THE GENERAL TYRE AND RUBBER COMPANY

OF
PAKISTAN LIMITED

“ INTERNSHIP REPORT ”

Duration: TWO WEEKS

(1ST JUNE - 14TH JUNE 2017)
Submitted To: Mr. Muhammad Shahab Paracha
(Div.Manager- Electrical/Electronics)
Submitted By: Raza Jahangir {BE-1-15-7655}
(Interne) (3rd year student of Electrical Engineering)

PAF - KARACHI INSTITUTE OF ECONOMICS

&
TECHNOLOGY
 ACKNOWLEDGEMENT
At the very beginning I would like to express my deepest gratitude to almighty ALLAH
for giving me the strength and the composure to complete my internship and prepare this
report within the scheduled time.
During the period of my internship work, I have received generous help from many
quarters, which I like to put on record here with deep gratitude and great pleasure.
First and foremost, I am grateful to my supervisor, Muhammad Shahab Paracha, (Div.
Manager-Electrical/Electronics). He give his precious time from the very beginning till
the completion of my internship. Her guidance, encouragement and suggestions provided
me necessary insight into the problem and paved the way for the meaningful ending the
internship in a short duration. I have no hesitation to say that, without his constant
support and valuable advices from time-to-time, I would never learn in an appropriate
manner.
I am grateful especially to Capt S. Khusro Iqbal (Div.Manager of Human Resources). I
am also thankful Mr. Mehmood and Mr. Burhan for their sincere co-operation and
support for giving me the opportunity and help me for make a standard report.
 PURPOSE OF INTERNSHIP

In GENERAL TYRE & RUBBER COMPANY OF PAKISTAN,

 I had visited many different sections and areas according to the schedule provided
by Division Manager.
 These visits were very helpful. All the personals, I referred were very
cooperative.
 I learned a lot by them and their experiences.
 I learned so many ways of how to prepare a Tyre effectively and efficiently.
 The main purpose of this internship is to know about the working principle of
Motors with their drives, Relays, Contractor, Timers, Sensors, PLC from the
industrial point of view in the GENERAL TYRE and much more.
 This internship is very useful for me for my upcoming educational and
professional life.
 1. BASIC KNOWLEDGE
Industry is the production of goods or related services within an economy. It is an
economic activity concerned with the processing of raw materials and manufacture of
goods in factories. Every industry work on the phenomenon of system. A system is a set
of detailed methods, procedures and routines created to carry out a specific activity,
perform a duty, or solve a problem.

INPUT PROCESS OUTPUT

In industries the input may be (Pressure, Temperature, Speed, Distance, Load/Weight,
Proximity, Light, Voltage) the process would be (PLC, Relay logic, Designed card) and
at final the output (Motors, Heaters, Values etc).

2. INTRODUCTION:
The General Tyre and Rubber Company of Pakistan Limited (Gentipak) is the Pakistan’s
premier Industry. It was established in 1963 by General Tyre USA and has been in
production since 1964.
Gentipak has a Technical Services Agreement (TSA) with Continental AG (Germany’s
largest tyre manufacturer) which enables it to product tyres of “GENERAL” brand and
provides the latest technology for production of tyres based Continental’s, Research and
Development (R&D).
The plant and the office are located in Karachi. Initial production capacity was only
120,000 tyres per annum but is now around 2,000,000 tyres per annum. General tyre
plant is constantly upgraded and is equipped with the most modern technology in tyre
manufacturing.

3. PRODUCTS OF GENERAL TYRE:

 Bike Front & Rear Tyres

 Passenger Car Tyres
 Truck & Light Truck (Bus) Tyres
 Tractor Front & Rear Tyres
 Tubes
 4. TYRE MANUFACTURING PROCESS
Tyre manufacturing process and operations are technically complex so tyre making
procedure is divided in different sections:
 Mixing
 Extruding
 Calendaring
 Stock Preparation, Bead & Band Building
 Tyre Building (Bias Tyre & Radial Tyre)
 Tube Section
 Curing
General tyre is divided into three area for the manufacturing of (cars, truck and tractors)
tyres. There is also a specified area for motorcycle tyres and its tubes.
Before discussing area-1 firstly discuss the utility area which come under area-3.

5. UTILITY AREA
As we know brain is called the CPU of human body in such a way utility area is the CPU
of this industry. The KE supply 11,000VA to General Tyre. In General Tyre company
three feeders are coming from KE which would be distributed to three areas with their
need. 11,000VA will be step down to 25-30 KW and 380/400 volt. There is also a backup
system in order to continue production without facing any difficulties. There are three
generators for backup produced 1.2 MW electricity each. These generator having auto
transfer switch (ATS) which automatically supply electricity when there will be short fall
or any problem from KE.

6. AREA-1

This area will be the main production for the tyre. Three types of method is used for
making sheets of the carbon tyre namely:

 MIXING
 BN-1 (F-270)
 BN-2 (HF-270)
 BN-3 (XMN-320)
 EXTRUDER
 SINGLE (TFT)
 DOUBLE (X-2)
 TRIPPLE (X-3)

 CALENDAR
 CL-2
 INNER LINER

 The mixing process is done in two stages. First stage is called “Master Batch” and the
second stage called “Finish”.
In the first stage, the natural rubber, synthetic rubber, carbon black and other chemical
ingredients are placed onto a conveyor system, and the Banbury mixer is charged to
initiate the mixing process to create a homogeneous rubber material. This homogeneous
rubber blended is called “Master Batch”. Time, Temperature, Pressure and raw materials
are factors utilized to material composition. The mixing temperature do not rise up to
(135 to 160) °C. If the temperature is exceed from this limit then the compound can be
damage. The pressure of the Ram is 120 Psi.
In the second Stage, Curatives package is added in the mixing process. The temperature
for this stage is not exceed (95 to 110) °C, here pressure of Ram is also 120 Psi. After this
the reaction is completed. The complete compound called “Finish”. The finish is sent to
series of machines to form the specific sizes of sheets, coding on fabric and made slabs
for bladder and flaps.
F-270 is called Banbury mixer (4 wing rotor). It is mostly used for Master Batch mixing.
F means Feral and 270 shows volume of this mixer. It is PLC based mixer. The main
motor use in this machine is Ac machine. It is necessary to control the speed of motor so
for that Ac Drive is used. The main motor operate on 1500 KW/ 690V.
HF-270 is also a Banbury mixer (2 wing rotor). It is widely used for the finish mixing.
HF is the company name while 270 is volume of this mixer. It is also a PLC based mixer.
The main motor is High Tension motor having 3000V and speed will be 1750 hp. Drive
use for this HT motor is Ac Drive.
XMN-320 is a new mixing machine. It main motor operates on 440V Ac. It take four
process to complete the sheet for tyres.
 Mixer & TSR
 Up steam
 Batch off
 Small component
The rubber sheet comes out from the mixer is not that perfect. So, in this operation the
shaping of rubber takes place. Milling machines shape the rubber into flat, long strips by
forcing and some heating. For this operation, two roll mils rotating in different directions
at different speeds. The first mill is called “Dump Mill” and the second mill called
“Shelter Mill”. After the milling operation this will cold by the fans and then sent it to
different section for different working.

 Extruding converts the thick and heavy rubber sheets into thin rubber sheets. It is
often referred to as a “Tuber”, because it creates tube like rubber sheets. It consists of
a screw, barrel, head and die. A core or spider is used to form the hollow inside of
tubing. By this operation, many of the tyre components such as large, flat sectio n of
tyre are made like Tread, Inner Liner, Side wall etc.
SINGLE EXTRUDER is new technology of the era. This machine is imported from
china it also work same as dual and triple extruder will. This machine is not started yet
during my internship period. It is PLC based machine main motor is Ac motor.
DUAL EXTRUDER is called “Hot Feed Extruder”. It is only used to form Bias tyre
components making like Tread and Side Wall for Passengers, Truck and Tractor tyres. It
work on Relay logic with Dc Drive and use Dc Motor having rating of 220V Dc. It has
four mills and two large screws. Mills name are follows:
 Break down Mill
 Feed Mill
 Hopper
 Screws and Die
Finish is transported to break down mill and it makes the slits into strips. By the conveyor
belt it carried to the feed mill then hopper mill. Then the coming compound forward to
screws and here screws push the material in the direction of the die here the line speed is
maintain in FPM (Foot per Minute). Two different sizes of screws are used for extrusion
(i.e. 8 ½” & 10”). The screws move with different rpm according to required
specification. “Y-head” die is used. Die have the cavity of the size of either tread or side
wall to be extruded. If required, Cushion gum is applied after the extrusion of the die.
The extruded component is sent to the cooling purpose. This extruder has spray water
system for cooling. After cooling, its goes to the cutting machines, there it can cut into
different sizes.
The drawback of this extruder is:
 It required valuable worker for milling.
 Water is more required for cooling purpose.
TRIPLEX EXTRUDER is called “Cold Feed Extruder”. It is more efficient extruder as
compared to Dual Extruder. It is only used to form Radial tyre components making like
Tread and Side Wall. It has three screws of different sizes of diameter. 1st Screw
diameter is 50 mm. 2nd Screw diameter is 90 mm. 3rd Screw diameter is 120 mm. These
screws are sealed in the housing and having separately feed area. In this extruder, small
pins are fitted to blend the rubber properly. In this extruder, different dies can be mounted
at the same time. If required, Cushion gum can be applied separately. After extrusion, the
material forward for cutting (Because It is cold feed extruder and here is no requirement
for mill to warm up the feed) where, it can cut at the specific angle mostly cut at 280
degree. It is PLC based machine main motor is Dc motor work at the rate of 400V Dc.
The drive use in this is Ac but further convert into Dc due to Dc motor.
It has one cutter (Fair wood) for cutting purpose.
The advantages of triplex extruder:
 No need mill workers.
 Cost efficient and high productive.
CALENDERING is the operation which continues to shape rubber. This machine
consists of one or more rolls (often it have four rolls). In this operation the rubber sheets
are forced by rolls for shaping.
The main functions of calendaring are:
 To prepare compounded rubber as a uniform sheet of definite thickness and width.
 To place a thin coat of rubber on a fabric (Coating).
 To force rubber into the interstices of fabric by friction.
In the General Tyre 4-rolls calendar is using for calendaring purpose. It is set of large
diameter rolls that squeeze the rubber compound into a thin sheet. It produces an upper
and lower rubber sheet with a layer of fabric in between rubber sheet. Calendar is used to
produce the Body Plies and Belts. For Calendaring many types of fabrics can be used like
nylon, polyester and rayon. It work on Relay logic with Dc Drive and main Dc Motor
having rating of 440V Dc having 2000 RPM.
 7. AREA-2

BEAD & BAND BUILDING is also known as “Component Assembly Building”. In this
stage all the tyre components are assembled together with the help of assembling
machine. The components of a tyre include Beads, Chafer, Plies, Side Walls, Chipper and
Treads. After the components are assembled, the tyre is often referred to as a “Green
Tyre” and also called “Uncured Tyre”.
In General Tyre: For the making of Beads, two different machines are using:
 BT-2 > It making two bead at a time.
 BD-3 > It making three beads at a time.
For the making of Stock Preparation, five different machines are using:
 FC-2 to FC-4  FS-1 to FS-2
For the making of Band, Five machines are using:
 BB-1 to BB-5 (BB Means Band Building).
These machines consist of two rollers, which press multiple piles together by the
pneumatic pressure. Band is the set of plies. Plies are cut according to the circumferential
of size of the tyre. These plies are build up at opposite angles forming the criss cross
pattern.
For making Green Tyre of truck:
 TK-1 to TK-6 (TK Means Truck)
For making Green Tyre of tractor:
 TR-1 to TR-7 (TR Means Tractor)
The Bias Tyre construction is build up in one stage. One machine is required for the
assembly of Bias tyre. The following components are assembled:
 Inner Liner
 Bands
 Beads
 Chaffer
 Breaker
 Tread
After the tread applied, final product is the Bias’s green tyre and it is ready for curing.
RADIAL TYRE BUILDING is build up into two stages. In 1st Stage a carcass is built in
tyre building drum:
 Inner Liner
 Ply
 Bead
 Chafer
 Side Wall
In the 2nd Stage reaming parts applied:
 Belt-1
 Belt-2
 Cap Ply
 Tread
After the 2nd stage the final product is the radial’s green tyre and it ready for curing.
In STEELASTIC AREA DEPARTMENT steel belts are build for Radial tyre. In the
construction of this belt used high tensile brass coated steel cords. The brass coating is
done to make the cross link with rubber (Copper + Sulphur = Coppersulfied). The main
function of brass coated steel cords is in a temperature and humidity controlled
environment. If it is not used so corrosion due to moisture may cause the steel belt to lose
adhesion with rubber. The machine for radial tyre are PR-1 to PR-7. In this area most of
the machines are PLC based. (Allen Bradley, Siemens, and Mitsubishi).

8. AREA-3

CURING means treated by a chemical or physical process to improve properties

(hardness and strength and elasticity). Curing machine commonly known as “Press
Machine”. In this process the “Green Tyre” is cured under extreme pressure and
considerable heat using either mechanical or hydraulic press mould and gives the tyre
final shape. Smooth functioning of the press mould parts is critical to the final shape of
the tyre as the process lasts different minutes to few hours depending on the size of the
tyre. In General Tyre all curing machines are pneumatic.
Basically bladder curing is a special case of compression moulding. A bladder inside an
uncured (green) tyre pushes it against a hold mould surface. In general tyre we usually
used bladder curing. There are two type of pressing machines:
 Platen Type Press
 Dome Type Press
PLATEN TYPE PRESS is also called Bag-o-Matic type curing press. It is “Two Piece
Molding” press machine. This curing machine based on All Steam process. This type of
pressing machine used for light truck tyre and radial tyre. Design Parameters for platen
type curing machine based on All Steam:
 240 psi steam in bladder, Orifice opens.
 240 psi steam in bladder, Orifice closed.
 140 psi steam circulating in hollow plate mold.
This steam pressure full fills the external temperature requirement. Temperature of platen
surface is about 165 °C. Temperature of mold is about 158 to 160 °C due to resistance
during heat transfer. Dain valve open. Apply vacuum at 144 psi. Open the mold &
removed tyre.
DOME TYPE PRESS is also known as conventional type curing press. It is “Segmented
Molding” press machine. It is based on All Steam and Steam, Hot Water and Cold Water
curing process. This type of pressing machine used for tractor and bus tyres. Design
Parameters of Dome type curing machine based on All Steam:
 240 psi steam in bladder, Orifice opens.
 240 psi steam in bladder, Orifice closed.
Apply steam in dome, 140 psi. Drain valve open. Apply vacuum in bladder. Open the
mold & removed tyre. Design Parameters of Dome type curing machine based on Steam,
Hot water & Cold Water:
 200 psi steam in bladder, Orifice opens.
 200 psi steam in bladder, Orifice closed.
Apply steam in dome, 100 psi. Mold temperature 155 to 158 C. Non-circulating hot water
in bladder at 280 to 300 psi. Drain dome steam. Circulating cold water in bladder at 280
psi. Full blow down. Apply vacuum in bladder. Open mold & remove tyre.
FINAL FINISH is the last operation in the tyre manufacturing process after the tyre has
been cured.

 In this operation, trims the flashes or excess rubber from the tyre.
 Measurement the tyre uniformity where the tyre is automatically mounted on wheel
halves, inflated, run against a simulated road surface, and measured for force
variation.
 Measurement the tyre balance where the tyre is automatically placed on wheel halves
rotated at a high speed and measured for imbalance.
 Large commercial truck/bus Tyres, as well as some passenger and light truck tyres,
are inspected by X-ray machines that can penetrate the rubber to analyze the steel
cord structure.
 In the final step, tyres are inspected by human eyes for numerous visual defects such
as incomplete mold fill, exposed cords, blisters and blemishes.

SUGESSTIONS
 Automatic machines should be used instead of Manual machines to reduce errors and
defects.
 Safety measures should be taken in mixing department due to spreading of Toxic
gases and Carbon black e.g. Masks, Gloves and workers should wear full sleeves
clothes to avoid contact. Strictness should be implied for it.
 More Ventilation systems should be installed in Curing Department to control the
excessive heat.
 Lectures should be conducted for workers to create awareness about their work so that
they can work more effectively.
 Safety vehicles should be on standby in the premises of General Tyre to counter any
kind of harmful situation immediately.
 A student guide should be available who guide the students about the given plan and
also help them to visit the plant.
 Seminars should be arranged for workers to guide them about safety measures.
 Too much scrap is generated; it should be reused by company itself.