MADHAV INSTITUTE OF

TECHNOLOGY AND SCIENCE

BRIEF INTERSHIP REPORT

SUBMITTED TO – Dr R. K. DUBEY

SUBMITTED BY – ARPIT DUBEY

JK Organization has been a forerunner in the economic and social advancement

of India. It always aimed at creating job opportunities for a multitude of country men and

provides high quality of products. It has driven to make India self reliant by pioneering

the production of number of industrial and consumer products, by adopting latest as well

as developing its own know-how. It has also under taken industrial ventures in several

other countries.
JK Organization is an association of industrial and commercial companies and

charitable trust. Its member companies, employing nearly 50000 persons are engaged

in the manufacture of variety of products and in diverse fields of commerce.

Trust are devoted to promoting industrial, technical and medical researches,

education, religious values and providing better living and recreational facility. With the

spirit of social consciousness uppermost in mind, JK organization is committed to cause

the human advancement.

The flagship company of JK Organisation, JK Tyre & Industries Ltd is one of India’s foremost tyre
manufacturers and is also amongst the top 25 manufacturers in the world. Its head office is situated
in New Delhi.

JK Tyre is present in 105 countries with over 180 Global distributors. The Company has 12 globally-
benchmarked ‘sustainable’ manufacturing facilities - 9 in India and 3 in Mexico – that collectively
produce around 35 million tyres annually.

JK Tyre launched India’s first ever ‘Smart Tyre’ technology-and introduced Tyre Pressure Monitoring
Systems (TPMS) by offering TREEL Sensors, which monitors the tyre’s vital statistics, including
pressure and temperature. JK Tyre is also synonymous with motorsport in the country. For over three
decades, the Company has relentlessly worked towards shaping India’s positioning as the motorsport
hub of Asia, developing the right infrastructure for the sport and promoting young talent in the
arena.
 MANUFACTURING PROCESSES

 Internal Mixing (rubber, carbon, process oil, accelerator, activator, resin) & formation

of compound.

 Bead winding

 Calendaring

 Extrusion

 Green tyre

 Curing
 Work Flow Model

BU 1

1) Compound At Banbury:

Compound is the process of mixing the necessary raw materials with selected

elastomer in the Banbury. Banbury is an internal mixer, which consists of a completely

enclosed mixing chamber with two spiral shaped rotors. There is a hoper to feed the

ingredients and a door to discharge the mix. The rubber ingredients like chemicals are

weighted as mentioned in specification file and feed into hoper. Then the mixing

process takes place. Required mixing time is fixed to get better quality mixing.

2) Extruder:

The main function of an extruder is to produce tread and side wall, bead, apex.

Extrusion is a process of forcing the mixed compound by means of screw, which rotates

inside the barrel. There are two types of extruder: a) Screw extruder, b) Ram extruder.

3) Zell Plant: : Dipping

The dipping process takes places in a zeal plant. Here rayon, nylon. Polyesters

are dipped in a solution containing normally a latex based resorcinol formaldehyde to

improve adhesive properties. Then the fabric is dried at a temperature of about 280-300

F for 150-180 sec, the fabric is stretches to about 0-15%

4) Calendaring:

Calendaring is a machine, which consists of three or four rolls held in a frame

work used to produce the rubber sheets of required strength and length. To get a better

quality calendared fabric with uniform gauges, viscosity is important in the same way,
hot temperature of about 110-137mm.
BU 2

5) Bias Cutter:

It is a machine used to make ply’s or to the rubber coated fabrics at required

width and angle, which are used in the production of tyres. Bias angle is the angle of

cords in tyres with respect to the central line. Based on the ideal cured angle, required

for particular type size and pattern, bias angle is calculated for the particular drum.

6) Pocket Making:

It is a process of making the pocket from the angle cutter fabrics. In pocket

making section, three types of pockets are constructed. The ply’s used for the first and

second pocket are known ad inner ply and those used for third pocket are known as

outer ply.

7) Bead Assembly :

Bead wire – High tensile copper coated Steelwire coated with compound wound on a former ,
fillered and flipped

8) Tyre Assembly :

All individual components of tyre Viz Beads , Pockets, Tread and

Sidewall are assembled on a Building drum and the finished product is called as Green

– Tyre.

BU 3

9) Bladder:

Butyl rubber compound is used for making the bladder. As first, butyl rubber is

mixed with specified chemicals properly and then it enters the extruder section by the
use of the extruder, a specific length and width of slug is extruded. Then the ends of the
slugs are cut into the specified angle for proper joining.

8) Tyre Moulding:

Before moulding operations, the green tyre has to be made ready for painting

with inner lubricants inside tyre for easy release from the bladder and the side walls are

to be coated with blemish paints.

10) Tyre Curing:

It is a process of cross linking the rubber compounds through heat and pressure.

For the pressure of curing tyres presses are used. These pressed are pre warmed

before loading of green tyre is done in the top ring raise condition with vacuum.

10) Tyre Finishing and Inspection:

After curing, the tyres obtained by trimming of the extensions on the tyres

surfaces are checked for defects. Thus the process of removing excess materials from

the tyre after curing is called finishing. The finishing process is done either by buffing or

trimming method. All the tyres then are inspected and separated.

BU 5 :

Finished Goods Storage and dispatch : Storing of Okay tyres and arranging

logistics to various depots / STUs / OEMs as per the marketing requirements

Tan delta (tanδ) value optimization in T7234 & PCRT15 compound

Both are silica base tread compound

The tire compound material in contact with the road surface and under the cyclic deformation
dissipates energy due to its viscoelastic nature. On the other hand the friction between the road and
the tire surface is required for a safe drive.

Loss factor (tanδ) is a determining parameter in analyzing the tire tread material performance. It has
been accepted that the tanδ value of a tread compound measured at a temperature around 60°C
and a frequency of 10Hz can be representative of the Rolling Resistance performance of a tire made
thereof. Part of this thesis deals with different dynamic mechanical measuring methods and the
analysis afterwards to receive a reliable viscoelasticity and defines the interpretations of the results.
With the introduction of silica technology in passenger car tire tread applications, the filler-polymer
interactions have become of key importance.

Tyre rolling resistance refers to the resistance experienced by your car tyre as it rolls over a surface.
The main causes of this resistance are tyre deformation, wing drag, and friction with the ground. The
higher the rolling resistance is, the more energy to overcome it is needed.

Tyre rolling resistance is the energy that your vehicle needs to send to your tyres to maintain
movement at a consistent speed over a surface. In other words, it is the effort required to keep a tyre
rolling.

It means Low rolling resistance tyres can be much more fuel-efficient tyre than conventional tyres.