International Journal of Mechanical Engineering and Technology (IJMET)

Volume 6, Issue 9, Sep 2015, pp. 112-119, Article ID: IJMET_06_09_011

Available online at
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=6&IType=9
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
IAEME Publication
________________________________________________________________________

ENERGY ANALYSIS IN TIRE

MANUFACTURING INDUSTRIES
Mandar Gudadhe, Pranay Lohakare, Mukesh Meshram and Ashlesh Padole
G. H Raisoni Academy of Engineering and Technology
ABSTRACT:In this paper an analysis of energy use and energy analysis in the Tyre
manufacturing industries is presented. It has been found that rubber industries
consume a substantial amount of energy. Excessive use of energy is usually
associated with many industrial plants worldwide, and rubber plants are no
exception. This study is based on the realization that enormous potential exists for
cost-effective improvements in the existing energy-using equipment. Through the
method of a walkthrough energy audit, power rating, operation time of energyconsuming equipment/machineries and power factor were collected. The data were
then analyzed to investigate the breakdown of end-use equipment/machineries
energy use. The analysis of tyre curing various temperatures at different time. The
results of the energy audit in Tyre manufacturing industries showed that the electric
motor accounts for a major fraction of total energy consumption followed by
pumps, heaters, cooling systems and lighting. Since the electric motor takes up a
substantial amount of the total energy used in rubber industries, energy-savings
strategies such as the use of high efficient motors, and variable speed drive (VSD)
have been used to reduce energy consumption of motors used in rubber industries.
Energy-savings strategies for compressed-air systems, boilers, and chillers have
also been applied to estimate energy and cost savings. It has been found that
significant amount of energy and; utility bills can be saved along with the reduction
of emission by applying the foretold strategies for energy using machineries in the
rubber industries.
Key words: Energy, Tyre Manufacturing industry, Curing, Vulcanizating and
Rubber industries
Cite this Article: Gudadhe, M. and Lohakare, P. Energy Analysis in Tire
Manufacturing Industries. International Journal of Mechanical Engineering
and Technology, 6(9), 2015, pp. 112-119.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=6&IType=9

http://www.iaeme.com/IJMET/index.asp

112

editor@iaeme.com

Energy Analysis in Tire Manufacturing Industries

1. TIRE MANUFACTURING PROCESSES CONSIST OF:

1. Preparing intermediate products (members) utilizing the fluidity and plasticity of
crude rubber,
2. Laminating the members covered with crude rubber utilizing the tackiness of the
covering crude rubber,
3. Assembling the members to make raw tires, and
4. Vulcanizing them at the final stage to produce chemically stable and elastic tires.

2. RUBBER COMPOUNDING (MIX FORMULATION AND

COMPOUNDING):
A variety of raw material elastomers and various compound ingredients are used for
tires by mixing and compounding them for use in respective members. In former
days, this compounding was carried out with open rolls, and naturally the working site
was made terribly dirty due to the scattering of carbon black a nd other chemicals.
Today, intensive mixers, including internal and Banbury mixers, are widely used.
This intensive mixer is of enclosed type and computer-controlled so that raw material
elastomers, various compounding ingredients, and oil are automatically fed, and. This
has resulted in reducing dirt to a considerable degree. Since the properties of rubber,
uncured and cured, vary greatly depending on various factors as described below,
attention has been focused on producing rubber compounds to specifications with a
slight variance by computer control.
The various factors include the kind, quantity, order and time of feeding, the
extent to which ingredients are mixed evenly,compounding time, and temperature of
raw material elastomers and compounding ingredients. In this process, high-capacity
motors are used. This inevitably involves large power consumption, which accounts
usually for 35 to 55% of the total power consumption of the factory. It is a common
practice to recycle cooling water used in large quantities.
Following Table shows Non pro and Pro rubber standard value:Table 1 Non pro and Pro rubber standard value
MATERIAL
NON PRO
PRO

TEMP.(C)
145150
100105

TIME(SEC)
STD
130
90

MIN
110
80

MAX
160
110

ENERGY(KW Hr)
1314
6.57

During Non pro mixing for 160 kg rubber temperature should be 145150 C, standard
time 130 second and Energy produce 1314 KWhr while in pro rubber temperature should
be 100105 C, standard time 90 second and energy produce 6.57 KWhr.

3. CURING AND VULCANIZATING OF TIRES:Molded tires are fed to a mold (a metal mold with a tread pattern, a side pattern, a
marking, and a trademark carved thereon) of the specified vulcanizer, pressed against
the inside of the mold from the inside, and heated simultaneously from both s ides,
internal and external, with heating media, such as steam and hot water, so that, after a
given period, vulcanization proceeds throughout the entire tire. Thus, a finished tire
with a vulcanized rubber structure is elastic and stable. Operators have o nly to prepare
green tires and watch the process. Since synthetic fibers shrink by nature if left standing

http://www.iaeme.com/IJMET/index.asp

113

editor@iaeme.com

Mandar Gudadhe and Pranay Lohakare

when hot, hot tires after vulcanization diminish in size when left standing. A device (a
post-cure inflator) is therefore provided, with which bias tires in which synthetic fibers
are used are inflated by applying air pressure immediately after vulcanization, and
cooled in an inflated state. Two types of molds are used for molding tires: one is a full
mold that splits into upper and lower parts, and ma inly used for molding bias tires,
while the other is a split mold widely used for molding radial tires.
Curing press operators place green tyres into the curing press or onto press
loading equipment. Curing presses in operation in North America exist in a variety of
types, ages and degrees of automation. The press utilizes steam to heat or cure the
green tyre. Rubber curing or vulcanization transforms the tacky and pliable material
to a non tacky, less pliable, long lasting state. When rubber is heated in curing or in
earlier stages of the process, carcinogenic N-nitrosamines are formed. Any level of Nnitrosamine exposure should be controlled. Attempts should be made to limit Nnitrosamine exposure as much as feasible. In addition, dusts, gases, vapours and
fumes contaminate the work environment when rubber is heated, cured or vulcanized.
The green tire is transferred for vulcanization. The tire is coated with a liquid to
ensure that it will not stick to the mold. In the mold the green tire is placed over an
inflatable rubber bladder. Typically, the vulcanizing machine is a two piece metal
mold. The bladder forces the tire against the mold, forming the sidewall patterns and
tread pattern. The molding is accomplished through the use of steam pressure or hot
water inside of the bladder. The rubber components of the tire are vulcanized by
steam generated heat in the mold and bladder at pressure as high as 400 psi and
temperatures of approximately 200 C for approximately ten minutes. This heat
results in chemical and physical changes in the rubber compounds. At the molecular
level, profound chemical changes occur during vulcanization. The green tire rubber
components are transformed from plastic consistency to the consistency found in a
finished tire. The vulcanization process chemically and physically links the various
components, forming what should be an inseparable bond.
The smaller rubber molecules are linked to the long polymer chain linked
molecules. When the molecules in the various components properly bond, all inter
facing surfaces are obliterated forming the finished green tire. Thus, any liner pattern
marks from the fabric liner used during storage should be totally obliterated in a
properly cured tire. One should never see liner pattern marks on a tire that has been
properly cured (vulcanized). Manufacturers use various time periods for the
vulcanization process. In an effort to reduce the time required for the manufacture of a
tire, manufacturers are continually attempting to reduce the vulcanizing time. One
method that is utilized is radiation of components prior to vulcanization. It should be
noted that under-vulcanization will result in a lack of adhesion of the components. One
indication of this lack of adhesion in a failed tire can be pattern liner marks. As a result
of vulcanization, the rubber becomes essentially insoluble and cannot be processed by
any of the means used to manipulate the green rubber during the assembly process.

4. CURING PRINCIPLE:In order to minimize the disadvantages of the conventional process, nitrogen can be
used as a flexible and inert pressure agent. After the steam- induced preheating,
nitrogen takes over the part of keeping the systems pressure at the desired level. The
ideal system pressure und curing temperature can be selected independently from
each other. The rubber cannot overheat any more because of excessive steam supply
and less steam can condense in subsequent stages of the curing process.

http://www.iaeme.com/IJMET/index.asp

114

editor@iaeme.com

Energy Analysis in Tire Manufacturing Industries

Figure 1 Temperature and Pressure variation during curing process

Principle of curing process shows in Figure 1. When tyre placed in lower mold
after that upper mold closed the curing mold and pressure of steam 14 Bar are passed
through outside mold then temperature of curing increase up to 190 C to 200 C.
When temperature increases nitrogen gas with 21 Bar pressure passes through curing
mold to maintain the shape of tyre. Nitrogen is inert gas it does not react with other
material and improve efficiency of curing mold. After some time temperature of
nitrogen gas decreases, steam pressure reduce and temperature of tyre decreases.
During curing time in curing mold we measure temperature at various point
following are the location to check temperature of tyre part.
Table 2 List of Locations
I/L C/L-1
INNER S/W TOP-1
INNER S/W BOT-1
S/W S/C TOP-1
S/W S/C BOT-1
TS-1
I/L C/L-2
INNER S/W TOP-2
INNER S/W BOT-2
S/W S/C TOP-2
S/W S/C BOT-2
TS-2

http://www.iaeme.com/IJMET/index.asp

115

editor@iaeme.com

Mandar Gudadhe and Pranay Lohakare

CH.No.

1
I/L C/L-1

2
INNER S/W TOP-1

0.00
33.1
54.0

0.00
34.2
67.1

0.00
31.7
58.7

LOCATION
CLASS OF BLOWPOINT
TIME (SEC) Initial temperature
0.0
TEMP

3
4
INNER S/W S/C
S/W BOT- TOP-1
1

5
S/W S/C
BOT-1

6
TS-1

7
I/L C/L-2

8
9
10
INNER
INNER S/W S/C
S/W TOP- S/W BOT- TOP-2
2
2

0.00
34.3
67.4

0.00
34.4
78.2

0.00
34.5
53.2

0.00
31.5
53.6

0.00
33.1
67.7

0.00
31.5
57.1

11
S/W S/C
BOT-2

12
TS-2

0.00
31.2
57.4

0.00
32.6
74.1

0.00
31.0
45.7

0.5

TEMP

70.1

72.1

65.9

139.5

147.5

126.7

67.4

72.2

63.0

138.2

136.5

135.1

1.0

TEMP

90.8

87.5

84.6

147.2

152.7

138.9

87.1

87.4

78.6

146.4

143.7

142.5

1.5

TEMP

104.4

102.2

100.4

151.7

155.4

144.4

100.6

101.9

92.3

151.2

147.8

146.6

2.0

TEMP

115.0

114.6

112.9

155.1

157.5

148.1

111.3

114.1

103.9

154.9

150.9

149.6

2.5

TEMP

124.0

124.8

122.8

157.8

159.3

151.0

120.3

124.3

113.7

157.9

153.5

152.0

3.0

TEMP

131.7

133.2

130.6

160.1

160.8

153.3

128.1

132.6

121.9

160.3

155.7

154.0

3.5

TEMP

138.6

140.3

137.0

162.0

162.2

155.3

135.0

139.7

128.8

162.4

157.7

155.9

4.0

TEMP

144.6

146.4

142.4

163.7

163.5

157.1

141.1

145.9

134.5

164.1

159.4

157.5

4.5

TEMP

150.0

151.9

146.9

165.3

164.6

158.6

146.6

151.3

139.5

165.7

161.0

158.9

5.0

TEMP

154.9

156.8

151.4

166.7

165.7

160.1

151.7

156.3

144.4

167.2

162.5

160.2

5.5

TEMP

158.7

161.0

157.1

167.9

166.8

161.3

155.7

160.5

150.1

168.4

164.0

161.4

6.0

TEMP

161.6

164.5

161.7

169.1

167.8

162.4

158.7

164.0

154.9

169.6

165.4

162.5

6.5

TEMP

164.0

167.3

165.3

170.0

168.7

163.4

161.3

166.9

158.7

170.5

166.6

163.4

7.0

TEMP

166.0

169.7

168.1

170.9

169.6

164.3

163.4

169.3

161.9

171.4

167.8

164.3

7.5

TEMP

167.7

171.7

170.4

171.6

170.3

165.1

165.3

171.3

164.7

172.2

168.8

165.1

8.0

TEMP

169.2

173.3

172.2

172.3

171.0

165.9

167.0

172.9

167.0

172.8

169.7

165.8

8.5

TEMP

170.7

174.7

173.7

172.8

171.6

166.6

168.6

174.3

169.0

173.3

170.5

166.5

9.0

TEMP

172.1

175.8

174.8

173.3

172.2

167.3

170.1

175.5

170.6

173.7

171.2

167.1

9.5

TEMP

173.2

176.7

175.7

173.7

172.6

167.9

171.4

176.5

172.0

174.1

171.9

167.7

10.0

TEMP

174.1

177.4

176.4

174.0

173.0

168.4

172.4

177.2

173.2

174.5

172.5

168.2

10.5

TEMP

174.9

177.8

176.9

174.3

173.3

168.9

173.2

177.7

174.2

174.7

172.8

168.6

11.0

TEMP

175.8

178.2

177.4

174.6

173.7

169.3

174.2

178.0

175.0

174.9

173.2

169.1

11.5

TEMP

176.4

178.5

177.7

174.8

174.0

169.7

175.0

178.4

175.6

175.2

173.7

169.5

11.8

TEMP

176.8

178.5

177.8

174.9

174.1

170.0

175.4

178.5

176.0

175.3

173.9

169.7

MAX TEMP

176.8

178.5

177.8

174.9

174.1

170.0

175.4

178.5

176.0

175.3

173.9

169.7

Chart 1 Temperature at various points

From above value we plot a graph temperature v/s time with different point

http://www.iaeme.com/IJMET/index.asp

116

editor@iaeme.com

Energy Analysis in Tire Manufacturing Industries

200.0

Series
1

180.0

Series
2

160.0

Series
3

140.0

Series
4

120.0

Series
5

Series
6

100.0

Series
7

80.0

Series
8

60.0

Series
9

40.0
Series
10

20.0
Series
11

0.0

6 11 16 21 26 31 36 41 46 51 56 61 66 71 76 81 86 91 96 101 106 111 116

Graph 1 Curing temperature v/s time at various compound parts

5. ENERGY LOSS DUE TO FOLLOWING REASONS :Table 3 Energy Loss

PROCESS

WASTE STEAM

Curing

Energy loss
Un-insulated steam pipe lines
Power failures
Waste water

Water leaks in the pipelines

Release of wastewater to the drain

http://www.iaeme.com/IJMET/index.asp

117

editor@iaeme.com

Series
12

Mandar Gudadhe and Pranay Lohakare

5.1. Following are Reasons for Energy Losses:5.1.1. Piping

There were many complex piping parts and naked pipes by installations.
5.1.2. Traps
There were some traps having an excessive discharging capacity against the loading,
resulting in generating an energy loss. Further, such traps were located at a place
where the inspection work was hard to carry o ut, and their actuation was sometimes
difficult to be judged.
5.1.3. Heat insulation
The main pipes were fairly heat-insulated, but some of flange valves, pressure
reducers and covers of the curing cans were not.
5.1.4. Loading equipment
1. The loading might be light in the case of operating the one machine, but its
fluctuation became violent in the case of operating the multi-equipment in parallel at
the same time. Therefore, the boiler loading sometimes got 18 t/h at the maximum
against its capacity of l0 t/h, resulting in decreasing the boiler pressure and in
interfering with the production.
2. There was some curing equipment which threw away the steam each time when the
curing processing was finished.
3. There were leaks of the steam.

5.1.5. Valves
There were marked leaks from the ground parts of valves for a high pressure and from
the parts of bonnets.

5.2. Blow Point:The blow point is the limiting cure time which bubble no longer form when tire is
cured.

5.3. Other Benefits

1. The employees are experiencing more comfortable working conditions inside the
factory, due to reduced heat loss from steam pipelines and moulds.
2. Reduction of cycle time because heat loss of moulds was reduced, and therefore
production was increased.

6. ENERGY ANALYSIS AT TIRE MANUFACTURING

FACTORIES:From the Table 3, the process which consumes lots of fuel is the curing process, and
both the refining section and the driving section consume the electric power
prominently. The key points to improve the manufacturing processes from the
viewpoint of carrying out the energy conservation are as follows.

6.1. Mixing:
Heating up the crude rubber, Investigating on the peptizer, Investigating on milling
conditions, circulating the warm water, Exhausting fan.

http://www.iaeme.com/IJMET/index.asp

118

editor@iaeme.com

Energy Analysis in Tire Manufacturing Industries

6.2. Extruding:
Temperature of the warming sheets, Investigating on the roll size (face length and
number of roll), Heating the mouth rings, Controlling the remolding amount,
narrowing the width of cooling conveyer.

6.3. Sheeting:
Same with extruding.

6.4. Vulcanization:
Controlling the outgoing radiation, improving the curing method, preheating the die
assembly, Shorteninzg the time for exchanging the die assembly, Investigation on the
blowing air, improving the ventilation fan.

6.5. Driving:
Rising the temperature of boiler feeding water, Drain recovery, jointing the steam and
the warm water systems, miniaturizing the boiler, withdrawing the disused pipings,
Reducing in the number of air compressor.

6.6. Others:
Natural illumination, Controlling the steam and air leaks, Reducing in the idling time,
Inspecting the optimum capacities of equipment and motors, Installing the
instruments and gauges.

7. CONCLUSION:One of the subjects for the international problems to be solved in parallel with the
energy analysis is at present the establishment of countermeasures for the
environmental problems. In the process that the earth warming is advancing, various
subjects of such as reducing in carbon dioxide and so are being discussed. We believe
that the clean earth can be regenerated only when we use effec tively the valuable
energy. Therefore, the countermeasures for the energy analysis and for the earth
warming should not be separately considered and discussed.

REFERENCES:[1]
[2]
[3]
[4]
[5]

[6]

Energy conservation in rubber industry by united Nations Industrial Development

Organization
Energy performance assessment of boilers
Energy use, energy savings and emission analysis in the Malaysian rubber
producing industries. Applied Energy, 87, 2010, pp. 27462758
Malaysian Rubber Industry & Products Directory, 20062007.
Vikhar, A. D. and Dr. Modak, J. P. Formulation of Field Databased Model: A
Case Study at PVC Pipe Manufacturing Industries. International Journal of
Mechanical Engineering and Technology, 4(3), 2013, pp. 94-99.
Malaysian rubber review, 4th Quarter, 2007.

http://www.iaeme.com/IJMET/index.asp

119

editor@iaeme.com