INTRODUCTION

The General tyre and Rubber Company of Pakistan

Limited (Gentipak) is Pakistans premier industry. The
Company was established by General Tire International
Corporation (GTIC) and has been in production since 1964.
GTIC sold 90% of their shares to the present owners M/s
Bibojee Services Ltd. in 1977 and retained 10% of the
ownership. In 1985, the Company completed a major expansion,
which took the capacity to 600,000 tyres annually.
Continental AG, Germanys number one tyre manufacturer
purchased GTIC in 1987 and thus became 10% owners in GTR.
Continental provides technical assistance to GTR under a
program, which includes training of people, formulations,
recipes, selection of equipment from potential suppliers. GTR
under this agreement, is bound to follow all rules and
regulations including the given quality standards.
The brand name GENERAL also belongs to Continental AG.
This brand name is now synonymous with quality as we have
experience in the art of making tyres for last 50 years. The name
GENERAL carries the highest top of the mind brand recall in
Pakistan when it comes to tyres.
Initial production capacity was only 120,000 tyres per annum
but is now around 2,000,000 tyres per annum. GTR plant is
constantly upgraded and is equipped with the most modern
technology in tyre manufacturing.
Now Muhammad Shahid Hussain is the managing director of
the company, Hussain Kuli Khan Khatak is the COO of the

company; Mr. Jilani Baig is the executive director of

manufacturing.

TYRE MANUFACTURING

Types of Tyre
Bias Tyre
Radial Tyre

Bias Tyre:
In the construction of bias tyre in which ply cords extending from
bead to bead are at angle lying between 30 to 40 degrees.
In bias tyre building here is only single stage.
Plies are at opposing angles are laid over each other to form a
crisscross pattern to which the tread is applied.
Green tires of bias construction are assembled in a single stage thus
only one machine is required for complete assembly of tire.
There are currently six tyre building machines for Bias
construction. These machines are old and some are totally manual.
The main components of bias tyre building machine are:
Drum
Bead applicator
Back tool assembly
The following components are assembled:
Drum squeegee
Bands
Beads
Sidewall
Chafer
Breakers (Breaker are used in bias tyre to give more strength)

 Breakers to be used are dependent on the type of tyre manufactured

i.e. truck/bus, tractor.

Radial Tyre:
In this type of construction of tyre in which ply cords extending from
beads are at right angle to the center line of tread and parallel to each
other. A radial tyre is built on a flat drum in a two-stage process.
In the first stage, the inner liner is wrapped around a drum.
And then body ply is wrapped on top.
The bead assemblies are then positioned and paste beads on
both sides
And then a bladder on the drum is inflated and pushed in from
both ends of the drum, forcing the body ply to turn up to cover
the bead assemblies.
Then sidewall paste sidewall on both sides.
At this stage assembly is called carcass.
In the second stage of the tyre building process,
Another machine is used to apply the steel belts in crisscross
pattern.
Nylon cap ply is applied over steel belt but at radial angle.
And then tread on top and must assure that all the assemblies
applied is perfectly aligned.

 At this stage assembly is called a green tire.

The main components of first stage machine (PB-11, PB-13 to
PB-19). These machines are automatic but operator is required:

Drum
Bead applier
Turn up assembly
Bladder(Bead stitch apply pressure)
Berry bar(To remove air)

The main components of second stage machine (PR-1 to PR-6)

are:

Belt and tread drum

Transfer ring
Expander
Power sticker(Stick sidewall)
Back tool

Components of Tyre:
Inner liner:
The inner liner is an extruded half butyl rubber sheet
compounded with additives that result in low
air permeability.
The inner liner assures that the tyre will hold highpressure air inside.
And inner liner is made on 3-roll calendar which is
discus below.
Body ply:
The body ply is a calendar sheet consisting of one
layer of rubber, one layer of reinforcing fabric, and a
second layer of rubber.
Nylon and polyester are used as fabric.
Passenger tyres typically have one or two body plies
on different angles.
In radial tyres ply and steel belt both are on radial
angle.
Body plies give the tyre structure strength.
The fabric cords are highly flexible but relatively
inelastic.

 Sidewall:
Sidewalls are non-reinforced extruded profiles with
additives to give the sides of the tire good abrasion
resistance and environmental resistance.
Additives used in sidewall compounds include
antioxidants and anti-ozonants.
Bead:
Beads are bands of high tensile-strength steel wire encased in
a rubber compound.
Bead wire is coated with special alloys of copper or brass.
Coatings protect the steel from corrosion.
Copper in the alloy and sulfur in the rubber cross-link to
produce copper sulfide, which improves bonding of the bead
to the rubber
. Beads are inflexible and inelastic, and provide the
mechanical strength to fit the tyre to the wheel.
Bead rubber includes additives to maximize strength and
toughness.
Filler:
The filler is a triangular extruded profile that mates
against the bead.
The apex provides a cushion between the rigid bead and the
flexible inner liner and body ply assembly.
Chafer:

A component of the tyre that is the contact point between the

tyre and the wheel, designed to withstand forces the wheel
puts on the tyre during mounting as well as the dynamic
forces of driving and braking.

 Belt package(steel belt):

Belts are calendar sheets consisting of a layer of rubber, a

layer of closely-spaced steel cords, and a second layer of
rubber.
The steel cord oriented radially in radial tyre construction,
And at opposing angles in bias tyre construction.
Belts give the tyre strength and resistance while allowing it
to remain flexible.
Passenger tires are usually made with two or three belts.
Cushion gum:
Many higher-performing tyres include an extruded
component between the belt package and the tread to isolate
the tread from mechanical wear from the steel belts. It is just
used to stick the belt and tread.

Steps in the manufacturing of Tyre

MIXING:
Raw Materials:
Rubber:
Rubber is an elastomer, having visco-elastic behavior
Types of Rubber:
Rubber is classified into two main types:
Natural Rubber
Synthetic Rubber

Fillers:
Carbon Black: it increases tensile strength, resistance to abrasion
and tearing and protects from ultraviolet radiation.
White fillers (china-clay): it makes rubber compact.
Fillers generally reduce cost.
Additives:
Anti-oxidants: used to prevent the harmful effect of atmospheric
air (oxygen) on tire.
Initiators: used to initiate the vulcanizing process.
Accelerators: used to accelerate the vulcanizing process.
Adhesion promoters: used to promote adhesion.
With the passage of time, antioxidants evaporate and oxygen
attacks the tire surface and as a result of this cracks are
produced.

Banbury Mixer:
Banbury is an internal mixer, used for mixing plastics and
rubber. In this type of the mixer Pressure and heat are applied
simultaneously. It has two interrupted rotors that move in
opposite directions, with one moving at a higher speed than the
other.

Formation of master batch and finished compound:

Master batch is produced by mixing rubber (synthetic or natural/
both in some fixed proportion), carbon black and other additives
except vulcanizing agents.
Multiple master batches are produced for decreasing viscosity.
After master batch, finished compound is produced by mixing
sulfur and other additives in master batch.
Then after internal mixing, open mixing is done with two-roll
rolling mill for achieving homogeneity.
Cooling mechanism: water coolant is used for cooling parts of
the internal mixer, because they heat up due to friction.
Drying: drying is done by means of fans using atmospheric air
Promol solution is applied after open mixing, so that rubber
sheet may not stick to the conveyer belt.
RAM of both the internal mixers is operated either by water
(Hydraulic) or by means of air (Pneumatic).

 Extrusion
Extrusion:
In the extrusion process of rubber, the finished compound is fed
into the extruder.
The primary purpose of the extruder is to do three things
To make the rubber compound softer
To mix the components more efficiently
To pressurize the rubber into the die, to form the required
shape.
The die: is a sort of metal disk that has a machined opening in
the desired shape of the part that needs to be extruded.
The process of extrusion is usually applied for making tread and
side wall portion of the tyre.
Types of Extrusion:
Hot-feed extrusion: This type of rubber extrusion requires a hot
feed, i.e. the material is fed to the extruder from a warming mill.
Cold-feed extrusion: This type of extrusion does not require a
hot feed; instead the feed to the cold-feed extruder is at room
temperature.

Dual Extruder:
Dual extruder is the hot-feed type rubber extruder.
At a time two compounds are fed into dual extruder, both
compounds are pre-heated in the warming mill.
Components:
Dual extruder has the following parts:

Breakdown mill
Feeding mill
Y-head
Hopper
Screws
Die

Water Cooling:
Then the water is showered to reduce the temperature of the
extruded product to 40-42oC, the cooling time is usually 45
minutes.
Cutting and Printing:
After cooling the extruded product is cut at an
angle of 29o (for biased tyre) and at 0o (for radial
Tyre). The coding, brand name etc. are printed.
Then the extruded compound (tread or side wall)
is sent to the storage.
Triple Extruder:
Triple extruder is cold-feed type rubber extruder
At a time three compounds are fed into the extruder, all three
compounds are fed at room
temperature.

Components:
Triple extruder has the following components:

Hoppers
Screws
Extruder die
Cooling line
Cutting wheel

 Stock preparation:
Stock preparation is the department where all the tyre parts like
plies (only cutting at require angle like 32, 0 degree etc.) beads,
bands are made.

Tyre Bead making:

Tyre bead is also manufactured by a small scale extrusion

process.
First the copper (copper and steel alloy) wire is aligned by
passing through one or two rollers (stretchers), and then it
is coated with rubber on both sides by a small scale cold
feed extruder.
Then the rubber coated copper wires are coiled shaped to
form into the shape of the circular ring, and then taped.
Theses rubber coated wire rings are then fed into the bead
making machine which applies filler (in case of radial
tyres) or flip (in case of truck tyres) to the ring.
These beads are stored and then sent to green tyre building
department.

 3 & 4 ROLL CALENDERING

3-ROLL CALENDERING
Two mills are used in this process one is for blending (XM12) and second is for feeding (XM-11).
Then passes through conveyer belt to 3-rolls which as
direction 1st and 3rd moves in clockwise direction and 2nd
roll moves in anti-clockwise direction.
Here also use four gauge knives which are used for cutting.
These 3-rolls are heated by a steam and the temperature of
these rolls is above 100 degree Celsius.
Here after cutting there are 4-rolls for accumulation and for
cooling our batch.
In this process tensionative rolls are used to introduce
tension.
After that there is a wind up table for winding our batch.
There are four rolls at a time 2-rolls are in working and
these 2 are completely fills next 2-rolls ready for winding.
Then book these rolls at a temperature of 45-50 degree
Celsius.
Then these winded rolls again let of for the pasting of scuji
layer.
This scuji layer is used because it has high air permeability.
On 3-rolls calendaring process we basically produce inner
liner for the radial tyres.

4 ROLL CALENDERING
In this process tyre cord fabric coated with rubber on both
sides and passes through 4-roll.
This process is known to be 4 roll calendaring, moreover
the roller temperatures and gauges depends on
specification. In General tyre two types of fabric are used
nylon and polyester. Nylon is for bias tyre and polyester for
radial tyre.

Procedure of 4 Roll Calendaring:

1st of all the fabric is passed through let off unit, and
just for saving time two units are used.
Then is passed through tensionative units and by name
we know that this unit creates tension in the fabric.
Then again is passes through pre calendaring tension
unit to give more tension to the fabric.
Then banana rollers are used to stretch the fiber
horizontally so that rubber material easily penetrates
in the fabric and our coating will be perfect.
Then passes through trimming unit where extra
material cut down with respect to our rollers size.
Then fabric is moves into 4 rolls where coating
operation is takes place in direction.
(1st and 4th are input roller i.e. rubber and fabric and
2nd and 3rd are output roller i.e. our coated fabric )
Then perforator is fitted which is used for removing
air from coated fabric.
Then coated fabric goes for cooling and then
accumulation is done just for safety of material
because it is a continuous process.
Then coated fabric is winded in a wind up unit.
At last these fabric coated rolls shifted in storage area.

Ply Cutting
Three cutting machines are used for ply cutting:
1. FC- 3
2. FC-4
These machines cut plies at angles ranging from 15o-22o as
per required.
These machines have 99 teeth cutters.
Upper coating of biased tyre ply called screw-G is also
cut by these two machines.

Assembling of different components:

A Bias-Ply tire has criss crossing layers that are generally 32 to
40 degrees from each other from the center line of the
tread. Each layer is only strong going one direction, so the criss
crossing pattern gives the tire its strength in both directions.
Bias tyre building is done in a single stage
First the body plies, breaker and screw-G are assembled at
suitable angles as given by designing department, to form
carcass

Then carcass is placed on the tyre former, and beads are applied
on both sides
Finally the tread is applied and the sides are folded.
Naphtha solution is used for lubrication during green tyre
building, so that it may not stick to the machine.

Steel belt manufacturing for radial tyres:

Steel belts for making inner lining of radial tyres are also
manufactured by a small scale calendering process.

Creel room

Stretching

Calendering
machine

Water Cooling

Steel wires
Rubber (finished) compound

Cutting

Storage

Why radial tyre ply is cut at 0o and the tyre is made in two
stages?
While designing any tyre three types of forces are of primary
consideration:
Lateral force: to control the effect of this force stretching of tyre
should be controlled.
Radial force: to control the effect of radial force mass off tyres
across the whole circumference should be uniform
Conicity: it arises due to the transfer of mass at a certain part.

Radial force and Conicity are controlled by joining the

components at specified points suggested by the designing
department, so that all joints may not appear at the same point
causing non-uniform distribution of mass.
Radial tyre is designed to absorb shock, for giving comfort to
the passengers, since plies that are cut at some angles has
approximately zero flexibility, therefore plies of radial tyres are
cut at 0o.
Radial tyre is made into two stages due to the reason that tyre
should not be stretched in the mold during curing because if we
do so the ply may tear out, as it has been cut at 0o, therefore the
radial tyre is pre-expanded in the second stage of building to
prevent stretching, also pre-expansion reduces the effect of
lateral force.
Lubrication:
Biased tyre: On inner side of the tyre calcium based lubricant is
applied and on outer side naphtha based lubricant is sprayed.
Radial tyre: for radial tyres water based lubricants are applied on
green tyre.

 Vulcanization / Curing:
Vulcanization is the molecular transformation of the soft,
gummy green tire into the tough, and long-wearing, modern
tyre.
Curing converts partially elastic and partially plastic rubber to
highly elastic rubber i.e. to show visco-elastic behavior.
Every rubber product is to be cure either through molding or by
other means, either at room temperature or at elevated
temperature, curing is a process of vulcanization or cross linking
by sulphur.
Molding is an act of shaping the green (uncured) rubber into a
cured product of required geometry by using a mold.

Types of Curing:
1. All Steam curing:

It is very efficient type of curing; only steam is used for the

purpose of curing
Usually used in production of small tyres like passenger car
tyres, bicycle tyres and smaller agricultural tyres.
2. Hot Water Curing:

This is the most common type of curing, used for the

production of big tyres.
Often a circulation of cold water is used in the end of the
curing phase to cool the tyre before release (temperature
25-50 o C).

Curing Steps:
Typically hot water curing has the following steps
1. Steam in bladder, orifice is open
2. Steam in bladder, orifice is closed
3. Delay cure for cool mold
4. Non CIRC hot water through bladder
5. CIRC cold water through bladder
6. Full blow down
7. Apply steam flush in bladder
8. Apply vacuum in bladder
9. Open mold and remove tyre
Curing Press:
The pattern around the outside of the tread is pushed inward by
the curing press to form the outside shape of the tread.
At the same time, a large rubber bladder, sort of like an inner
tube, inflates inside the green tire, to push the tire against the
mold from the inside.
Between the mold moving in and the bladder pushing out, the
green tire is forced to fill the mold, creating the tread pattern.

Types of Presses used in Curing.

The tyre is vulcanized in a curing press, which receives the
energy required for the vulcanization process bladder.
The press requires four types of energies

electricity (control commands, press motion open/closed)

compressed air (lubricators, confirmation of the control
commands, other compressed air powered equipment)
Hydraulic pressure (tyre loading/offloading equipment,
bladder motion etc.)
steam or hot water (vulcanization energy)
There are two basic types of presses:
1. Dome type
2. Platen type
Dome Type Curing Press:

 In this type of press heat is supplied to the tyre from all

side, so that all sides of tyres uniformly cured.
Temperature range: 160oC-165OC
Dome type presses are usually used for large tyres, e.g.
truck tyres, tractor tyres etc., because their large size
require uniform curing so any part may not be under cured.

Platen Type Curing Press:

 In platen type press heat is supplied from the top and

bottom of the tyre
Temperature range: 180 to 185oC.
Large tyres are usually not cured in this type of press,
because as heat is only supplied from the top and bottom
of the tyres and from all sides as in case of dome type
presses, therefore the middle portion of the tyre may
remain under cured.
Small tyres, e.g. radial and bias passenger tyres, rickshaw
tyres, and front tyres of tractor are cured platen type
presses.

Types of moulds used in curing:

There two types of molds used in curing:
1. Two piece mold
2. Segmented mold
Two Piece Mould:
These types of molds are made into two
pieces.
These moulds are used for large
agriculture and truck tyres.

Segmented Mould:
Segmented moulds are made into eight or
more than eight segments
These moulds are used for small
passenger and light-truck tyres.
PCI (Post Curing Inflation):
PCI is done so that tyre should not
deshape, or in order to achieve
uniformity in temperature throughout
the body of the tyre. It is necessary
for the tyres in which nylon fabric is
PCI unit
used in plies (bias tyres) and it may
be done on demand to the tyres in
which polyester fabric is used in plies (radial tyres), because
polyester is thermally stable.

Requisites of PCI:
Immediately after release from the press, the tire is
mounted on the flanges
either automatically or manually
The post curing inflation pressure has to be about 20-35 %
or even may be double than what
the normal inflation pressure of the tire would be.

 The inflation time has to be long enough (at least one

curing cycle) depending
on the size of the tire (thickness of materials).
The distance between the flanges needs to be same as the
width of the
recommended rim for the tire.

Final Finish and Inspection:

Trimming:

For showroom quality, any excess rubber is trimmed off the

cured tire. Every tire is thoroughly inspected.
Tyre Uniformity Test:
This test refers to check the
dynamic mechanical properties
of tires as strictly defined by a set
of measurement standards and
test conditions accepted by
global tire makers. These
measurement standards include the parameters of radial force

variation, lateral force variation, Conicity, radial runout,

lateral runout, and sidewall bulge.
Radial Force Variation:
Radial force is the force that acts
upward to support the vehicle,
therefore radial force variation
describes the change in this force
as this force changes when the
tyre rotates under load. As the
tyre rotates and spring elements
with different spring constants enter and exit the contact area,
the force will change.
For example: Consider a tyre supporting a 1,000 pound
load running on a perfectly smooth roadway. It would be
typical for the force to vary up and down from this value. A
variation between 995 pounds and 1003 pounds would be
characterized as an 8 pound radial force variation.

The Lateral Force Variation:

The lateral force is the force that acts side-to-side along the tire
axle, therefore lateral force variation describes the change in this
force as the tire rotates under load. As the tyre rotates and spring
elements with different spring constants enter and exit the
contact area, the lateral force will change.
For Example: As the tyre rotates it may exert a lateral force on
the order of 25 pounds, causing steering pull in one direction. It
would be typical for the force to vary up and down from this
value. A variation between 22 pounds and 26 pounds would be
characterized as a 4 pound lateral force variation.
Tangential force variation:
The tangential force is the force that acts the direction of travel;
tangential force variation describes the change in this force as
the tyre rotates under load. As the tyre rotates it exerts a high
traction force to accelerate the vehicle and maintain its speed
under constant velocity. Under steady-state conditions it would
be typical for the force to vary up and down from this value.
This variation would be characterized as TFV.

Conicity:
Conicity is a parameter based on lateral force behavior. It is the
characteristic that describes the tyres tendency to roll like a
cone. This tendency affects the steering performance of the

vehicle. In order to determine Conicity, lateral force must be

measured in both clockwise (LFCW) and counterclockwise
direction (LFCCW). Conicity is calculated as one-half the
difference of the values.
Ply steer:
Ply steer describes the lateral force a tire generates due to
asymmetries in its carcass as is rolls forward, It is the
characteristic that is usually described as the tyres tendency to
crab walk, or move sideways while maintaining a straight-line
orientation. This tendency affects the steering performance of
the vehicle. In order to determine ply steer, the lateral force
generated is measured as the tyre rolls both forward and back,
and ply steer is then calculated as one-half the sum of the values.
Radial runout
Radial Runout (RRO) describes the deviation of the tires
roundness from a perfect circle.
Lateral runout:
Lateral Runout (LRO) describes the deviation of the tires
sidewall from a perfect plane.

X-ray inspection:
X-ray inspection is done to determine the position and

 Wrapping:
Once the tires have passed all the checks and inspections, they
are wrapped and then sent to the finished goods warehouse,
from where they are sold.

TYRE WRAPPING MACHINE

WRAPPED TYRES

 Raw Materials
Ware House:
Raw materials are basic
ingredients of any product

All the materials that are either required for production or

maintenance are stored in raw materials ware house. Here raw
materials required for manufacturing of tyre including natural
and synthetic rubber, carbon black, zinc oxide, sulfur and other
additives that are brought from local or international market are
stored, other than process raw materials different types of oils
including aromatic oil, paraffin oil and also the oils used for
lubricating machinery is also placed here. Tools and equipment
used for repairing of machinery and other necessary equipment
are also stored here.

 FINISHED GOODS WAREHOUSE

The products that fulfill all the quality parameters are
sent to F.G.W.H for shipment to the dealers and OEMs.
Tire packaging is also done here.
They also collect the claimed tires.
A warehouse sheet is generated in the holding area when the tires
are been handed over to F.G.W.H.
The sheet is verified and signed by warehouse supervisor
before the tires are let in the warehouse.
A locking key system is used which means when tires are in the
holding area, the warehouse gate is locked and similarly when tires
are in the F.G.W.H, the gate to holding area is locked.
A Sales Invoice is generated in the sales department when tires are
to be dispatched from F.G.W.H.
In case of transfer of tires to branch offices, a Transfer Invoice is
generated. F.G.W.H verifies the invoices and plans the
logistics.

 TUBE DEPARTMENT

Formation of tube:
Basically a tube is torus-shaped balloons made from an
impermeable material, such as soft, elastic synthetic rubber, to
prevent air leakage. The tubes are inserted into the tire and
inflated to retain air pressure.
In general tyre the compound used for tube is ME 5901 and is
extruded in a simple extruder; firstly the compound is blended
on a mill and then passes to feeding mill so that there is no need
of proper mixing in extruder then through conveyer belt passes
to the hopper of extruder. The temperature of screw is specified
and fixed with respect to aspects given. Then the extrude exit
out from a cone shaped die, our die is design in such a manner

that there is a nozzle inside the die whose purpose is to sprayed

powder name soft stone inside and outside the tube so that tube
material cannot stick inside or outside by other material, now
our extrude i.e. tube is passing through conveyer belt by
different process such that after powdering then we suddenly
stick a Rapcon whose purpose is that it remove powder from a
part where we have to applicate our wall, before this rapcon tube
is passes through chiller process so that it maintains its
temperature i.e. 56-60 degree Celsius, the tube is cut to our
desired size. Then tube is taken to splicing unit and splice by
heating, by name we came to know splicing purpose is to joint
two ends of a tube. Then the splicing part is taken to chiller unit
and cooled at a temperature of - 9 degree Celsius. After chilling
then we fills air in a tube to check whether our splicing is done
properly or not then the air filled tube is taken to the ring unit.
This is done just to give a desired shaped for the mold of a
curing machine.
Then after all this processes finally a green tube is taken for
curing and cured at a temperature of 100 degree Celsius and
maximum time taking is 5- 6 min. The curing of tube is doing by
steam process, as we above discuss the steam process for curing.

Formation of Bladder:
Generally we say that bladder are a flexible membrane that
forms the inside surface of a tyre during the tyre
curing/vulcanizing process.
Bladder is cured at a temperature of 200 degree Celsius

Formation of a Flap:
Tyre flaps to our understanding were used for two reasons. The
first being any spoked wheel, to keep the spoke nut from
rubbing against the tube. The other, being a solid wheel, the
flap, or liner was used as a precaution if there was any scratch or
imperfection in the inside of the rim, to once again keep the tube
from rubbing or moving against it.
Flap cures at a temperature of 140 degree Celsius and time taken
is 6 min but the mold of a flap is in 3 parts.

 Information Technology Department:

Information technology department is responsible for all

communications with in the company and outside the company.
All systems are online, mostly based on integrated systems.
Functions of I.T department include raw materials inventory
records, receipts, online orders, product inventory record, gate
passes spooling (transfer of data from system to system) etc.
three operating systems are being used namely IB (main series),
Linux operating system and Microsoft windows. These systems
also allow remote excess to check configurations of machines
that are being imported, e.g. from USA, China, and Germany
etc. within the company data is transferred from one department
to other through shared folders further more central locations are
also available for the data, if it id required to be made visible to
everyone.

 QUALITY ASSURANCE
Quality Assurance department ensures that ISO standards are
followed and is responsible for its certification.
Its main purpose is preventing the claims from customers. In case
of receiving such claims on quality of provided products and
services.
The department starts searching the reasons and effects of the
revealed discrepancies. If a tire on examination is found to
behaving some manufacturing defect, the Company will either
repair it free of cost or make reasonable allowance on pro-rata basis
on the purchase of a new tire.
This allowance will be based on the actual wear and balance left
of a tire.
It is also responsible for taking market surveys to check if the
product is meeting its requirement.
The department also carries out investigations in case of
recurring problems.

 QUALITY CONTROL
Quality Controls include product inspection, where every
product is examined visually, and often using a stereo
microscope for fine detail before the product is sold into the
external market. Inspectors will be provided with lists and
descriptions of unacceptable product defects such as cracks or
product.
The quality of the outputs is at risk if any of these three
aspects is deficient in any way.
Quality control emphasizes testing of products to uncover
defects and reporting to management.
Quality control department play very important role in a factory. This
department is basically a supporter of customer but in real it gives
valuable advantages to the company. This department has to check the
product without checking one of the product does not out from the
production because if any defected product is sale in market it is great
risk of company and also very dangerous for the lifes of customer. This
departments responsibility to maintain the quality of the product by
perfect testing.
Quality Control Department has following responsibilities and sections.
1. X-Ray testing
2. Material Testing Lab
3. Reliability Test
i). Endurance Testing
ii) High Speed Testing
4. Plunger test
5. Tire Uniformity machine used to check if forces are balanced.
6. Statistical Process Control e.g. control charts etc.

7. In Process Inspection
8. Final Inspection
Quality control begins with the delivery of raw materials. Company
chemists do random testing of the raw materials in the material testing
lab. Throughout the batch mixing operation, samples of the rubber are
drawn and tested to confirm if the rubber fulfills its requirement. A
variety of nondestructive evaluation techniques are also used such as
X-ray videography, reliability testing, and plunger testing for cured
tires.

 PRODUCTION PLANNING AND CONTROL

The department has following functions:

Sell forecast (Received from market)

Production forecast
Master production schedule
Three months manufacturing schedule
Monthly schedule
Daily Manufacturing schedule
Inventory management
Production control
Daily update

Sells Forecast:
Sells forecasts are plans that when and how many products will
be required, in these plans chart sheets are formed in which three
things are primarily set according to the purchasers demands.
1. Type of product
2. Quality
3. Time

Production Forecast:
Production forecasts are possibilities of production. These
forecasts are also made in the form of chart sheets, in which the
same three things i.e. type of tyre, quality and time; are set
according to production capacity of the factory. Actually these
chart sheets are formed in reply of sells forecast sheets.
Master Production Schedule:
Master production schedule may be understood as a mutual
contract in which the same three things are i.e. type of tyre,
quality and time; are set according to the demands as set by sells
forecast and possibilities that are given in production forecast.
This document is made for three months.

Three Months Production Schedule:

Three months production schedule are given to the different
departments e.g. compounding department, curing department,
tyre building department etc., according to the master production
schedule.
Monthly Production Schedule:
Monthly Schedule is formed using three months schedule i.e.
three months production schedule is divided into three short
term schedules.

Daily Production Schedule:

Daily schedules are made according to the monthly schedule i.e.
monthly schedule in divided into 30 short term schedules.
Inventory Management:
Inventory management manages the factory stock, it has three
components:
1. Raw materials inventory
2. Inventory of in process products
3. Finished goods inventory
Production Control:
Production department also makes checks to know that things
(production processes) are going according to plans or not. For
this purpose reports are made after every shift then actions are
made if required.
Daily updates:
Meeting of production department is held on daily bases, to have
knowledge of last days production.

 BOILER HOUSE
Boiler house is also known as steam generator. Basically this
department is also called utility department. This department
fulfills all the utilities requirements. Without this department
production process is work. This department has great
important in any company because this department is just act
as back bone of the production.
In general tyre there is two boilers one is new and another is
old are as follows:
1. Train boiler:
18-tons capacity
260 psi working pressure
40000 lb/hr flow rate
2. Deskon boiler:
22-tons capacity
260-psi
49000 lb/hr
Supply from boiler house:

Steam supply
Hot water supply
Cold water supply
Standby generator

 Air supply
There are two compressors of 150psi and 100psi.
Two pumps hot water and cold water.
Two generator of 735KW.

Assignment
Cooling operations in a plant :
Cooling Towers :
A Cooling tower is a heat rejection device which extracts waste
heat to the atmosphere through the cooling of a water stream to a
lower temperature. Cooling towers may either use
the evaporation of water to remove process heat and cool the
working fluid to near the wet-bulb air temperature or, in the case
of closed circuit dry cooling towers, rely solely on air to cool the
working fluid to near the dry-bulb air temperature.
Cooling towers vary in size from small roof-top units to very
large hyperboloid structures that can be up to 200 metres
(660 ft) tall and 100 metres (330 ft) in diameter, or rectangular
structures (as in Image 3) that can be over 40 metres (130 ft) tall
and 80 metres (260 ft) long.
The generic term "cooling tower" is used to describe both direct
(open circuit) and indirect (closed circuit) heat rejection
equipment. While most think of a "cooling tower" as an open
direct contact heat rejection device, the indirect cooling tower,
sometimes referred to as a "closed circuit cooling tower" is
nonetheless also a cooling tower.

A direct or open circuit cooling tower is an enclosed structure

with internal means to distribute the warm water fed to it over a
labyrinth-like packing or "fill." The fill provides a vastly
expanded air-water interface for heating of the air and
evaporation to take place. The water is cooled as it descends
through the fill by gravity while in direct contact with air that
passes over it. The cooled water is then collected in a cold water
basin below the fill from which it is pumped back through the
process to absorb more heat. The heated and moisture laden air
leaving the fill is discharged to the atmosphere at a point remote
enough from the air inlets to prevent its being drawn back into
the cooling tower.
The fill may consist of multiple, mainly vertical, wetted surfaces
upon which a thin film of water spreads (film fill), or several
levels of horizontal splash elements which create a cascade of
many small droplets that have a large combined surface area
(splash fill).
An indirect or closed circuit cooling tower involves no direct
contact of the air and the fluid, usually water or a glycol
mixture, being cooled. Unlike the open cooling tower, the
indirect cooling tower has two separate fluid circuits. One is an
external circuit in which water is recirculated on the outside of
the second circuit, which is tube bundles (closed coils) which
are connected to the process for the hot fluid being cooled and
returned in a closed circuit. Air is drawn through the
recirculating water cascading over the outside of the hot tubes,
providing evaporative cooling similar to an open cooling tower.
In operation the heat flows from the internal fluid circuit,
through the tube walls of the coils, to the external circuit and

then by heating of the air and evaporation of some of the water,

to the atmosphere. Operation of the indirect cooling towers is
therefore very similar to the open cooling tower with one
exception. The process fluid being cooled is contained in a
"closed" circuit and is not directly exposed to the atmosphere or
the recirculated external water.
In a counter-flow cooling tower air travels upward through the
fill or tube bundles, opposite to the downward motion of the
water. In a cross-flow cooling tower air move horizontally
through the fill as the water moves downward.
Cooling towers are also characterized by the means by which air
is moved. Mechanical-draft cooling towers rely on power-driven
fans to draw or force the air through the tower. Natural-draft
cooling towers use the buoyancy of the exhaust air rising in a
tall chimney to provide the draft. A fan-assisted natural-draft
cooling tower employs mechanical draft to augment the
buoyancy effect. Many early cooling towers relied only on
prevailing wind to generate the draft of air.
If cooled water is returned from the cooling tower to be reused,
some water must be added to replace, or make-up, the portion of
the flow that evaporates. Because evaporation consists of pure
water, the concentration of dissolved minerals and other solids
in circulating water will tend to increase unless some means of
dissolved-solids control, such as blow-down, is provided. Some
water is also lost by droplets being carried out with the exhaust
air (drift), but this is typically reduced to a very small amount by
installing baffle-like devices, called drift eliminators, to collect
the droplets. The make-up amount must equal the total of the

evaporation, blow-down, drift, and other water losses such as

wind blowout and leakage, to maintain a steady water level.

Natural draft wet cooling tower

Natural draft wet cooling hyperboloid towers

CNG cooling system

 Heat Exchangers
A heat exchanger is a piece of equipment built for
efficient heat transfer from one medium to another. The
media may be separated by a solid wall to prevent mixing
or they may be in direct contact.
Types of Heat Exchangers:
Double pipe heat exchangers are the simplest exchangers
used in industries. On one hand, these heat exchangers are
cheap for both design and maintenance, making them a
good choice for small industries. But on the other hand, low
efficiency of them beside high space occupied for such
exchangers in large scales, has led modern industries to use
more efficient heat exchanger like shell and tube or other
ones.

Shell and Tube heat exchangers Shell and tube heat

exchangers consist of a series of tubes. One set of these
tubes contains the fluid that must be either heated or
cooled. The second fluid runs over the tubes that are being
heated or cooled so that it can either provide the heat or
absorb the heat required. A set of tubes is called the tube
bundle and can be made up of several types of tubes: plain,
longitudinally finned, etc. Shell and tube heat exchangers
are typically used for high-pressure applications (with
pressures greater than 30 bar and temperatures greater than
260 C)This is because the shell and tube heat exchangers
are robust due to their shape.

Heating Operations in plant:

Boiler:
A boiler is a closed vessel in which water or other fluid is
heated. The fluid does not necessarily boil. The heated or
vaporized fluid exits the boiler for use in various processes
or heating applications.

Heating and cooling operations in General Tyre:

The steam produced from the boiler in used in the curing
process to provide the desirable temperature in order to
accompany the process of moulding.
In curing process high pressure steam at a temperature of
206 C and low pressure steam at a temperature of 186 C are
used which are provided by boiler.
The temperature of the hot water is reduced by means of
heat exchanger by bringing it in indirect contact by cold
water and therefore the cold water can be utilized in
cooling operations.
Water can also be cooled by other equipments such as
cooling towers.

Cooling is an essential step in order to bring the material to the

desired temperature and in order to avoid excessive heating
which may be harmful and cause problems .Over heating makes
the handling difficult, and would require a good amount of time
to cool so its better to cool the material step by step .A high

temperature material if directed into an equipment may cause

considerable damage to the machinery and even increase the
temperature of the surrounding.
Cold water is used throughout the industry in various
departments for specific cooling purposes right from the
mixing to the curing .Some of them are listed below:
Promol solution is used as a cooling agent in the
mixing department to cool the master and finish
batch.
The compound from the dual and triplex extruder
are cooled by cold water
Rolling mills are equipped with a cooling
mechanism and use water as a cooling agent to
avoid excessive heating which may cause
premature curing.
Curing process also uses cold water.

SUGGESTIONS

Steam leakage is the main problem which occurs in many

pipes and curing presses. Steam leakage results in the loss
of both latent and sensible energy.
Countering the steam losses might reduce the cost and is
optimum for the safety of plant personnel.

The safe operation of plant and well-being of the plant

personnel should be given consideration. Workers must be
provided proper accessories such as masks, gloves, safety
helmets, safety shoes and glasses.

There should be an addition of Research & Development

department in the industry, which would be beneficial in
the near future.

Finished tyres must not be piled up in open atmosphere, in

order to prevent them from getting dilapidated.

 A large scale industry like General Tyre must produce

electricity for its own use rather than using the electricity
from K-Electric, this would in turn save a large amount of
electricity of K-Electric which would be useful for the
Residential Areas because we are living in a country where
energy is scarce and a large scale industry such as General
Tyre consumes a large amount of energy.

Recommendation for production of

electricity:
Rice husk & scrap tyres can be used as a source of energy
for producing electricity. Rice husk is widely available in
rural areas of Sindh and Punjab and is of negligible price,
so rather than wasting it, it can be utilized as a fuel in the
production of electricity. Scrap tyres are also available in a
large amount; therefore the cost of these two raw materials
is negligible which are of high calorific values and can
provide immense benefits.