THE GENERAL TYRE AND RUBBER

COMPANY OF PAKISTAN LIMITED

INTERNSHIP REPORT
BY
REHAN AAMIR BHATTI
HASSAN KHALID
&
WASSEM ABBAS
STUDENTS OF PLASTICS TECHNOLOGY
CENTRE 4TH (FINAL) YEAR
B.E POLYMERS ENGINEERING

Submission of report to Mr.MOIZ SARWAR

(Head of Compounding Department) on 14
April 2014
 Acknowledgement
ALHAMDULILLAH for four weeks we undergo our
internship that begins on 19th of March 2014 till 15th
of April 2014, we successfully completed our
Internship. We would like to extend our admiration to
our internship advisor Mr. Khalid Khan for their
advices and generously guiding us through while we
were training in General tyre as an Internee. All the
staff working at General Tyre, We appreciate their
kindness and sharing knowledge when we were
training here.
During these 4 weeks we were learnt many new things
which are very precious for us to learn and carry out
with affection when we start working as professionals
in the future. We also realized that learning
theoretical is never the same when it comes to
practical work. There is a lot more to experience than
learning from the book. We also realized the
importance of team work while working with a well
established organization. We also learnt that time is
an important factor for the development of an
organization. As we know that the world of
professionals is a completely different phase
compared to the time when we are studying, therefore
by going on an industrial training program we hope
and pray that we will be well prepared and have self-
belief to serve the industry.
The General Tyre and Rubber Company of Pakistan
Limited (Gentipak) is Pakistan‘s premier industry. It was
established in 1963 by General Tire 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 produce tyres of
“GENERAL” brand and provides the latest technology for
production of tyres based on Continental’s, R&D.

Gentipak is a public limited listed company with majority

shares held by Bibojee Services Ltd., Pak Kuwait Investment
Company (Pvt) Ltd. and National Investment Trust.

The Plant and the Offices are located in suburb of Karachi.

Initial production capacity was only 120,000 tyres per annum
but is now around 2,000,000 tyres per
annum. Our plant is constantly upgraded and is equipped
with the most modern technology in tyre manufacturing.

Vision:
To be the leader in tyre technology by building the Company’s image through
quality improvement, competitive prices, customers’ satisfaction and meeting
social obligations.

The awareness of the “GENERAL” brand name is very high.

Recently, Gentipak has also launched a new line of passenger
car tyres of latest European designs under the brand name
“EURO”. All the radial tyres are tubeless and steel belted and
have a full cap ply for safety and durability.
Gentipak produces radial tyres for passenger cars and light
trucks in rim sizes ranging from 12” to 16”. It also produces
bias (cross ply) tyres for light trucks, trucks/buses and farm
(agricultural) tractors.

Gentipak is the major supplier of tyres to the local

automotive and tractor assembly plants. It has contracts to
supply 15” radial passenger car tyres to Toyota and Honda
approved after stringent testing by their principal companies
in Japan. Beside above, Gentipak is also supplying tyres to
Pak Suzuki Motor Company, Hino Pak, Ghandhara
Industries, Ghandhara Nissan, Al-Ghazi Tractors, Millat
Tractors and others.
 Gentipak is also exporting tyres to few neighbouring and
Middle East countries. It is currently exploring other markets
as well for export.

Gentipak employs directly and indirectly approx. 1800

persons all over the country. It has offices in three other
cities of Pakistan besides having its Head Offices in Karachi. It
is selling its products in the replacement (after) market
through a network of more than 100 dealers and has a
backup in the shape of sales and technical force covering the
entire territory.

All tyres produced by Gentipak are marketed after stringent

testing and quality assurance and backed up by a
comprehensive after sales warranty.
 MANAGEMENT

Lt. Gen (Retd) Ali Kuli Khan Khattak

Chairman

Mohammad Shahid Hussain

Nasser Kamal Asif Jameel Ashraf Teli Hussain Kuli Khan

Chief Operating
Executive Director Executive Director Chief Financial
Officer
Marketing & Sales Corporate Affairs / HR Officer
(Plant & Projects)

Brig (Retd) Najam uz

Sarfraz A. Zahid Muhammad Amin Khan Jeelani Baig
Zafar

Group Resident
General Manager - O.E & Sr. General Sr. General Manager
General Manager -
Government Sales / CS Manager Works Corporate Services
Islamabad

Muhammad Arshad
Raashid I. Malik Zubair A. Mufti Mussarat Ahmed
Ansari

Head of Internal Div. Manager

General Manager Sales General Manager Finance
Audit Industrial Engineering

Tariq Soulat

Div. Manager
Administration
 Raw Materials:
 Rubber Industry
 Textile Industry
 Chemical Industry
 Steel Industry

Rubber Industry:
Natural Rubber:
Latex is obtained from tree called “Hevea Brasiliensis”. Cuts are made in the
tree’s core (cambium) where the rubber is stored; Slanted cuts from left to
right side of 10 to 20 degrees are made.

Natural Rubber is obtained from latex by co-egulating with different Chemicals

e.g. Oxalic, Citric or Formic acid.

In latex the quantity of rubber is 35% and the rest is serum.

Synthetic Rubber:
Elements or Compounds of various synthetic materials, similar to natural
rubber, made by polymerizing Unsaturated Hydrocarbons, such as Isoprene
and Butadiene.

General Tyres are using NR, SBR (O.E),(W.O.E),PBR, IBR, BBR.

Textile Industry:
In GTR Nylon and Polyester fabric are imported from approved sources of
Continental AG (Germany).

Chemical Industry:
The chemicals used in General Tyres according to specific requirements are:

Peptizing Agents, Plasticizers, Carbon Black(filler), Bonding Agents, Organic &

In-Organic Activators, Extenders, White Fillers, Vulcanizing Agents(Sulphur),
Accelerators, Retarders, Mould Release Agents(Silicon).
Steel Industry:
Steel cords (Brass coated) are used In General Tyre for the formation of Bead
& Steel Belts.

Components Of A Tyre:

Radial Tyre Bias Tyre

• Tread – it is thick layer (approx. 18-20 mm) of rubber which comes into
contact with road.

• Rib – it is designed for noise suppression.

• Grooves – to traction in all weather, directional control, cool running
and all rolling resistance.

• Sips – serves as the support for the wheel moving on the road.
• Shoulder – upper portion of the side wall just below the tread edge
that affects tyre heat behavior and cornering characteristics.

• Cap Plies – main load baring components layers of fabric cord

extending from bead to bead to reinforce the tyre and maintain the
shape.
 • Steel Belt –located below cap plies to increase tensile strength of
tyre. steel belt or layer provides well balanced combination of rubber &
fabric. Thickness is 0.2 to 0.38 mm. this are the steel cord plated with
copper or zinc.

• Radial Plies – thin layer of rubber inside the tyre containing

compressed air tube.

• Sidewall –portion between tread to bead. it is rubber sheet 1.5 to 3.5

mm thick protecting tube from any kind of mechanical or physical
damage and moisture penetration.

• Bead Chafer – narrow strip of flex material around the outside of

the bead that protects tyre against wear & tear and prevent dirt and
moisture from getting into the tyre.

• Bead – structure composed of high tensile strength steel wire which

holds the tyre assembly onto the rim of the wheel for handling
performance.

• Inner Liner – The Inner liner is the air retaining member and is usually
calendared as a two layer laminate having stepped edges. Usually
thickness=2.5mm

• Breakers- . These are fabric plies placed directly on the upper-most

ply beneath the tread rubber. They disperse stress throughout the tyre.

Rubber Compounding:
The objectives of rubber compounding may be essentially defined as
providing optimised performance and process ability, generally at
minimum cost, by the incorporation of non-rubber ingredients.
Optimised performance in this context refers not only to mechanical
properties but also, for example, resistance to bacteria or particular
chemicals. In some applications a rubber may also need to be
coloured, or bonded to another material, and further ingredients
may be required. For many years, rubber compounding was largely
empirical and frequently described as a black art. Today it is
practised predominantly on the basis of scientific principles
Elucidated over years of study and is still the subject of intensive
research.

Properties Of Different Rubbers:

Properties NR SBR Poly Butyl Neoprene Nitrite Silicone
butadiene
Tensile E P P F G P P
Strength
Tear Strength G P– E G G G F
F
Abrasion E G– E F–G E E F
Resistance E
Heat G G G G–E G G E
Resistance
Impermeability F G P–F E G G F
Flame P P P P E E F
Resistance
Aging P P P–F G–E E E E
Resistance
Acid G F– G E E G G
Resistance G
Solvent P P P P G G G
Resistance
Animal + P– G P–G E G G G
Vegetable oil G
Resistance
E = Excellent, G = Good, F = Fair, P = Poor

The various ingredients may be classified according to their specific function

in the following groups [2]:

 fillers (carbon blacks and non-black fillers);
 plasticized and softeners (extenders, processing aids, special
plasticizers);
  age resistors or antidegradants (antioxidants, antiozonants, special age
resistors, protective waxes);
 vulcanizing and curing ingredients (vulcanizing agents, accelerators,
activators);
 Special-purpose ingredients (colouring pigments, blowing agents, flame
retardants, odorants, antistatic agents, retarders).
However, many ingredients are capable of functioning in more than one
manner.

Creating A New Compound:

When creating a new compound there are three main criteria compounders use
to guide them. Listed in order of importance they are as follows:
1. Customer requirements
2. "Process ability"
3. Cost
Nearly all new compounds are modifications of some existing formulations.
Nowadays, development of a completely new compound is seldom attempted.
Moreover, such an attempt is usually unnecessary. In order to be efficient and
effective in rubber compounding, chemist should take full advantage of technical
information readily available inside as well as outside of his organization. He must
be analytical, resourceful, and innovative.

The Following Is A Useful Procedure To Guide Compound

Development:
1. Set specific objectives (properties, price, etc.)
2. Select base elastomer(s).
3. Study test data of existing compounds.
4. Survey compound formulations and properties data presented by material
suppliers in their literature.

5. Choose a starting formulation

6. Develop compounds in laboratory to meet objectives.
7. Estimate cost of compound selected for further evaluation.
8. Evaluate process ability of compound in the factory.
9. Use compound to make a product sample.
10. Test product sample against performance specification.

Five Main Systems:

Compounding can be broken into five main systems as follows:
1. Elastomer System:
 One or more elastomers for characteristics
 Elastomers for improved processing
2. Filler System:
 Reinforcing filler
 Semi and non-reinforcing fillers
 Plasticizers
3. Protectants
 Antioxidents
 Antiozonants
 Inhibitors/Promoters
4. Processing Aids
 Mixing Aids
 Modling Aids

5. Cure System
 Vulcanizing Agents
 Activators
 Accelerators
 Scorch retarders
One important detail to note is that nearly all compounders use the unit of
measure of "parts per hundred" (PHR) for their formula. This is a unit of
weight for the relationship between the elastomer system and the other
systems. If we always utilize 100 parts of elastomer for all formulas then it is
much simpler to change the other systems to create changes and different
formulas.
 Manufacturing Of Tyre

Tyre manufacturing is a complex process which involves various steps which

are as follows:

 Mixing
 Calendaring
 Side wall and Tread Construction(Extrusion)
 Bead construction
 Green tyre making
 Tyre curing
  Flash trimming
 Final inspection and testing

Mixing:

Just like selection of rubbers & additive, mixing is necessary to achieve desired
properties and performance of a rubber product. It is also important to know
how these different ingredients should mix i.e. procedure of mixing, time
duration, temperature, energy consumption, batch weight etc.

In General Tyre we visited Mixing department under the supervision of Mr.

Abdul Bari who guided us about the mixing operation for different
components.
There are three basic techniques of mixing a rubber compound.

 Conventional method.
 Late oil addition method.
 Upside down mixing method.

Conventional Method:
In this method, rubber is first grinded and dry ingredients are added and then
oil is added after ingredients are well dispersed. This method achieves a
homogenous dispersion of all ingredients, including filler of very small particle
size. However mixing time required is long. In a conventional mix low polymer
content is difficult to mass at the start of the cycle simply because so little is
present.

Late Oil Addition Method:

In this case also rubber is grinded first and oil is added after addition of dry
ingredients. This method is used when highly viscous oils are used.

Upside-Down Mixing Method:

This is the fastest and simplest way of mixing. It is specially efficient and
effective for those compounds containing a large volume of plasticizers and
large particle size fillers.

In this method all dry ingredients are added first, then all liquids and finally all
rubber on top. This method is not suitable where small particle size fillers are
used, or high loading of oil is used & rubber of high Mooney viscosity is used.
Conventional and late oil addition cycles are most often used with polymers
having good self adhesion.

Two Stage Mixing:

Premature vulcanization of a rubber compound, scorch, can occur if the
reaction temperature of curatives is reached before time.
Breakdown of rubbers and incorporation of different ingredients require high
temperatures and long duration. That is why a master batch is mixed first, is
cooled and allowed proper aging before curatives are added in the 2 nd stage
which is done at lower temperatures and for shorter duration.Proper Aging (2
to 4 hrs) of all master & finished batches is necessary so that all reactions that
take place during mixing are completed & stabilized.

Mixing Equipment:

1. Mixing Mills:

These are open two-roll mills of various sizes ranging from 13"to 84", for batch
capacities.
Front & back rolls have either same friction ratios or are different depending
upon usage. The gap/nip between the two rolls is adjustable. The back roll
usually runs faster.
The surface of these rolls is made of specially treated steel for corrosion &
scratch resistance. The rolls are hollow from inside for cold/hot water/steam
circulation through pipes or directly from one end to other.
The rolls are heated for easy breakdown of compound & cooled to avoid
scorching. The temperature of the rolls and gauges and other specification is
given by compounding department of general tyre.

2- Internal Mixers:

The basic concept of mixing is the same in an internal mixer as is with the open
rolls i.e. the rubber is broken down in between two rolls running in opposite
direction at different speeds. In this case there are two spiral-shaped rotors
enclosed in a chamber where mixing takes place with water cooling
arrangement for rotors, casing, drop door and ram.

A hopper is at the top to receive compounding ingredients for mixing, an air

operated ram is there to exert pressure on the batch and to prevent it riding up
the hopper. A door is at the bottom for discharging the mixed batch. A
thermocouple is attached either at the rotor end frame of the chamber or at
the drop door to indicate the temperature at which the mixing is carried out at
different stages.
 Probable flow lines
and filling
configuration of an
internal mixer

Banbury 2-wing
Principal components of an Internal Banbury 4-wing
Rubber Mixer Shaw intermix 3-wing
Werner & P.Fleiderer4-
wing

Mixing Process:

It is the first step in developing product for tyre. Rubber sheets are made by
mixing of rubber and different ingredients. In General Tyre making is carried
out by by Banburry (Internal Mixer) HF-270. The specs of mixing is different for
each component e.g. temperature, pressure, time duration, energy.
There are different ingredients used in making of rubber compound for tyre.
Most probably we use rubber and other is filler. Many types of filler are
present but in tyre manufacturing different grades of carbon black are used for
making different compound for different objectives and carbon filler provide
higher strength and used due to black colour of tyre standard.

Standards Of Rubber:
There are major standards of rubber in the world.
 ISNR(Indian Standard Natural Rubber)
 SIR(Standard Indonesian Rubber)
 SLR(Standard Lankan Rubber)
 SMR(Standard Malaysian Rubber)
And all these standards sub divided in two standards depends on quality
i.e. grade 10 and grade 20.
(Grade 10 is more efficient than grade 20 in finishing and
smoothness whereas grade 20 is not much more efficient in all
these properties).
In GTR, four major rubbers are used for different application such as Natural
rubber, Styrene Butadiene rubber (Oil Extended, Without Oil Extended), Poly
Butadiene rubber (PBR) and Butyl rubber (Halogenated Butyl rubber), first
three used for tread and sidewall. Butyl rubber is used for inner liner in radial
tyre and for tube purpose because it has a property of air retention.
There are two steps for mixing operation first we make “Master” and then
“Finish”.

Preparation Of Master:
In preparation of master batch there is no addition of cure package. In master
batch making, rubber, filler and some processing aids are used in Banbury
mixer (HF-270) at (170-180 °C) and create a master batch of 200 to 240kg of
rubber compound in three minutes. In Banbury operation different carbon
grades (Furnace Black) silo (carbon bags) are attached to the Banbury mixer
and used according to given specs. The temperature is very high that’s why
cure package is not added during this process. Then this batch is placed for 2 to
4 hours for Aging.

Preparation Of Finish:
Master batch is used for finish process at a temperature of (110-115 °C) the
addition of cure package such as Sulphur, Accelerator and different curing
agents with specific recipes. There are two types of Sulphur used (Oil treated
and Without Oil treated). And oil is used as Plasticizer (547 highly paraffinic
oil). After mixing the compound, passes to the Permol solution for providing
protective layer and avoid it to stick to each other.

Mixing Steps:
The following steps for mixing are done in a Banbury.
 The Feed door is open and feed is entered through conveyers.
 Then Feed door is closed and ramp moves downward and exerts
pressure on feed and rotors rotate at a set rpm for mixing action.
 Now Ramp moves upward and door opens and carbon feed enters and
then door closed and ramp again moves downward and mixing starts.
 Again ramp moves upwards, oil feed enters (plasticizer) and door is
closed.
 Ramp moves downward and mixing continues.
 When mixing is done, door opens and mixed compound drops on the
dump mill.
EQUIPMENTS USED IN GENERAL TYRE FOR MIXING PURPOSE:
  F-270 BANBURY MIXER (4 wing rotor)
 HF-270 BANBURY MIXER (2 wing rotor)
 KNEADER-1 (KN-1) (2 wing rotor)
 KNEADER-2 (KN-2) ( 2 wing rotor)
HF 270 and f 270 is used for making master batch because master need very high
temperature where as finished is made on F-270, one major drawback in HF-270
is that we cannot change its parameter with respect to our specification and
requirement, but in f 270 we have no drawback because its parameter changes
with respect to our requirement so that’s why we make master as well as finished
in F-270.

Kneader:
The kneading reactor is a horizontal mixing machine with two Sigma, or Z-type
blades. These blades are driven by separate gears at different speeds, one
running 1.5 times faster than the other. The reactor has one powerful motor
and a speed reducer to drive the two blades. The kneader reactor usually has a
W-type barrel with a hydraulic tilt that turns it, and a heating jacket outside. In
General Tyre Kneader is used for making Finish batches.
 Components Manufacturing:

Extrusion:
Rubber extruded products will differ from
moulded rubber products based on the process where
extruded parts are forced through a die of the required cross
section under pressure of an extruder, this process is called
extrusion.
There are two types of extruders used in GTR.
 Dual Extruder
 Triplex Extruder
Dual Extruder:
A machine in which two hoppers are connected to produce two components
of a product. It is a hot feed extruder.

Mr. Osama and Mr. Akhter guided us a lot about the operation of Dual
extruder.
The operation consists of following steps:
 Breakdown mill
 Holding mill
 Feeding mill
 Hoppers
 Two screws of different sizes
 Die

Process:
Finish sheets of rubber from mixing depart are subjected to Breakdown
mill, holding mill then feeding mill. In feeding the gauges are set(according
to required specification). The three roll mill setup is ideal for hot feed
extrusion. Sheets from feeding mill go into hoppers through conveyers. Two
different sizes of screws are used for extrusion (i.e. 8 ½” & 10”). “Y-head”
die is used. The screws move with different rpm according to required
specification. Compound is extruded from the die. After extrusion through
the die cushion compound is applied if required from separate cold feed
extruder. The extruded part then passes through the cooling line by
conveyer belt. After cooling the automatic running cutter cuts the part
 according to the given sizes. After cutting the part is booked in a shafered
truck.

Triplex Extruder:
Triplex is a machine which can extrude three components of a product at a
single time. It can also work as dual extruder for inner liner, side wall extrusion.
It is a cold feed extruder.

Process:
Feed is conveyed by conveyer belt to three hoppers. These hoppers are
attached to their respective barrels and the extrudates which are extruded
through die. Self skiving is done. Then the extrudate part passes through
dancing rollers which maintains the tension in it. Then to the weighing
conveyer for weighting and also this function is done by camera sensing
weight. Then the part is set for chilling and chilled in a zig zag manner. After
cooling, the automatic running cutter cuts the part according to specification.
Then part is booked in shafered truck.

Triplex is used for the extrusion of sidewall and tread of passenger car and light
truck tyres in GTR.

Extrusion Temperatures:
The temperature of the extruded treads shall be measured with a Pyrometer at
the centre line of the tread and sidewall.

Booking Temperatures:
A needle Pyrometer shall be used to determine the temperature of cooled
treads and sidewalls at the thickest temperature.

Treads and sidewalls shall be air blown so as to be completely free form water
before booking.

Calendaring:
Calendaring is a very important process in tyre building because the plies used
in a tyre gives strength to tyres are made by calendaring.

We visited calendaring department under the supervision of Mr. Nusratullah

who guided us about the technology and the procedure of calendaring.
 Four Roll Or Z Calendaring:
In this process, tyre cord fabric coated with rubber on both sides passes
through four rollers known as “Four roll calendaring” or “Z calendaring”.

Major Raw Materials:

Rubber:
 Natural
 Synthetic
Fabric:
 Nylon(for bias tyres)
 Polyester(for radial tyres)

Procedure:
 Let off unit
 Splicing unit
 Tensiometer unit
 Pre cure tension unit
 Banana rolls
 Trimming unit
Rubber is feeded to four roll calendar through following process.
Calendaring Mills:
 Breakdown mill
 Warm up mill
 Feeding mill
 Holding and Blending mill
After coating with rubber on both sides of fabric.
 Perforater
 Post calendar
 EPI(ends per inch)
 Cooling down
 Accumulator unit
  Windup
 Storage
Every fabric procedure is done by specification given by compounding
department.

Three Roll Calendaring:

 Two mills are used in this process one is for blending (XM-12) and
second is for feeding (XM-11).
 Then passes through conveyer belt to 3-rolls which as direction 1 s t and
3rd moves in clockwise direction and 2 nd roll moves in anti clockwise
direction.
 Four gauge knives are used for cutting.
 These three rolls are heated by a steam and the temperature of these
rolls is above 100 degree Celsius.
 Here after cutting there are four rolls for accumulation and for cooling.
 In this process tensionative rolls are used to produce tension.
 A wind up table is used for winding.
 There are four rolls at a time two rolls are in working and these two are
completely fills next two rolls ready for winding.
 These rolls are subjected to temperature of 45-50 degree Celsius.
 These winded rolls again let off for the pasting of squeegee layer.
 Squeegee layer is used because it has high air permeability.
On three roll calendaring process GTR produce inner liner for the radial
tyres.
 Steelastic Area:
Steelastic area produces steel belts which are used in Radial tyres.

 High tensile brass coated steel cords areused in theconstruction of tyrebelts.

 The brass coating is done to makerubber adhere to the steel.
 The storage of these brass coated steel cords is in a temperature and
humidity controlled environment which is called “Creel room”.
 The temperature is kept around 27 degrees Celsius and humidity around 30%.
 Dueto moisturecorrosion can occur whichmay causethesteel cord to loseadhesion
with rubber.
 The steel wire passes from the creel room through rollers.
 Then thesewires are coated through crossheadextrusion with rubber.
 Ensureproper penetration of rubberbetween thecords and desired adhesion
between rubber and steel.
 Cooling drums cool down thecoated strips.
 Cutter cuts the belts at required angleand length according to specification.

Winder assembly windsthebelts which then go into storage area.

 Bead And Band Manufacturing:
Bead Manufacturing:
Tyre bead wire used for the reinforcement of virtually all
types of pneumatic tyres such as trucks, buses, passenger
cars, jeeps, OTR equipment, farm equipment, motor cycles,
scooters and cycle tyres. The main function of the tyre bead
wire is to act as reinforcement and it helps to get a proper
grip of the tyre on the rim. The type of tyre and structure of
bead rings used, determine the size of bead wire.
We visited this depart under the supervision of Mr. Imtiaz
who guided us about different procedures.
Band Manufacturing:
Band is a set of plies utilized in tire building.

 Plies are cut according to the circumferential sizeof tireand at an angle.

 The plies are built at oppositeangles forming crisscross pattern.
 Band is built according to theply rating of the tire.
It is distinguished by two types
 Tractor
 Truck/Bus

Band Building sections of fivemachines:

 BB-1
 BB-2
 BB-3
 BB-4
 BB-5
These machines consist of two rollers which press multiple plies together with
help of pneumatic pressure.
There are three types of bands made:
1. First band - 4 plies, breaker and drum squeegee assembly.
2. Second band - Only plies
3. Third band – 2 plies and 2 breakers
 Tyre Building:

In this department the components are assembled to form “ Green Tyre”.

We visited this department under the supervision of Mr. Akhter. The staff
working in this depart are very friendly and co-operative.
In this department following green tyres are built:

 Passenger Car (Bias and Radial both)

 Light truck
 Truck, Bus tyres
 Farm Tyres
 Rickshaw Tyres

Radial Tyre Building:

The Radial tyres built in General Tyre are

 Euro Star
  Euro Komfort
 Euro Glide
 Euro Tycoon
 Euro Kompact
 ST. Radial
 XP 2000 II

Radial tyres are built in two stages

1st Stage Assembly “Carcass”:

The tyre carcass is built on an assembly drum. Components can be added for
example in the following order:

 Inner liner
 Body ply
 Beads
 Sidewall

In General Tyre the assembly drum used in 1-stage assembly consists of a

shaping bladder and rotating drum.

 Beads are fitted onto the drum using specific bead applicators.
 By inflating the shaping bladder, the stretching of the tyre carcass
begins. Whilst this is being done, the distance between the beads
shortens.
 In the stage sidewalls and bead area components are stitched.
 After the shaping bladder has been deflated, the tyre carcass can be
taken off the drum.

2nd Stage Assembly “Green Radial Tyre”:

The components fitted in this assembly stage:

 Belt Package
 Cap Ply
 Tread

The Carcass is placed on a regular assembly drum.

 The tread and belt package is stitched carefully onto the tyre carcass.
  The stretching pressure is released from the tyre carcass, and the green
tyre is taken off the drum and moved to intermediate storage.

Bias Tyre Building:

 In the construction of bias tyreply cords extending frombead to bead are at angle of
30 to 40 degrees.
 In bias tyrebuilding thereis only singlestage.
 Plies are at opposing angles laid over each other to form a crisscrosspattern on which
the tread is applied.
 Thereare currently six tyrebuilding machines for Bias construction in GTR. These
machines areold and somearetotally 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 (Breakerareused in bias tyreto give morestrength)
  Breakers to beused are dependent on the type of tyremanufactured i.e. truck/bus,
tractor.

Tyre Curing:

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

(hardness and strength and elasticity)
‘CURING’ is the process where the shape of the tyre is set under extreme
pressure and considerable heat using either mechanical or hydraulic press
mould. Smooth functioning of the press mould parts is critical to the final
shape of the tyre as the process lasts form 11.5 minutes to few hours
depending on the size of the tyre.
In General Tyre all curing machines are pneumatic.

In this department we learnt a lot from Mr. Aziz Ur Rehman, Mr. Asad and
Mr. Subhan.
 Curing Department:
Rubber product has to be cure either through moulding or by other means,
either at room temperature or at elevated temperature.

Moulding is an act of shaping the green (uncured) rubber into a cured product
of required geometry by using a mould.

Green tyre is lubricated internally and externally. This lubricant helps in mould
releasing.

Bladder Curing:
Although used for many several different products but most widely used in
tyre manufacturing.

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 types of curing

 All Steam curing

 Steam and Hot water curing

The difference between all steam and hot water is just that all steam need
very less time for final curing than hot water but the drawback in all steam
is that it require very finished green tyre because a slightly unfinished green
tyre if cured by all steam, the steam cannot recover the unfinished, but in
Hot water this thing cannot happen it will take a long time but can recover
all the losses in green tyre.

 Also there is a test name T20 that indicate that how much time required
for curing of any size or compound for tyre.

The Steps For All Steam Curing Are:

 High pressure steam enters at 240 psi and at temperature 206 C, and
then drain out.
 Low pressure steam enters at 140 psi and at temperature 186 C and
then drain out, here we suddenly use low pressure because
temperature comes down gradually so that to avoid degradation and
maintain stability.
 Then introduce vacuum of 5 inches of mercury and generally mercury
we used because mercury is the high density and viscosity element.

The Steps For Steam + Hot Water:

This is also same as all steam but the difference is,

 Firstly we introduce steam at a pressure of 200 psi/inch and at

temperature 198 C, and then drain out.
 Then hot water introduce at a pressure of 250 psi /inch and at
temperature of 166 C and then drain.
 Then cold water introduce at a pressure of 250 psi/inch and at
temperature 32 C, just because to maintain stability and avoid by
degradation because cold water brings temperature gradually.

There are two types of machines by which we cures,

1. Dome type (batch).

2. Platten type (continuous).

The major difference is that in dome type, steam flows at specific time so
that afterwards temperature becomes low whereas in platten type steam
 flows continuously but here we have no option for setting time but in dome
type we have.

Platten curing time is faster than dome time.

Moulds For Machines:

There are two types of mould which are used in GTR,

 Segmented mould (latest)

 Two piece mould (older)

We can make more than one part on segmented mould but in two pieces we
cannot. Segmented mould is more beneficial than two piece mould because at
the time of curing we have to keep tyre dynamics, uniformity and disturbing
values in our mind, In segmented type mould itself moves towards green tyre
so our values cannot changed and maintain as they was, but in two piece type
our green tyre moves towards mould and there is a big chance of changing a
uniformity, dynamicity of a tyre and our tyre also be off cure.

Motorcycle Tyre Department:

Motor cycle department is the latest department in General Tyre. It was
started in 2012 because General Tyres is considering the production of
motorcycle tyres as it looks to expanding its production line.

This depart is equipped with all the latest machinery setup and we visited
this department under the supervision of Mr. Kaleem.
 Motor Cycle Plant:
General tyre is making different sizes of tyres of motorcycles which are,

Design Hyper Sonic

Available sizes 2.25 - 17F

Load Range C

Description Front tyre for excellent grip.

Design Hyper Sonic

Available sizes 2.50 - 17R

Load Index C

Description For better and comfortable ride

 .

Design Duro Grip

Available sizes 2.25 - 17F

Load Index C

Rib type pattern provides excellent

Description
road grip.

Design Duro Grip

Available sizes 2.50 - 17R

Load Index C

Better fuel economy & cool

Description
running tyre.

Design Mustang

Available sizes 2.50 - 17R

Load Index C

Directional pattern tyre for

Description
excellent traction

.
 Design Tuff Rider

Available sizes 2.25 - 17F

Load Index C

New generation tread design for

Description
better performance.

Design Black Cobra

Available sizes 2.50 - 17R

Load Index C

Provides excellent floatation,

Description
powerful control.

Construction of a motor bike tyre is very simple as compare to any other rear
tyre or in simple words than a car or a truck tyre.

Bike Front Tyre Construction:

 1s t ply at an angle of 32 degree
 Then 2nd ply shorter than 1s t ply in size also at an angle of 32 degree.
 Then beat applied.(3 turn , 3 wire)
 At last tread is applied and then green tyre is sent for curing.
Bike Rear Tyre Construction:
 1s t ply at an angle of 32 degree
 Then 2nd ply shorter than 1s t ply in size also at an angle of 32 degree.
 Then breaker is applied just opposite to last ply.
 Then beat applied.(3 turn ,3 wire)
 At last tread is applied and then green tyre is sent for curing.

Curing Of Motorcycle Tyre:

Platen curing is used for motor cycle tyre .The process is same as for car or a
truck tyre but some specifications are changed i.e.

 Temperature of a platen is 175 degree Celsius

 Mould temperature is 65-69 degree Celsius
 Internal steam pressure 200 psi.
 Tube Department:
This is one of the oldest departments in GTR. Some parts which are now made
on the latest machines i.e. The Extruders, Curing machines on which flaps and
bladders are cured.

We visited this department under the supervision of Mr. Kaleem who guided
us about the formation of tube through a number of processes.
 Tube Department For Bias Tyres
In GTR different sizes of tube are made e.g. 12-4 , 450-12 etc. And bladder, flap
of tyres are also made.

Formation Of Tube:
Basically a tube is torus-shaped balloon made from an impermeable material,
such as soft, elastic synthetic rubber, to prevent air leakage. The tubes are
inserted into the tyre and inflated to retain air pressure.
In General tyre Butyl rubber is used for tube making and is extruded in a simple
extruder; first 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 it is feed into the hopper of extruder. The temperature of screw
is specified and fixed with respect to given specs. Then the extrudate exits
from a cone shaped die. The die is designed in such a manner that there is a
nozzle inside the die whose purpose is to spray a powder named “Soft Stone”
inside and outside the tube so that tube material should not stick with each
other. Now the extrudate i.e. the tube is passing through conveyer belt by
different process such that after powdering, we stick a Rapcon whose purpose
is ro remove powder from a part where we have to applicate wall, before this
Rapcon tube pass through chilling process so as to maintains its temperature
i.e. 56-60 degree Celsius. The tube is cut to desired size. Then tube is taken to
splicing unit and spliced by heating, by name we came to know splicing
purpose is to joint two ends of a tube. Then the spliced part is taken to chilling
unit and cooled at a temperature of - 9 degree Celsius. After chilling, air is filled
in tube to check the splicing joint. Then tube is taken to the ring unit. This is
done just to give a desired shaped for the mould of a curing machine.

Then after all this processes finally green tube is taken for curing and cured at
a temperature of 100 degree Celsius. The curing of tube is doing by steam
process.

Formation of Bladder:
Generally we say that bladder is 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 Flap:
Tyre flaps are used for two reasons.

 The first being any spooked wheel, to keep the spoke nut from rubbing
against the tube.
 The other, being a solid wheel, the flap, or liner is used as a precaution if
there is any scratch or imperfection in the rim, to 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 mould of a flap is in 3 parts.

Motorcycle Tube Manufacturing:

 The tube is made by Butyl rubber, and it is first blended properly
in some steps that are,
 First the Butyl rubber is blended in Dump mill.
 Then through conveyer, it is transferred to Feeding mill.
 Then it passes through Strainer (extruder type) that decreases its
viscosity.
 Then again through conveyer, it is transferred to Breakdown mill.
 After Breakdown it is transferred to Feeding mill.
  And then it passes through extruder where gauges are set
according to specs for final output, and also output is powdered
with Soft Stone Powder inside and outside so that layers should
not stick, that is die has a nozzle inside it that provides powder for
a tube.
 After the extrudate exits, it passes through Hot blowing (cooling)
and cut off to desired size.
 Rapcon paper is also pasted where the air valve is fitted (Hole
punch and Valve punch).
 Splicing is done.
 After splicing cooling is done.
 After cooling air is filled in tube for checking splicing joints and is
placed on a round cylinder to maintain shape.
 Finally the Green tube is sent for curing.
 After Curing final inspection is done and tube is sent to packaging
department.

Raw Material Ware House (R.M.W.H):

R.M.W.H receives, holds and releases material for operations and production.
The main responsibility of the R.M.W.H is to keep control of inventory so that
there is no material shortage. As rubber is main raw material required to make
a tyre and is currently imported, R.M.W.H purchases material from the
approved sources by Continental Tyres Germany and locally as well. This is
department is in direct link with the Production department.
We visited this department under the supervision of Mr. Abdul Bari and Mr.
Ubaid Haqqi who guided us the working process of R.M.W.H.

It is divided into three sections:

 Hardware Section
 Raw Material Section
 Scrap Sales Management Section

Hardware Section:
It is responsiblefor providing tools and machinesparepartsrequired for themaintenanceof
machine.

Raw Material Section:

Its responsibility is to issue raw material. Production Planning and Control

prepares a RMR (Raw Material Requisition) and sends it to R.M.W.H by AS-
400 system. R.M.W.H verifies the availability of raw material and dispatches
the material.
Scrap Section:

The purpose of scrap section is to ensure the sale/disposal of factory process

scrap material, obsoletespare partsand fixed assets.

Finish Good Ware House(F.G.W.H)

In this department, the finished goods, All the manufactured items stored and
are then supplied to the OEM’s and to the market dealers and retailers of
General Tyre and Rubber Company Pakistan.

We visited this department under the supervision of Mr. Zafar Lodhi who
guided about the sales of goods from GTR.
  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 donehere.
 They also collect the claimed tires.
 A warehousesheet is generated in theholding area when the tires are been handed
over to F.G.W.H.
 The sheet is verified and signed by warehouse supervisorbeforethetires are
let in the warehouse.
 A locking key system is used which means when tires arein the holding area, the
warehousegateis locked and similarly when tires arein the F.G.W.H,thegateto
holding area is locked.
 A Sales Invoiceis generated in thesales department when tires areto be dispatched
from F.G.W.H.
 In caseof transfer of tires to branch offices,a Transfer Invoice is generated.
F.G.W.H verifies the invoices and plans the logistics.

Utility House:
This depart provides all those parameters which are used in the manufacturing
of tyres for example Hot water, Cold water, Steam, electricity etc.

We visited this department under the supervision of Mr. Siddique Sheikh who
guided us about the operations of this depart.
Boilers:

This department fulfils all the requirements needed for tyre curing
purposes. It provides Steam and Hot water at specific temperature
pressure.
In GTR there are two boilers.

1. Train Boiler:
 18-tons capacity
 260 psi woking pressure
 40000 lb/hr flowrate
2. Deskon Boiler:
 22-tons capacity
 260-psi
 49000 lb/hr

Other Supplies from Utility House:

 Steam supply
 Hot water supply
  Cold water supply
 Standby generator
 Air supply
There are two compressor of 150psi and 100psi.
Two pumps for hot water and cold water feed.
Two generators of 735KW.
 Quality Control And Quality Assurance
Department:
Quality Control:
Quality is the main aspect. General Tyre and Rubber Company Pakistan are
very conscious and strict in maintaining the quality standards of their product
for Customer Satisfaction.

We visited this department under the supervision of Mr. Abid Raza who
guided us the various tests performed for maintaining quality standards.

Quality Control includes indoor Product Inspection, where every product is

examined visually, and often using a Stereo Microscope for fine detail before
the product is sold to external market. Inspectors are provided with lists and
descriptions of unacceptable Product Defects.
Quality control emphasizes on testing of products to uncover defects and
reports to management.
Quality control department plays a very important role. This department is basically a
supporter of customerbut in real it gives valuableadvantagesto thecompany. This
department has to check the product. Without checking, theproduct is not for sale because
if any defected product is sold in market it is great risk to company and also very dangerous
for the life of customer. This department’s responsibility is to maintain the quality of the
product by perfect testing.
Quality Control Department has following responsibilities and sections.
 X-Ray testing
 Material Testing Lab
 Reliability Test
 Endurance Testing
 High Speed Testing
 Plunger test
 Tire Uniformity machine –used to check if forces arebalanced.
 Statistical Process Control.
 In Process Inspection
 Final Inspection

Quality control begins with thedelivery of raw materials. Company chemists do random
testing of the raw materials in the Material Testing Lab. Throughout thebatch mixing
operation, samples of therubber aredrawn and tested to confirm if therubber fulfils the
requirement. A variety of non-destructive evaluation techniques arealso used suchas X-
ray video graphy, reliability testing, and plunger testing forcured tires.
Quality Assurance:
 Quality Assurancedepartment ensuresthat ISO Standards arefollowed and is
responsiblefor its certification.
 Its main purposeis to resolve theclaims from customers. In caseof receiving such
claims on quality of provided products and services.
 The department searches thereasonsand effects of therevealed discrepancies. If a
tire on examination is found to misbehaving or somemanufacturingdefect, the
Company will either repair it free of cost or makereasonableallowanceon pro-data
basis on the purchaseof a new tire.
 This allowancewill be based on the actual wear and balanceleft of a tire.
 It is also responsiblefor taking market surveysto check if theproduct is meeting its
requirement.
 The department also carries out investigations in case of re-curring
problems.

Production Plaaning And Control

Department:
By name it is clear that planning control means “When, Where, Time and
Quality”. The work of this department is to deliver order on time, qaulity and
on when and where basis. This department has three basic functions:

1. Planning.
2. Scheduling.
3. Controlling.

Planning:
 Market demand(Sale forecast)
 1s t check Technical specification and machine capacity.
 Then check our workers efficiency either they are eligible or enough for
the production order.

Scheduling:
 Create production forecast.
  Then create a production forecast: (1 s t order divided in three months
then in 15 days and then create schedule on daily basis). This benefit is
to deliver order on time.

Controlling:
 Check daily shift production.
 And also check all specification is followed or not.
 Then check time schedule either it is followed or not.
 By checking all these above points we assure that we deliver our order
on given time.

Other Operations of this department are:

 Components Manufacturing Schedule
 InventoryManagement
 Production Control

Material Testing Department:

General tyre has the state of the art material testing department equipped
with all the latest and updated testing equipments, all the compound first test
in the material testing lab and are then forwarded to other departs for further
processing.
We visited this department under the supervision of Mr. Shahid and Mr. Amir
who guided us about various testing equipments used and the tests performed
on daily basis.

Material Testing Lab:

All compounds after mixing 1s t come to test in material testing lab before
further processing. It is the responsibility of lab to check all the mixed
compounds fulfil the requirements according to specifications or not. If not
then lab has authority to hold or reject the compound batch.
The material testing lab is divided into two sections:
 Rheology Testing Section.
 General Testing Section.

Rheology Testing Section:

MDR is used in this section (Moving Die Rheometer)
Alpha technology Rheometer:
 Fast Rheometer
 Upper temperature is 372 *F
 Lower temperature is 372 *F
 Time 2 min 30 sec.
 Torque sensor (MH indicates hardness of compound)
 Define all Curing Properties

Regular Rheometer:
 It is slow rheometer.
 Time and temperature is constant.
 Temperature is 320 degree Celsius.
 It shows the actual picture of curing behaviour.

Mooney Rheometer:
 This reheometer is also known as mooney viscometer and
mooney means viscosity.
 Temperature is 100 degree celcius.
 Time taken 4 min.
Components of Rheometer:
 Heater
 Rotors

CARBON BLACK ADSORPTION TEST:

 DPB solution is used.
 Adsorption rate of Carbon Black is checked after specific internal
of time.

Petroleum Distillation:
 This test is done for Neptha.
 Process is similar as Fractionl distillation (obtaining of materials at
their boiling points).
 Condensation of Product is done to obtain Neptha in liquid form.

Density Test (Specific Gravity Test):

 Density is compared to water.
 Distilled water is used

Other tests performed in General Tyre are:

 Extraction Test
 Automatic Hardness Test
 Abrasion Test
General Testing Section:
Equipments used in control lab section are used to test the raw material. Test
performed are Mechanical, Chemical and Physical properties of the raw
material before use.

Instruments Used For Testing:

 Instron (used to test the strength of material for example nylon)
 Adsorption (used to test the carbon’s iodine number and pore density)
 Twist counter (used to test at paricular distance how many twist are
there)
 Monosorb (used to test chemical surface area)
 Wallace Rapid Pastimeter (used to test the plasticity of the natural
rubber)
 Absometer (used to test Carbon grade)
 PRI (Plasticity retention index)

Product Industrialization Department:

This department has its own value because the machine repairing ,operating ,
mould designing and then tyre designs, sizes are all under their considerations.

We visited this department under the supervision of Mr. Shaheer, Mr. Ayub,
Mr. Umair.
Functions of PID:
 Mould and Equipment design.
 Product designing & development.
Departments:
Repair shop:
All the machine parts are repaired.

Die Shop:
General tyre is making their own dies.

Drawing:
This depart draws the mechanism of a tyre according to its Drive, Flexibility
and one very important factor which is its Comfort.

Specification:
This department gives specification about the mechanism or procedure
which should be applied to get desired result.

Tyre Nomenclature:
 Compounding Department:
Compounding department has a wide role in GTR starting from procurement
to curing department and all the departments that are in contact with the
product.

In Compounding department Mr. Khalid Khan, Mr. Aziz Ur Rehman and Mr.
Moiz Sarwar benefited us with their knowledge and experience and guided us
about various functions of this department.

Operations Of Compounding:

Compounding department covers a large area which starst from procurement

to ware house, then to mixing & then it further goes to material testing lab,
then to 4/3 roll calendaring, then to Dual/ Triplex Extruders and then to curing
department. Because the products that are made from the recipes given by
them are circulated in all these departments and how to process, temperature
and then they apply check and balance on them. Compounding department
makes recipes for the tyres and then forwards it to a specified department.

There are two types of recipes:

 Theoretical Recipe (PHR).
 Plant Recipe (Kgs).

Ingredients PHR Plant Recipe (kg)

Natural Rubber 80.0 57.31
BR 20.0 14.33
Plasticizer 12.0 8.59
Antioxidant 1.5 1.07
Antiozonant 1.5 1.07
Carbon Black 60.0 42.98
Stearic Acid 2.0 1.43
Zinc Oxide 3.0 2.15
Sulfonamide 1.2 0.86
Sulphur 1.8 1.29
TOTAL 183.0 131.1

Things We Appreciate Of General Tyre

& Rubber Company:
 Healthy environment inside company
premises. Workers avoid any kind of drug
usage/Smoking.
 Staffs are very co-operative.
 Employees are highly talented and
professional regarding to their work.
 Security measures are taken efficiently and
Cameras are installed in company premises.
 Daily meetings are conducted to discuss any
problems regarding product or machinery.
  Medical and Transport facilities provided to
staff.
 General Tyre doesn’t approve any sort of
defected product in the market no matter
how much loss they have to bare.
 General Tyre really appreciates their
customer and tries to fulfil their
requirements efficiently.

Suggestions:
 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.
 R & D department should be developed so General Tyre can produce
their own standards or specifications.
 Latest designing software should be provided to PID so the work can be
done more efficiently and save precious time.
 Safety vehicles should be on standby in the premises of General Tyre to
counter any kind of harmful situation immediately.
 Sometimes it is observed in Curing department that machine is free due
to unavailability of Green tyres. Steps should be taken for this so that
time should not be wasted and required production target can be
achieved.
 Too much scrap is generated; it should be re-
 used by company itself through De Vulcanisation process.