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Belts for the Tyre industry

Belting solutions for: Rubber compound handling Extrusion and rubber calendaring Non vulcanised rubber transport Finished tyre handling

Ammeraal Beltech is a leading manufacturer of Process and Conveyor belting and has a unique reputation for developing innovative solutions for belting applications. Manufacture of a tyre not only requires the latest technology, precision instruments and qualied people but also requires qualied suppliers. We at Ammeraal Beltech are able to offer a full range of belting products to meet the ever-increasing performance demands and to provide well considered solutions for all belting processes in the tyre industry. Content Introduction ...................................................................... 2 Process steps in green tyre production Mixing and Batch-off ........................................................ 3 Extrusion and Calendaring ............................................... 4 Handling of nished tyres ................................................ 5 Special applications .......................................................... 6 Our product portfolio Process and Conveyor belts .............................................. 7 Modular belts .................................................................... 8 More of our products ........................................................ 9 At your service ................................................................ 10

Providing quality and innovation

Ammeraal Beltech continues to prove its commitment to a combination of quality and innovation through the ongoing introduction of new materials. Working together with our customers and leading research institutions, we have developed a large number of alternative solution concepts. With the unique product portfolio of Ammeraal Beltech fabric based Process and Conveyor belts, as well as Modular belts, High performance at belts, and Timing belts, we provide the best technical belting solution for tyre processing: from mixing raw materials via semi-nished products and green tyre production to vulcanisation.

Process steps in green tyre production

Mixing

Batch-off

Mixing is the rst of many important processes in tyre manufacturing and is typically a batch operation with each batch producing more than 200 kilograms of rubber compound. In the Banbury mixer, rubber bales are mixed with many chemicals, to precise specications, to become the building block of each component of the tyre. As mixing is the rst step of a long process, quality of process is of utmost importance.
For handling of high temperature sticky rubber compound, our Silam belts provide excellent release due to the highly non-stick top cover surface

Once the mixing is completed, the batch is unloaded from the mixer and sent through a series of process steps to form it into a continuous sheet. The batch-off process involves dipping, cooling, drying and stacking of rubber strips and slabs.
The best solution for dip tank applications is our F53 modular belt which offers improved process reliability and easy maintenance.

The slab is then transferred to other areas for bead wire assembly, inner liner calendaring, steel belt and fabric cord calendaring, and tyre tread and sidewall extruding. The mixing temperature can rise up to 180 Celsius and the operation is accomplished in two stages to prevent damaging of the compound.
For batch-off applications we are able to offer our coated and impregnated fabric based belts for long belt life

Our famous Hot Stock & Water belts are used for inclined conveying of rubber

Extrusion

Calendaring

Extrusion is one of the most important operations in the tyre manufacturing process since it processes most of the rubber produced from the mixing operation and then prepares various components for the ultimate tyre building operation.
For efficient cooling of extruded uncured rubber our Modular belts offer the best technical and cost effective solution.

Calendaring is the process by which a mixed rubber compound coating is applied to fabrics such as polyester, nylon, rayon, aramid, or steel cords, to form composite sheets of rubber coated material. Precise control of the process is required to ensure uniform coating of the fabric or steel material, as well as an overall consistent thickness of the nal sheet. This material is fed through cutting machines to form the cut, to rigid specications to form the body plies, steel belts, and fabric reinforcing materials of the tyre. Strict control of this process is required to ensure quality and a uniform nal product.

Mixed rubber sheets are heated on mills, cut into narrow strips and forcefed through precision dies by powerful screw driven extruders. Tread slabs, sidewall, apex, and other thick components are precision manufactured in the extrusion process. This process must be strictly controlled to ensure the consistent manufacture of the component and the uniformity of the nal product. Precision take-off conveyors, cooling stations, and cutting equipment are also required for this process.

A wide range of abrasion resistance belts with nonstick properties are available for infeed/outfeed and cutting applications

Cutting to precise measurements is critical for quality, uniformity of nal product, and overall cost control and protability. These products are then supplied to the tyre building machines.

Handling of nished tyres

Tyre building & curing

Inspection

The highly robotic tyre building machine assembles all the extruded, calendared and wound precision components to form the green tyre. The assembly process must be exacting, as any error here will negate the quality of the individual components, and is magnied in the nished tyres quality, uniformity and performance. This process may be fully automated, or operator driven, depending on the types of building equipment chosen.
For handling of green tyres before vulcanising we advise our Modular belt RAM 208

When the vulcanising process is completed nished tyres are loaded onto a long conveyor which carries them to nal nishing and inspection.
Modular belts with lateral rollers for loading side ways are used for transport from vulcanising to final stages

Inspection is the last step in the manufacturing process and is important in ensuring quality of both performance and safety. Tyre inspection includes: trimming, visual inspection, X-ray inspection, balance (weight and uniformity) inspection. Curing is the nal step in the manufacturing process, where the green tyre is exposed to very high temperatures and pressure, while being captured in an aluminium or steel tyre mould. The pressure/heat causes the tyre to ow to the shape dictated by the mould shape, while the heat completes all the chemical bonds required to form the adhesion that holds the green components together. Heat drives the nal formulation of compounds in this process, allowing the tyre to perform as intended in the eld.
To assist in positioning the nished tyre in the centre of the conveyor, Ammeraal Beltech has developed direction rollers for use with Solid Top Modular belts.

Special applications

Wind-up systems

Warehouse tyre storage system

Wind up systems are a critical part of the extrusion process, since the products need to be wound up with the highest accuracy to avoid stretching and to maintain other critical parameters. Due to our expertise in the eld of tyre manufacturing we fully understand the requirements of wind-up systems.
Wind up systems with Flexam and Fabric belts are used for treads, sidewalls and body plies.

After a tyre passes these rigorous inspections, it is stored in fully automated storage buildings, where high tech handling systems organise them.

Within the storage system our abrasion resistant Ropanyl belts with their high exibility are often utilised.

We are able to provide wind-up belts and fabrics with guiding strips or at belts up to a length of 200 meters.

Our product portfolio

The comprehensive range of Ammeraal Beltech Process and Conveyor belting is regarded as one of the most rmly established within the entire belting industry. A wide range of raw materials and production methods is available to satisfy ever increasing demands, such as high temperature resistance, higher speeds, increased exibility and durability, more stringent international standards, and many more. Ammeraal Beltech is able to offer a full range of high quality, light weight conveyor belts in silicone, rubber, PVC and PU material for every step in your production process. We have the technology and experience to full your most demanding material handling needs, efciently and effectively.

Proling Ammeraal Beltech has developed a comprehensive range of proled belts, capable of meeting all the requirements of industry in respect of efcient product handling. Practically every Ammeraal Beltech belt can be embossed with one of our available proles, while specic requirements can be developed in close co-operation with the customer. Fabrication Our belts can be made endless by means of various splicing methods. Semi-nished products are customised to exact requirements at local sites. Belts can be tted with accessories such as carriers, ropes and corrugated sidewalls, made endless and engineered with holes and grooves.

One of our more successful profiled belt is the Flexam with A18 Fine square pyramid.

V-ropes are fitted on Flexam belts for winding applications.

Process and Conveyor belts Products Silam belts (Silicone coated) Main features Excellent non-stick High temperature resistance Suitable for fasteners or thermoplastic splice Customer benets Highest rubber quality Very good rubber release Long belt life Less downtime Less maintenance costs Application indication Rubber mixing Batch-off

Fabric and Ropanol belts (Bare fabric or PU impregnated fabric) Flexam belts (PVC coated) Ropanyl belts (TPU coated)

Excellent non-stick Low friction coefcient Highly abrasion and cut resistant Different proles available Available in antistatic Longitudinal exible Abrasion resistance

Good rubber release Reliable product ow Reduced belt wear Cost efcient Reliable conveying Compact conveyor design Long belt life

Rubber mixing Batch-off Extrusion General use Calendaring Storage

For many years, Modular belting has been one of the basic product groups of Ammeraal Beltech. Ammeraal Beltech provides a complete range of straight, radius and spiral belts suitable for numerous conveying applications. With its extensive variety of top surfaces and materials (PE, PP, AC, and Nylon), our Modular belts offer the best solution in many applications in tyre manufacturing such as dip tanks, cooling processes and nished tyre handling.

Modular belts with positive drive are running with lower tension and using less energy thus resulting in a longer life. Use of modular belts in nished tyre conveying systems will automatically lead to cost savings as a result of no maintenance, easy replacement, reduced downtime of production and no jams. The nish area of tyre manufacturing involves complicated logistics and requires large stock areas. Our modular belts assist in meeting high demands with: efcient conveying system no tracking problems less power consumption Accessories Together with different supports, guide strips and sprockets, various accessories are available: Accumulation rollers Lateral and Position rollers Amights High friction inserts
Our belts with position rollers are the ideal solution for handling of nished tyres in merge and sorting applications

Position rollers are offered in the ST62000 solid top and are adjustable in 360 degrees

Modular belts Products F 50 Series belts (ush grid) Main features Non stick surface Temperature resistance (+190C) Raised rib less contact area Open surface 35% Customer benets Good release Long belt life Limited contact area Less downtime Application indication Rubber mixing Batch-off

Small Pitch belts (ush grid) Straight belts (ush grid) All-In-One Series (ush grid)

Non stick surface Small sprocket diameters Large open area up to 70 % Available in one inch Small diameters possible Straight and radius transport with one belt Also possible in Helix spiral applications Low friction rollers for loading sideways (90) Assist in positioning the tyre to the center of the conveyor Adjustable in any angle in comparison with the transport direction Low pressure accumulation

Good release Long life time Good drainage Less downtime Compact conveyor design Less transfers points Controlled conveying Less oor space

Wig wag belts Cooling belts

Curved transport Vertical transport

Lateral roller belt (2-inch solid top) Position roller belt (2-inch solid top)

Easy changing of transport direction Less damaging of tyres No conjunction of tyres Less damaging of tyres

Loading sideways

Merging and sorting

Accumulation belts

Low friction Low back pressure

Merging and sorting

More of our products

High performance at belts Ammeraal Beltech offers a complete range of quality at belts with classical nylon core belting for power transmission as well as modern belt constructions with thermoplastic inner layers.
Wear resistant flat belts Rapplon are found in cutting applications in tyre manufacturing to provide uniform feed and precise positioning

Woven fabric belts In applications where standard conveyor belts cannot be used because of small diameters, our in-house woven fabric belts are the perfect choice. These belts are made of synthetic yarns and customised with a wide variety of coatings and proles. Silam coated woven fabric belts are the ideal solution for conveying mixed rubber slabs in applications where high temperature resistance, non stock properties, and small diameters are required. Unique Maestro splice press Maestro splicing equipment is specially designed for joining of Ammeraal Beltech Process and Conveyor belts on site. The Maestro splice press is constructed of light weight materials allowing for easy transport around the plant. The unique Maestro concept makes Ammeraal Beltech the foremost supplier in global standardised splicing, leading to: Improved quality and efciency benets Short cycle time, approx. 10 min. or less depending on belt type Consistent, reliable splice results and superior belt appearance Less shrinkage of ngers, providing stronger, atter splices No glass bre sheets or other splice plates necessary
A new concept for fast, reliable and effortless splicing

A wide range of cover styles ensure the best solution for various applications e.g. soft covers to protect goods, high friction covers for high efciency or low friction cover for accumulation. Timing belts In todays tyre industry there is a requirement for more and more synchronised conveying. Positioning is very important, particularly under high speed.
Our timing belts with vulcanised rubber top or with splicable polyurethane top and Kevlar fibre are used for in-feed conveying

Ammeraal Beltech has standard solutions for all types of synchronised conveying, linear positioning and power transmission requirements, offering different pitches, tooth shapes, dimensions, cord and coating materials. Special treatments to the belt surface such as grinding, milling or the attachment of cleats are possible. Outstanding mechanical and chemical properties lead to high-performance operation and precision.

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At your service

Facts & gures Ammeraal Beltech is an international company with afliates in 25 countries. Our products are available globally via a network of distributors and service centres in more than 150 countries. We have 7 production plants, where incorporating R&D is an integral part, which manufacture our rolls of process and conveyor belting. More than 1,600 highly qualied employees in over 80 service centres, in close proximity to our customers, provide standard and tailormade solutions, often combined with 24 hours service.

Service network We understand the importance of keeping your business running and know how costly and disruptive downtime can be. Thats why we offer a service network worldwide, that is available round the clock at local level. We ensure that there is an Ammeraal Beltech branch near you, so the support you receive will be fast and convenient.

Innovation Within our purpose-built R&D centres we are continuously optimising and improving our products to satisfy constantly changing demands, such as higher speeds and temperatures, increased cleanability and durability, and more stringent international standards of hygiene and safety. Because Ammeraal Beltech manages every aspect of the belting quality from the fabric to the nal fabrication we are condent that we are able to develop the belt that meets your future needs.

Technical support With the on-site support of Ammeraal Beltechs experienced team of Sales Engineers, nothing is left to a chance and ensures valuable support and your complete satisfaction. Our Product Specialist have the technical prociency to develop a belt for most difcult operating conditions in any industry. A sound combination of a global network, market segment knowledge and product management is the basis for our innovative and service orientated organisation.

Your global contact

International Head Ofce: Ammeraal Beltech Holding B.V. Handelsstraat 1 P.O. Box 38 1700 AA Heerhugowaard The Netherlands T +31 72 5751212 F +31 72 5716455 [email protected] www.ammeraalbeltech.com

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Reference: 44.0 GB Date: 02 / 2006