There are less than 1000 factories that produce tire
worldwide. This is such a small number considering million of tires sold daily.
The methodology of making a standardized tire is tedious
and requires heavy duty equipment. The process is divided into five sections or
factories.
The numerous components that go into tire production
include chemicals and bulk materials. All the different elements are compounded,
processed then assembled and cured under heat pressure.
Every process is standardized and monitored to create a
durable long plastic that consists of different elements. Starting a tire
manufacturing business is capital intensive and requires specialized knowledge
and equipment.
Every stage of the production is closely monitored to prevent impurities and defects that hamper the quality, durability and performance of the tire. The manufacturing process entails the need for five factories within a vast landed space.
Other challenges are purchase of standard machinery, hire
experienced staff, utilities such as electrical power and sourcing raw
materials.
How
to Start a Tire Manufacturing Business
Basic
Components of Long Elastic Tire
.The tire is made up of different parts that are
essential to the performance of the object. The tire features the bead, filler,
liner and nylon belt.
Other elements are the thread, steel belt, plies,
sidewall and chafer. Beads are inflexible, inelastic steel wire encased in
rubber and coated with an alloy.
The steel wire has a high tensile strength while the
alloys generally used are brass or bronze. The bead is effectively bonded due
to the presence of copper sulfide and other additives.
A triangular extruded profile known as the apex cushions
the inner lining and rigid bead. Sidewall compounds consist of additives such
as antioxidants.
The purpose is to increase the tires abrasion resistance
to environmental pressures. The
effectiveness of sidewall adds to the tensile strength of the tire.
High pressure air is contained within the tire because of
the inner liner. The compounded rubber sheet prevents diffusion of air through
the rubber and is an important element to the overall effectiveness of tires.
The body ply consists of two distinct layers rubber and
reinforced fabric. The type of fabric depends on the manufacturer.
Common fabrics present in the body ply are polyester, nylon,
rayon and cotton. Higher impact vehicle tires such as trucks, caterpillars, and
commercial airlines need tires constructed with multiple body plies.
The tread helps
prevent wear or compromise to the tire. While more strength and durability is
provided by two layered rubber called the belt package.
The differences in the components of tires are predicated
on the manufactures design and structure. The components and compound
formulation vastly differ from one manufacturer to the next.
However there are strict compliance to standardization
and testing of each component.
Raw
Materials used to Manufacture Tires
Many materials go into the composition of tires. We have
the natural and synthetic rubbers such as chlorobutyl, bromobutyl, and polyisoprene. Others are
styrene-butadiene, halobutyl.
Abrasion resistance
is facilitated by the presence of carbon Black, sulphur used in the
vulcanization and activators. Other materials are textile fabrics,
antioxidants, antiozonants including vulcanization accelerators.
Manufacturing
Process
The manufacturing process is complicated and slightly
challenging. The process goes through six distinct stages which are the
compounding, mixing and component preparation. The other stages are the tire
construction, curing and finishing.
Blending
The different ingredients are compounded and introduced
to the mixer. The mixer blends the components in four stages until desired
results.
The mixing process is done through the implementation of
rotors. The desired result through the mixing process is to achieve a uniform
material consistency.
Milling
The compound is further mixed and vulcanized in oven and
cooled. Four components are extruded which are tread, core, wing and base
components.
Building
the Tire
The building process assembles all the elements to make
the tire. The process is done mechanically or manually depending on the
manufacturer.
They put together the tread, beads, steel belts, textile
and other components. Automated tire assembly machines are very efficient in
this regard.
Curing
Process
Heat energy is introduced into the green tire through a
curing machine. The components are compressed to produce the final shape of the
tire.
Finishing
The tire is tested for tensile strength, uniformity and
durability. It is thoroughly inspect to detect deformities or imperfections in
the steel cord structure.
Marketing
the Tires
There is a huge market both domestically and
internationally for tires. Major dealers worldwide are welling to partner with
tire manufacturers.
The manufacturer
needs to brand his tires to differentiate them from market tires. Makes sure
your factory produces high quality products for better chances of success.
Permits
and Licenses
Don’t forget to register you company as a LLC and get
insurance. There are many safety protocols to observe.
Apply for manufacturer’s license, trade license and add
value added tax. The company should have a comprehensive waste management
structure.
Tire manufacturing is big business and you need lots of
loans to finance the business. You could source funds through a pool of core
investors.
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