$pands and then reduces the inflation pressure simultaneously *ladder unit goes down. +his time utili5es the pedals to *e removed out from the #+ placed on the mold. .fter one mold close ",1 takes up the ne$t set of #+ and gets ready for the ne$t mold opening. #+ is placed in such a way that the line side of the tread comes in the *ottom portion. M!l- *$it +his essentially has the following parts. Platens +yre mold 2ladder unit
67
Safety *ars Pressuri5ing hydraulic motor Plat)$" Platens are provided with steam inlet and outlet valves and piping. Steam from the upper platen after heating it goes to the lower platen and maintains the same temperature to the *oth platens. M!lIn ,eat 0olds are of two types +wo piece molds@ +wo piece molds has upper and lower mold halves. Segmental mold@ In segmental mold *ottom mold has only a small portion of mold coming in the side wall regions present and the top mold is divided into 9 pieces. A-Ca$tag)" !0 ")gm)$tal m!l In a two piece mould green tyre outer diameter is kept lower than the cavity outer diameter and this may cause *elt center e$tension of up to =R. 2ut for segmental mould the gap *etween the green tyre and cavity surface can kept *elow :mm to get o *elt center e$tension of 8R Stripping of tyres from the two piece mould is very difficult due to stiff *elt package. 3hile mould opening the tread ru**er has to *e slide over the pattern ri* in the mould and as the stiffer *elt package doesnt flu$ to ease these movement which results in tread chipping. 3hile in the segmental mould as the mould get stripped radially from the tyre. So no chipping will occur. It is very difficult to make a two piece mould with a uniform dimension. +his will create some conicity in the tyre. 2ut in segmental mould uniform dimension of each component can *e easily achieved.
58
:la--)r *$it? +his mainly consists of a 2)0 type *ladder unit which is clamped with item num*er 8 : > and =. Inside of the *ladder unit consist of *ladder vertically moving cylindrical piston with two small pipes one for steam supply and other for steam draining from the *ladder. 2ladder has a num*er of surface grooves to leak out air during the molding. Sa0)ty (ar"? +his is provided for safety purpose to ensure safe opening and closing of mold. In case of any o*stacle find at the time of mold closing to this *ar will stop the curing cycle. C*ri$g +r!')""? In ,E.+ tyres 1td !alol most of the single ply tyres are cured under all steam cures. 2ut multiple ply tyres and light truck tyres are cured under conventional cure cycle. +he light truck tyres will *e put in P,I to reduce the flat spotting phenomenon. +he main advantage of all steam cures is that we can apply very large pressure and can achieve very high temperature within a very short time. So there will *e a corresponding reduction in cure cycle can *e achieved. 0ould is *lown out first to remove any foreign particle and mould spray is applied. .fter this the tyre to *e loaded is placed in the tyre holder. +he tyre should *e placed on the holder in such a way that when the tyre is inserted in the mould the tread splicing portion should *e at the serial num*er position. +hen vertical chuck loader comes down and takes the tyre from the tyre holder. +he vertical loader down and place the tyre on to the *ladder. .s soon as the tyre slides over the *ladder first shaping steam will *e applied in the *ladder to hold the tyre. +he green tyre holding pressure is 7.= /gFcm :. .fter that the chuck loader collapse and returned to the original position. Aow the
51
press starts closing. 3hen the top plate is a*out 8=Q a*ove the *ottom plate the second shaping pressure comes into the *ladder. .fter a specified dwell time shaping steam will stops and main drain valve will *e closed. ;or all steam cure process the e$ternal heating is always maintained at 8977c for whole cycle time. .fter the closing of main drain valve a high pressure internal steam of 8H.9 /gFcm : is applied. +his steam is not a circulating one. .fter that the internal steam valve for forced circulation is opened and closed after four or five minutes. +emperature of this forced circulating steam is 86:7c. +he pressure will *e gradually lowered from 8<.6 /gFcm: to 8>.: /gFcm: during this period. !igh pressure steam at 8:.> 7c is applied at the last minute and main drain valve opens. +hen a three second vacuum is applied and mould start opening. +he automatic carrier will collect the tyre and keep the tyre in the *ack of the press. .fter a specified time the tyre will *e automatically deposited on the conveyor and transferred into the final finish area.
52
=i$al 0i$i"h 1 i$"+)'ti!$?
CUR+D TKR+
V+@T TR1&&1@/
1@SP+CT1O@ 1R+N+CT+D ?OT
D+2+CT1V+
OL
&1@OR
&ANOR M.A AUD1T HO?D
U221@/
R+PA1R
1@SP+CT1O@
D&R CO&&1TT++
@OT OL
OL
OL SCRAP
OL
SCRAP KARD 3AR+ HOUS+
53
a3 Trimmi$g +rimming is the process of removal of flashes in the *ead region and the vents on the tread and sidewall region. It is done *y using a plane knife and a com* like knife respectively. ,are should *e taken to avoid cutting of the tyre *y the trimming knife. +his trimmed tyre is sent for final inspection. (3 =i$al i$"+)'ti!$ +he trimmed tyre is inspected for 877R *y placing the tyre on a hoist which consists of two rollers. +hese rollers help in rotating the tyre to facilitate the inspection. Inspection is in systematic manner. It starts from tread pattern followed *y shoulder *uttress sidewall and *ead area and inside area. 0ajor tyre defects are :)a- ar)a ;low crack ;iller *low Aarrow *ead /inked *ead Pinched *ead 2uckled *ead 1ight toe *ase heal
Car'a"" ar)a Severed cord ;0 cord through inner liner 2uckle carcass ;a*ric & *reaker *low Spread cord loose cord. )ff cure
54
Si-) .all a$- "h!*l-)r ar)a ;0 1ight side wall Side all *low Shoulder *low ;low crack ,ircumferential crack "ents cured in
Tr)a- ar)a 1ight tread ;0 )pen splice 2low *lister .ir under tread
Car'a"" ar)a Severed cord ;0 ,ord through inner liner 2uckle carcass ;a*ric & *reaker *low Spread cord 0issing cord 1oose cord )ff cure +he tyre without defects is stamped )/ *y production inspector. +he tyre with minor defects is sent to repair & major defected tyre & repaired tyre
55
are hold for the inspection of a second committee. +hey will decide the tyre of first 4uality or otherwise scraped. 33 R)+air +he area-re4uiring repair is *uffed without damaging the carcass. +he *uffed particles are *lown off and solvent is applied for cleaning. +he *lack repair cement is applied over there and dries it. +hen the repairing ru**er stock is applied and stitches thoroughly with rollers. +hey are placed under a hot steam plate at :977; for >7min and allowed to cool. +hen the area is *uffed smooth to original contour and finish paint is applied.
TESTING ON RADIAL T9RES +esting in general is classified as destructive and non-destructive.
56
1 D)"tr*'tiC) t)"ti$g ,ommon destructive tests done on the tyres are@ Plunger test: +his test is used to measure *ruise resistance of the tyre. +he e4uipment consists of a steel plunger which is forced to penetrate into the inflated tyre to *reak. +he force re4uired to *reak is measured along with penetration depth. +he dimension of the pro*e for 8H & 8= P' truck tyre is >9mm diameter and for 8: & 87P' light truck is >: mm. +he plunger will move at a speed of : inchFmin. +he tyre is fitted on a standard rim and inflated to a specified pressure. +he plunger is moved till it just touches on the tyre surface. +he scale readings are noted and allow the plunger to move. .t the time of fracture depth of penetration and *reaking force are noted. +hen the *reaking energy is given *y :E I :r)a%i$g 0!r') @ -)+th !0 +)$)trati!$ 2 Wheel bead endurance test: +his test is used to test the strength of the *ead area of the tyre. +he tyre to *e tested will *e *uffed off at the tread portion in order to facilitate the effective transferring of complete load to the *ead. +he test is divided into various steps in which load on the tyre will *e increasing in a step at a constant speed of the road wheel. +he tyre will *e inspected fre4uently for any defect at *ead area.
Step speed test:
55
+his is commonly done for passenger car and light truck tyres. In this tyre is usually loaded at 97R of the rated load of the tyre and the speed or run is increased step *y step. +he tyre is fitted to a standard rim and inflated to a specified pressure. . specified load is also applied. +he dimensions of the tyres are measured and run for a*out two hrs at 97 k.mph. .llow the tyre to cool for : hrs and speed is increased to 8:8 /.mph and run for T hrs. +here after the speed is raised at an increment of 9 /mFhrs at an interval of half an hour until the failure occurs. .t the same time of failure the speed total distance traveled nature of failure is noted Endurance test: +yre endurance test is done in tyre testing la*oratory using pulley wheel machine. It consists of two steel wheels with a diameter of a*out H?.:>Q on which four tyres can *e tested at a time. +here is a provision for applying load hydraulically as re4uired. +here are limit switches arranged to withdraw the tyre from the running wheel when they fail. +he main tyre of endurance tests are step load step speed and wheel *ead endurance test. 13 St)+ l!a- t)"t Step load test at constant speed is usually done for truck tyres. 2efore doing this the tyre should *e conditioned three hours minimum at 877 7;. +he speed is >< /.mph for 8= P' =9 /.mph for 8H P'. +he tyre is loaded and inflated to a specified pressure. +he tyre is loaded with HHR of its rated load and run for a*out ? hrs. .fter that load is increased to 9=R and then 878R for 8H and := hrs respectively. .gain the tyre is run at 878R load for 8: hrs and 887R for 8: hrs. +here after the load is increased at a rate of 87R at an interval of 8: hrs each. If the tyre is not failed on or *efore 8?7R tyre is run for >H hrs at 897R load. .t the time of failure the temperature at different parts of the tyre load distance traveled time and nature of failure are noted.
56
23 St)+ "+))- t)"t +his is commonly done for passenger car and light truck tyres. In this tyre is usually loaded at 97R of the rated load of the tyre and the speed or run is increased step *y step. +he tyre is fitted to a standard rim and inflated to a specified pressure. . specified load is also applied. +he dimensions of the tyres are measured and run for a*out two hrs at 97 k.mph. .llow the tyre to cool for : hrs and speed is increased to 8:8 /.mph and run for T hrs. +here after the speed is raised at an increment of 9 /mFhrs at an interval of half an hour until the failure occurs. .t the same time of failure the speed total distance traveled nature of failure is noted. Cut tyre analysis: +he tyre sections are cut from cured tyre and following parameters are measured. +hey are all critical gauges ply turn up height step off flipper and chafer height cured *ead width cured *reaker width etc. +hey are conducted to verify whether the cured lay out shows similarity with the cured tyre. Cured angle measurement . cut piece of a*out > $ > inch known as angle *ook is cut and properly *uffed to see the cords. ;rom this angle of the cords is measured using protracter. 2 N!$ -)"tr*'tiC) t)"t" 0ain tyre non-destructive tests are tyre *alancing and uniformity tests. a3 #$i0!rmity t)"ti$g +yre is composite material made up of large num*er of components which are placed manually or semi-automatically during tyre *uilding operation. (ue to the variation in placement or some other processing variations the homogeneity of the tyre will *e lost. Since the radial tyre is an efficient construction the homogeneity of the composite structure will *e more important. +his non-homogeneity will produce some non-uniformity in the tyre. +hey can *e classified as
57
(imensional non uniformity 0ass non uniformity Stiffness non uniformity 13 "ti00$)"" $!$ *$i0!rmity .s a result of variation in the stiffness of the structure at different parts of the tyre some force variations generated in the tyre during its running conditions. +he variation in stiffness is due to the splices difference in gauge EPI variation tyre. In a uniformity machine we are measuring the radial force variation lateral force variation and conacity. #$i0!rmity ma'hi$)? In ,E.+ tyres !alol radial plant t is e4uipped with > uniformity machine are used for uniformity measurement. It contains following parts. 13 0))- '!$C)y!r +his is a motor driven roller conveyor on which the tyre to *e tested are fed to the machine. +his conveyor system ensures the entering of the tyre at proper timing to the tyre test station. 23 T)"t F!$) +he test 5one consists of centering arms spindle and chuck assem*ly load wheel and a high point marker. .ll these things are enclosed inside a shell. +he centering arm consists of an arm with four segments which is used to position the tyre in the centre of the test spindle. +he movement of arm is controlled *y the sensor at the arm. +he spindle assem*ly consists of the rim at which the tyre is to *e tested should *e mounted. +he width of the rim can *e adjusta*le according to the re4uirement. +he spindle is rotated *y a motor at a speed of H7 rpm at the time of test. +he pressure inside the tyre should *e same as that under service condition. . load wheel is used to load the machine set up operator variations. +he force variation produced in the tyre may *e radial lateral or in the transverse direction of the
68
inflated tyre. +he loading is done *y applying pressure *etween the load wheel and tyre *y using a motor and *all screw mechanism. Each tyre to *e tested should *e loaded with specified amount during testing. . stamp marker is used to mark the portion with highest force. +wo load cells are applied on the spindle assem*ly to measure the radial and lateral force variation. 33 E@it '!$C)y)r +his is a roller driven conveyor for taking out the tyre from the test station. It is provided with a gate to hold the tyre to mark with the *ar marker on the *ead. 63 Sh!*l-)r gri$-)r +hese are used to correct the radial force variation *y selectively grinding the shoulder area at the high point of force variation to *ring down the value. In ,E.+ tyres these part is not activated. T)"t +r!')-*r) +yres after vent trimming operation are loaded on the feed conveyor. +his feed conveyor will feed the tyre on the test spindle one at a time. +he rim of the spindle assem*ly should *e suita*le for that tyre. +his tyre is mounted on the rim and inflated to the specified pressure and loaded against the load wheel. .t the same time the tyre drum starts rotating at a speed of H7 rpm. +he distance *etween the a$le and the tyre is maintained constant during the test. +he non-uniformity of the tyre will create a waveform of force variation in the tyre as it rotates. +he force variations in the lateral and radial directions are then measured using strain gauge transducer mounted on the a$il. +he point with highest force variation is marked with software called red dot +I#E' is used for processing the data and grading the tyre. 23 Ma"" *$i0!rmity
61
;or a tyre the mass distri*ution along the circumference of the tyre must *e uniform otherwise the ride will *e harsh and a *umpy effect is e$perienced. So in a tyre *alancing machine the point with lowest weight is found out and marked with a red spot. +his lowest weight can *e *alanced *y placing the tu*e valve at this portion while mounting the tyre on the vehicle rim. T)"t ma'hi$) ,E.+ +yres !alol has three tyre *alancing measurement machines for radial. +he maker is .avery Schenck. +he machine consists of following unit. 13 T)"t "+i$-l) +his is the place where the tyre to *e tested should *e mounted. +he tyre is loaded on chucks which can *e changed according to the tyre to *e tested. +his spindle is provided with a (, motor to rotate the spindle at specified rpm. 23 M)a"*r)m)$t "y"t)m +he measurement system is a microprocessor *ased measuring device working on watt metric principle. +he mass im*alance is picked up *y the pie5o electric sensor mounted on the spindle is converted into a digital value and displayed. +his system also locates the lowest im*alance point. T)"t +r!')-*r)? +he diameter of the chuck is adjusted for a specified tyre. +he tyre is loaded *y collapsing the chuck in such a way that the serial num*er side of the tyre pointing up and the drum s4ueegee splice 7 7 with the chuck. +hen the chuck is rotated at a speed of =77 rpm for a*out :7 seconds. .fter that the chuck will automatically inde$ to the low point of marker to mark a yellow dot. +his can *e done manually also. .fter that the chucks are collapsed and tested tyre is taken out.
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62

Inplant Traing

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Inplant Traing

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Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

IN-PLANT TRAINING REPORT

CEAT TYRE LIMITED Halol, Vadodara, Gujarat

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Rad"al pl( )*t Pl(

elt )*tt"$% 1$$er l"$er Tread - S"de .all

/ree$ t(re 0*"ld"$%

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

C2EMICAL NAME (iphenyl guanidine

#SE IN T9RE Secondary accelerator in

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Structure %(2P Ao& 88< 88< ?7 8:7 67 A.

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

7.6 0ild 7.9 Ao

,hemicals name Styrenated phenol (ihydrotrimethylGuinoline

"ery good 0ild E$cellent 0ild Ail E$cellent

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

Dept. Of PS&RT, CUSAT

Ceat Ltd, Halol, Vadodara

passed through series of mill for proper lending and reakdown.