Tyres are manufactured according to relatively standardized processes and machinery, in around 455 tire factories in the world. With over 1 billion tyres manufactured worldwide annually, the tyre industry is a major consumer of natural rubber. Tyre factories start with bulk raw materials such as synthetic rubber, carbon black and chemicals and produce numerous specialized components that are assembled and cured.
The tyre is an assembly of numerous components that are built upon a drum and then cured in a press under heat and pressure. Heat facilitates a polymerization reaction that crosslinks rubber monomers to create long elastic molecules.
In India, there are many tyre manufacturing plants of different companies, Yokohama Rubber Company, Apollo Tyre, Ceat Tyres, J.K. Tyres, MRF and TVS Tyres and many others.
There are many different parts that go into the making of a tyre as follows.
Raw materials for the preparation of the Tyre are Rubber - Natural + Synthetic, polythene, Carbon Black, Silica, Sulphur, Zinc oxide, Stearic Acid, Accelerators and Retarder - catalysts & Fabric.
The Banbury mixer is a sophisticated piece of heavy equipment with a mixing chamber that has two rotors inside. The rotor is named as BANBURY ROTOR and the chamber as BANBURY CHAMBER. There are two rotors; both the rotors rotate in opposite directions at a certain speed. The mixing takes place between the rotor tip and the chamber and not between the two rotors. Needling takes place between the two rotors. Each element added in mixing has its own importance i.e. Sulphur acts as a curing agent, zinc oxide and Steric acid increases the speed of the curing time, accelerators and retarders provide dispersive mixing. The batch is injected at a temp of 135°C and batch damping takes place at 165°C.
The function of the Banbury rotor is to mix the basic raw materials of the tyre. Lead time of the new Banbury Chamber is approx. 8-9 months and in the case of Extruder Screw, it takes around 3-4 months from the date of order.
It mixes Rubber and other raw materials in Banbury Mixture. Pair of rotors rotate in opposite directions.
The function of the Banbury rotor is to mix the basic raw material of the tyre.
Lead time of the new Banbury Rotor is approx. 8-9 months and in the case of Extruder Screw, it takes around 3-4 months from the date of order.
The function of the Extruder screw is to extrude rubber for the Left and right-side walls of the tyre for further process.
The recommended solution is EWAC special welding alloy EWAC Wunder 680 CGS/Xuper 680 CGS with high toughness, high strength and ductility and Ewac ChromCarb N*6006/Chromslide 6006 which is an all-position unique electrode for applications subjected to abrasion, erosion, corrosion combined with impact.
The recommended solution is Xuper Co 12 which is a stellite 12-grade new generation Cobalt base alloy with excellent resistance to Wear, Galling and Corrosion, even at elevated temperatures.
The recommended solution is EWAC special welding alloy Ewac Wunder 680 CGS/Xuper 680 CGS with high toughness, high strength and ductility.
The recommended solution is Ewac ChromCarb N*6006/Chromslide 6006 which is a unique electrode for application subjected to abrasion, erosion, corrosion combined with impact.
We have experience in the reclamation of Banbury Rotor, Chamber and Extruder screw.
We take this job, as a turnkey project and deliver the reclaimed component saving time and costing.