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INTERNSHIP REPORT

THE GENERAL TYRE AND RUBBER

COMPANY OF PAKISTAN limited

INTERNSHIP PROGRAM REPORT

(Production department)

Duration period is 19 July to 1 August 2016

PREPARED BY
SYED ASIM ALI SHAH
SUBMITTED TO
MR. ABDUL SUBHAN KHAN
(Sr. Manager Production)

DAWOOD UNIVERSITY OF
ENGINEERING AND TECHNOLOGY

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ACKNOWLEDGEMENT

All of the praise belongs to almighty Allah, without His guidance I am nothing. All of
our faith belongs to him and by his grace I have completed our two weeks internship
program in General tyres (production department).

It was really an interesting period of learning because the knowledge that I gained
theoretically from the books became practical here with additional technical aspects,
and the experts here made that much fruitful for me by their guidance. Another thing
is that the other staff (foreman, engineer, etc) became very helpful in the whole
process of learning they really showed their high moral behaviour to me.

I also want to pay high regards on behalf of my institution Dawood University of

Engineering and Technology for giving me this opportunity and I was very grateful
from the depths of my hearts to my supervisor Sr. Manager Productions and other
engineers and the other staff that was included in this program.

(Senior production manager Abdul Subhan khan)

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ABSTRACT

This report is based on the activities performed during the internship at General Tyre
And Rubber. Internship duration was 12 days and it provided practical knowledge of
working in professional environment. This learning experience is described in detail in
the various sections of this report.

Rubber and synthetic polymer industries is rapidly growing industries throughout the
world wide the total production reaching the billions of product per annum. The general
tyre and rubber has been the most prominent manufacturer of tyres in Pakistan and
the facility itself is very self-controlled and standardised according to the international
standards.
The group majorly in the production department where I learnt many new things about
the core process and also about the machines and logistic being used here.
Starting from the mixing department we saw use of raw materials and then learnt the
technical expects in triplex, and calendaring process, the process went on to the radial
and bias tyre building the curing process has been of the utmost important for us
because of our area of study I also learnt many little and vital detail about quality
control and material testing in the respective department

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INDEX
S.NO CONTENTS PAGE NUMBERS

1 PROCESS FLOW DIAGRAM 1

2 INTRODUCTION OF GENERAL TYRE 2
3 RAW MATERIAL 3-4
Rubber industries
Chemical industries
Textile industries
Steel industries

4 Chemical formula of tyre 4

5 COMPONENTS OF TYRE 5
6 COMPOUNDING AND BANBURY MIXING 6
7 EXTRUDER 7-8
Dual extruder
Triplex extruder

8 CALENDARING 9-10
Fabric
Process
Components of 4 roller calendar

9 STOCK PREPARATION AND BEAD/BAND BUILDING 11-12

Bead
Bent
Steelastic Area

10 RADIAL TYRE BUILDING 13

11 BIAS TYRE BUILDING 14
12 CURING DEPARTMENT 15-16
Bladder
Platen press curing
Dome press curing
Others

13 FINAL FINISH 16
14 QUALITY control 17
Raw material testing area
Rheometer area
Control area

15 TYRE NOMENCLATURE 18
16 SUGGESTION AND APPRECIATION 19

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PROCESS FLOW DIGRAM

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INTRODUCTION OF GENERAL TYRE

The General Tyre and Rubber Company of Pakistan Limited (Gentipak) is the Pakistans
premier Industry. It was established in 1963 by General Tyre USA and has been in production
since 1964.

Gentipak has a Technical Services Agreement (TSA) with Continental AG (Germanys

largest tyre manufacturer) which enables it to product tyres of GENERAL brand and
provides the latest technology for production of tyres based Continentals, Research and
Development (R&D).

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.

The plant and the office 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. General tyre plant is
constantly upgraded and is equipped with the most modern technology in tyre manufacturing.

PRODUCTS OF GENERAL TYRE

Bike Front & Rear Tyres
Passenger Car Tyres
Truck & Light Truck (Bus) Tyres
Tractor Front & Rear Tyres
Tubes

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RAW MATERIAL
Raw material are obtains from following industries.

Rubber Industry
Textile Industry
Chemical Industry
Steel Industry

RUBBER INDUSTRY:
1) There are two types of rubber used for making tyre i,e synthetic and natural rubber.
2) Latex contains about 70% natural rubber.
3) Latex is obtained from tree called Hevea Brasiliensis. Cuts are made in the trees core
(cambium) where the rubber is stored; Slanted cuts from left to right side of 10 to 20 degrees
are made.
4) Natural rubber, or polyisoprene is the basic elastomer used in tire making.
5) Halobutyl rubber is used for the tubeless inner liner compounds, because of its low air
permeability. The halogen atoms provide a bond with the carcass compounds which are
mainly natural rubber. Bromobutyl is superior to chlorobutyl, but is more expensive
6) 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.
7) Styrene-butadiene co-polymer (SBR) is a synthetic rubber which is often substituted in part
for natural rubber based on the comparative raw materials cost.

TEXTILE INDUSTRY
The tyre cord fabric is comprised of warp cords oriented in the longitudinal
direction and weft yarns oriented in the lateral direction. The warp cords are
used in reinforcing the carcass of the pneumatic tires. In General Tyre And
Rubber (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).

1) Carbon Black, forms a high percentage of the rubber compound. This gives reinforcement
and abrasion resistance
2) Silica, used together with carbon black in high performance tires, as a low heat buildup
reinforcement
3) Sulphur crosslinks the rubber molecules in the vulcanization process which makes the tires
hard and heat resistant
4) Vulcanizing Accelerators are complex organic compounds that speed up the vulcanization
5) Activators assist the vulcanization. The main one is zinc oxide

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6) Antioxidants and antiozonides prevent sidewall cracking due to the action of sunlight and
ozone
7) Tackifiers are added for formulating adhesives to increase the tack, the stickiness of the
surface of the adhesive. They are usually low-molecular weight compounds with high
glass transition temperature.

STEEL INDUSTRY:
Steel cords (Brass coated) are used In General Tyre for the formation of Bead & Steel Belts.
Bead wire is coated with special alloys of bronze or brass to protect the steel from corrosion.
Copper in the alloy and sulfur in the rubber cross-link to produce copper sulfide, which
improves bonding of the bead to the rubber. Beads are inflexible and inelastic, and provide
the mechanical strength to fit the tire to the wheel. Bead rubber includes additives to
maximize strength and toughness of tyres.

CHEMICAL FORMULA OF TYRE

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COMPONENTS OF 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.

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COMPOUNDING AND BANBURY

MIXING:
This section is known as compounding and it is consist of two
batches.
In first batch rubber stock, carbon black and other chemical
ingredients are mixed in banbury to create a homogeneous
rubber material is called master batch rubber.
In second batch, master batch rubber again fed into the banbury
with vulcanizing agent (sulfur) and other chemical additives
now the rubber formed is known as finish rubber.
The mixing operation is typically a batch operation, with each
batch producing more than 200 kilograms of rubber compound
in less than three to five minutes.
Banbury contains two rollers which movies anticlockwise and mix ingredients.
Ingredients mixed to produce heat of mixing which can rise the temperature above 160-170
degrees Celsius.
If the temperature is too high, the compound can be damaged, so the mixing operation is
typically accomplished in two stages.
Temperature should not exceed 100-110 degrees Celsius otherwise scorching may occur
Thermocouples are installed to monitor the temperature inside banbury
As batch exit from banbury it is transfer in to the dumb/sheeter mill which convers it in the
form of sheet called finish rubber.
It conveyers to cooling line in order to decrease its temperature and the collected
It is then transferred to other areas for bead wire assembly preparation, inner liner
calendaring, steel and/or fabric belt/ply cord calendaring, tyre sidewall extrusion, and tyre
tread extrusion.

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EXCRUDER
DUAL EXCRUDER
The operation consists of following steps:
Breakdown mill
Holding mill
Feeding mill
Hoppers
Two screws of different sizes
Die
This section is known as dual extruder because it is consisted of
two screws.
1st screw is 8.5 inch.
2nd screw is 10 inch.
The numbers of mills are arranged to heat up the finish rubber
It is then fed in to the extruder.
Two Mills are arranged for base and other two for cap.
In order to prevent from sticking from the drum cold water is circulated inside the drum.
Feed is heated in mill due to bond rupturing
Hot feed enters in triplex therefore it is also known as hot feed extruder
Cap and base both separately are fed in to the extruder and then combine together in such
way that cap with less width combine at the top of base having wide width and the exit
from die.
It is now known as tread.
It is then showered this water by passing through number of convers in order to remove
sensible heat so that further shrinkage cannot be done next process
Then it is cut in pieces of desired size of tyre.
It is used to make tread and side wall.

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TRIPLEX EXTRUDER
This section is known as triplex extruder because it is consist of two screws.
1) 1st screw is 50mm
2) 2nd screw is 90mm
3) 3rd screw is 120mm.
It is used to make inner liner and side wall in general tyre.
Finish rubber fed into triplex without heating in the sheeter mill therefore is also known
as cold feed extruder.
It is heated inside the tube with steam and pin between cavity of screw are used to blend
Thermocouple are located inside in order to monitor the temperature
Temperature of exit feed should not be more than 120 C otherwise vulcanization.
Feed exit through die pass through to dancing roller which are used maintain the tension.
Feed is then goes through conveyor to cooling lines where water is showered to decrease
its temperature to the ambient temperature.
Cooling is done in order to avoid the shrinkage during cutting
It is efficient than dual extruder because it reduces the cost of labor in mill.
If required, Cushion gum can be applied separately.

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CALENDARNG PRCESS.
FABRICS
General tyre buy two types fabric which are made of nylon and polyester. Nylon fabrics are
used for heavy bias tyre which are specially made for truck and tractor etc, while polyester
for radial tyre both the fabric are weaved in such manner that the distance weft thread half
inch while warp thread close to each other in order to provide maximum strength in
longitudinal direction.
NYLON TYRE CORD FABRIC
1. Optimum reinforcing material
2. It forms strong inter chain hydrogen bonds. This
results in a stronger & more crystalline polymer
that softens or melts at relatively higher
temperature
3. It has a higher tenacity and is less subjected to
shrinkage.
4. High toughness
5. Superior fatigue resistance
6. Good adhesion to rubber
POLYESTER TYRE CORD FABRIC
1. High strength
2. Low shrinkage
3. High modulus
4. Increase extensibility
PROCESS
Calendaring process is done for making ply for tyres.
In this process these rubber is applied both side of fabric.
General tyre buys nylon and polyester in fabric form so they do not need additional
assembly to weave.
Fabric is inspected in machine and then goes through conveyors.
Banana rollers stretches the fabric before entering in to the calendaring machine.
Calendaring machine consisting of four roller drum.
Fabric passes through two middle rollers which are driven by motors.
These rollers having quit large rpm than other two supporting rollers.
These three rolls are heated by a steam and the temperature of these rolls is above
100 degree Celsius.
Finish rubber feds in these roller, get melt and expend over rollers.
Middle roller applied melted rubber past on both sides of fabric.
These winded rolls again let off for the pasting of squeegee layer.
Squeegee layer is used because it has high air permeability.
Number of cotton yarns are then sticks with that fabric.

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These yarns are spaced at particular distance in order to avoid moisture or any trapped air
inside during curing.
These rolls are subjected to temperature of 45-50 degree Celsius.
Ply are wrapped in the fabric in order to avoid from sticking from each other.
Ply are then cut in next machine.
COMPONENTS OF 4 ROLL CALENDAR:

1. Let Off unit 1 and 2

2. Splicing unit
3. Torsiometer Unit
4. Pre calendaring unit
5. Banana roll
6. Trimming unit
7. 4 rolls or Z calendar
8. Perforator
9. EPI (Ends per inch)
10. Cooling drums
11. Accumulator
12. Winding Unit 1 and 2
13. Storage Area

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STOCK PREPARATION AND

BEAT/BAND BUILDING
BEATS
The main function of the tyre bead wire is to act as reinforcement
It helps to get a proper grip of the tyre on the rim and locks the tyre onto the wheel
The tyre bead component includes
Steel wire loop,
Apex or bead chafer,
Chipper and
Flipper.
The bead wire loop is made from a continuous steel wire covered by rubber and wound
around with several continuous loops.
The brass coating is done to make the cross link with rubber during curing i,e coppersulfied
(Copper + Sulphur = Coppersulfied)
The Apex or bead filler is made from a very hard rubber compound, which is extruded so
as to form a wedge.
The bead wire loop and bead filler are assembled on a sophisticated machine.
Chafer, which protects the wire bead components;
Chipper, which protects the lower sidewall.
Flipper, which helps hold the bead in place.
Note:
The precision of the bead circumference is critical. If too small, tyre mounting can be a
problem; but if too loose, the tyre can come off the rim too easily under loading and
cornering conditions. After the circumference is checked, the bead component is ready for the
tyre building operation.

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BANDS
Band is a set of plies utilized in tire building.
Plies are cut according to the circumferential size of tire and at an angle.
The plies are built at opposite angles forming crisscross pattern.
Band is built according to the ply rating of the tire.
It is distinguished by two types
1. Tractor
2. Truck/Bus

STEELASTIC AREA
Steelastic area produces steel belts which are used in Radial tyres.
High tensile brass coated steel cords are used in the construction of tyre belts.
The brass coating is done to make rubber 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%.
Due to moisture corrosion can occur which may cause the steel cord to lose adhesion with
rubber.
The steel wire passes from the creel room through rollers.
Then these wires are coated through cross head extrusion with rubber.
Ensure proper penetration of rubber between the cords and desired adhesion between
rubber and steel.
Cooling drums cool down the coated strips.
Cutter cuts the belts at required angle and length according to specification.
Winder assembly winds the belts which then going to storage area.

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RADIAL TYRE BUILDING:

The main components of first stage machine (PB-11, PB-13 to PB-19) for making carcass
are:
Drum
Bead applier
Turn up assembly
First stage of carcass building process.
First the inner liner is wrapped around a
drum for tubeless tyre portion.
Then ply of fabricated nylon covered with
rubber wrapped on top
The bead assemblies are then positioned,
and a bladder on the drum
is inflated and pushed in from both ends of
the drum, forcing the body ply to turn up to
cover the bead assemblies
side wall/pad wall apply on top
The main components of second stage machine (PR-1 to PR-5) are:
Belt and tread drum
Transfer ring
Expander
second stage of the tire building process
machine apply the steel belts in crisscross pattern
then nylon cap ply
in the end tread on the top
now this assembly is picked by transferred ring and then assembled with carcass on
expending drum
now assembly is called a green tire

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BIAS TIRE BUILDING:

A type of construction of tire in which ply cords extending from
bead to bead are at angle
lying between 30 to 40 degrees. Successive plies at opposing
angles are laid over each other
to form a crisscross pattern to which the tread is applied. Green
tires of bias construction
are assembled in a single stage thus only one machine is
required for complete assembly of tire. There are currently six
tire building machines for Bias construction.
The main components of bias tire building machine are:
Drum
Bead applicator
Back tool assembly
The following components are assembled:
Drum squeegee
Bands
Beads
Sidewall
Chafer
Breakers
Tread
Drum squeegee Bands Beads Sidewall Chafer Breakers Tread
Number of bands and breakers to be used are dependent on the type of tire manufactured
i.e. truck/bus, tractor.

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CURING DEPARTMENT
Curing is the process of applying pressure to the green tire in a mold in order to give it its
final shape, and applying heat energy to stimulate the chemical reaction between the rubber
and sulphur is known as vulcanization. Curing improve the physical properties of tyre like
hardness and strength and elasticity
In General Tyre all curing machines are pneumatic 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
The bladder is the flexible rubber which used in the curing press machine
One bladder can be used for curing 200 tyre
A bladder inside an uncured (green) tyre pushes it against a hold mould surface.
Curing machine commonly known as Press Machine.
There are two type of pressing machines
1. Platen type press
2. Dome type press
PLATEN TYPE PRESS.
In General Tyre, platen type press are used for curing radial tyre.
Platen type press are known as all steam curing.
In platen type plate are heated by steam.
It takes 11.5 min to cure.
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.
DOME TYPE PRESS.
In General Tyre, dome type press are used for curing bias tyre.
Dome type press are also known as steam and hot water cycle.
In dome type dome is heated by seam.
It can take 48min, 70min or 80min according to nature of tyre.
Firstly we introduce steam at a pressure of 200 psi/inch and at temperature 198C, 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.

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OTHERS
General tyre also make and cure
Tubes, which is made up of special butyl rubber
Bladder, which are made for curing machine
Flappers, which is used in the interface of the tyre.

FINAL FINISH
Tyre inspection is the last step in the tyre manufacturing processan important step in
ensuring quality in both performance and safety. The tyre inspection includes:

Trimming of the mold flash and micro-vents

Visual inspection for appearance and to spot obvious defects
X-ray examination to check internal structure and to spot defects
Tyre durability, uniformity and weight balance inspection

After a tyre passes these rigorous inspections its time for the rubber to meet the road! Our
tyre is ready to be put into service

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QUALITY CONTROL
In General Tyre, Quality Control Department is divided into three sections

Raw material testing area

Rheometer area
Control area

RAW MATERIAL TESTING AREA

Raw material quality are first checked by manual inspection on the base of appearance then
are checked in this area by following instruments.

1) Universal tensile machine (Insron)

2) Dispersion rating analyser (Ektron)
3) Surface area analyser (Monosorb)
4) Wallace Plastimeter
5) Brookfield viscometer
6) Saybolt viscometer
7) Twist counter
8) Furanace and oven

RHEOMETER AREA

This area is responsible for checking all batch process material and also check cure sample
for abrasion test, dispersion test, physical test.

1) Moni Viscometer
2) Rheometers
3) Fraction distillation assembly
4) Oil extraction assembly
5) Abbrasometer
6) Specific gravity analyser

CONTROL AREA

Pilot plant are installed there for experimental batches.

1) Mixer
2) Roller
3) Curing press
4) Weighting machine

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TYRE NOMENCLATURE

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FINDING
Latest designing software should be provided to PID so the work can be done more
efficiently and save precious time.
Employees are highly talented and professional regarding to their work.
More Ventilation systems should be installed in Curing Department to control the
excessive heat.
Staffs are very co-operative.
Workers should not allow eating harmful things like pan, tobacco and other types of
food etc but they not only eat those things also spit over there
There is no much concentration on Safety issue specially in mixing and curind department.
Not much protective equipments are provided to workers such as masks, gulfs, goggles and
full sleeves garments etc, in order safe form chemicals hazard in mixing area and burning
heat in curing department.
There is not much concentration given for staff s health, good and healthy food should be
provided.
There is no transport facility for local staff.

SUGGESTIONS
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.
Sometimes it is observed in some departments that machine is free. Steps should be taken
for utilizing man power.
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 doesnt approve any sort of defected product in the market no
matter how much loss they have to bear.
General Tyre really appreciates their customer and tries to fulfil their requirements
efficiently.

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