DISCHARGE DOOR:

It is operated by linear actuator by using hydraulic power pack. This

hydraulic power pack has one induction motor for pumping the oil.
The discharge door open or close by means of PLC signals (when the
motor attains the certain energy). There are 2 proximity sensors are placed near by linear
actuator for open and close the door.

LATCH ASSEMBLY:
The latch holds the discharge, when it is in closed position. Here, 2
proximities or 2 limit switches for latch operation. These sensors or limit switches are
also gives input to PLC.

BATCH OFF MILL:

When the discharge door opens, the indication lamp will glow nearer to
mill for operator indication. The mixed compound is dumped to mill. The mill blends
that compound and makes thick rubber sheets. The mill is rotated by 3phase induction
motor.

TAKE OUT CONVEYOR AND DIP TANK CONVEYOR:

The rubber sheet in mill is taken by take out conveyor. This conveyor gets
up and down movement by means of pneumatic cylinder, which is operated by hand lever
directional control valve.
The rubber sheets are dipped in soap solution, and then it becomes non
stick. The take out conveyor and dip tank conveyor are operated by an 3 phase induction
motor.

COOL RACK CONVEYOR:

The dipped sheets from dip tank are passes to cool rack conveyor. The
cool rack conveyor contains number of bars.
Diameter of each bar = 3cm
Distance between two bar = 9cm
No.of fans = 30
The cool rack conveyor can be operated by DC motor or AC motor, but
drive is required for vary the speed. The master batch rubber sheets are taken by take up
conveyor. The final batch rubber sheets are taken by wig wag conveyor.
Both this conveyor motors are working by photo sensor which is inside the
cool rack system. It senses the rubber sheets and gives the signal to PLC. Then the PLC
starts either the wigwag conveyor or take up conveyor motor according to batch.
When we switched off the dip tank conveyor, the signals stop the cool
rack conveyor and wigwag or take up conveyor. At the wig wag stacker changing time,
the operator switch this conveyor, but the cool rack is in ON condition. At this moment
the timer starts ON. Before the predetermined time, the operators have to change the
wigwag stacker.
After placed the stacker the timer off, then the conveyor becomes ON.
This process will continue.
MOTOR RATINGS:
Sl.No Motors Voltage Current(Amps) Power RPM

1. Carbon charger 415 1.8 1KW 1410

2. Weighing conveyor 415 3.3 1.5KW 1400

3. Oil charger 415 3.4 1.5KW 1400

4. Hydraulic power pack 415 7.9 5HP 1440

5. Batch off mill 415 256 200HP 990

6. Take out conveyor 415 2.5 5.5KW 1440

7. Cool rack conveyor 415 2 1HP 1405

8.
Cool rack fan motor 415 2 0.75KW 1440

9. Wig wag conveyor 415 1 5.5KW 1445

10. Auto stock loader 415 3.4 1.5KW 1400

EXTRUDER
 Extrusion is the process of forcing a material through which an opening (die) to
get a definite continuous shape. The machine used for this purpose is known as Extruder.

Parts of Extruder:
1) Feed box
2) Screw
3) Barrel
4) Head
a) Flow channel
b) Wedge
c) Performer
d) Die
5) Removable liner.

Auxiliaries:
1) Cracker mills
2) Feed mills
3) Transfer conveyors
4) DC motors
5) Induction motor
6) Gear box
7) Skiver unit
8) Weighing conveyor & scale.

Type of Extruder:

Extruders

Cold feed Extruders Hot feed Extruders

Smooth barrel Extruder

Pin barrel Extruder

HOT FEED EXTRUDER:

The compounds are preheated in the upstream mills before feeding to
extruder in strip form.

COLD FEED EXTRUDER:

 The cold compounds which are not been preheated in the mills are feed to
Extruder. In perambara plant, they are using Hot feed extruder for preparing tread and
sidewall.

PARTS OF TREAD:
1) Cap
2) Base
3) Cushion

For preparing cap, the cracker mill and feed mill are used to preheated
that compound, then feed in Extruder machine. In base preparation, we are using another
set of cracker mill and feed mill.

CRACKER MILL;
The final batch (rubber sheets) from Banbury is fed to cracker mill. It
blends and heated that compound at particular temperature and feed to feed mill by using
transfer conveyor.
It has two rolls. One is smooth surface roller and another one is grooved
surface roller for removing air bubbles in rubber sheets.
The grooved roller is driver and another one is driven. These rollers are
centrally drilled for cooling purpose by using chilled water, at particular temperature.

Size of mill = 84 X 26 inch

It produces friction up to 70-800 c. A 3 phase induction motor and its gear

box are used to rotate the rolls by bull gear mechanism.
 Gear box ratio = 9:1
 DOL starter is used to start the induction motor.

Mill motor switches:

1) Start
2) Stop
3) Jog forward
4) Jog reverse
5) Emergency switch

FEED MILL:
The compound from cracker mill is blend and heat by this feed mill at
particular temperature, then feed to Banbury’s hopper. This feed mill has one blender on
top for blending the compound very well.
The feed mill rollers have smooth surface. It has one blender roll on top
for blending the compounds very well. It is operated by an separate induction motor.
Two knifes cut the rubber sheets from roller and it is taken by transfer
conveyor then feed to hopper at specify width and thickness according to specification.

 Gear adjustment lever is provided for adjusting the roller clearance.

 Safety rope for operator safety while the accident occurs.
Mill motor switches:
1) Start
2) Stop
3) Jog forward
4) Jog reverse
5) Emergency switch
 PLC operates the switches command.

TRANSFER CONVEYOR:
The transfer conveyor is used to transfer the compound from cracker mill
to feed mill. From the feed mill it is transferred to Extruder feed box.

 10” Extruder = for cap preparation.

 8.5”Extruder = for base preparation.
 Small 2 roll calender = for cushion preparation.

EXTRUDER MACHINE DETAILS:

Make = Farrel, UK
Size = 8.5” &10”
Head temperature = 1600C
Screw type = Single flight.
FCW pressure in barrel = 100psi
Cooling medium = Chilled water or FCW
Preformer & Die clamping pressure = 600kg/cm 2
Preformer & Die clamping pressure = Hydraulic (Air driven pump is used to pump
the oil).

81/2” EXTRUDER:

Size = 8.5”
Screw diameter = 8.5”/8.499”
L/D ratio = 4.5:1
Output = 4,500Lbs/hour
Max. Operating speed = 5-15 MPM
Max. Screw speed = 76 RPM (It will vary according to spec).
Max. Screw clearance = 0.018”
Min. Screw clearance = 0.013”
Approximate water consumption = 35gal/min
Approximate steam consumption = 20Lbs/hour
Type of motor = DC shunt

MOTOR RATINGS:
RPM = 1150