HOW IT"S MADE: Car Tyres
Step One: Mixing Process

The first step in the process is the mixing of raw materials at a requisite heat to make the rubber compound with defined consistency. In order to gain uniformity, the said process is a computer-controlled activity, as this automatically measures the specifically required batches of rubber and chemicals for blending.

The work includes blending basic rubber with carbon black and process oils along with antioxidants and other additives. One thing to note is that the consistency of the rubber compounds used in different parts of a tyre varies on factors such as the use, climatic conditions and model of the tyre.

Step Two: Mill Process

The next stage in the tyre development is the milling process where the shaping of the rubber commences. The rubber is kept on a drop mill.

Once the rubber is cooled at a required temperature during the milling stage, it is further sent to a special mill where the rubber is cut into flat and long strips. These strips form the basic structure of the tyre which are used to make the specific parts of the tyre.

Moreover, other elements of the tyre are prepared during the process, some of which are then coated in another type of rubber.

During the process, the question of safety hazards associated with the open operation of the turning rolls comes into the picture. Many facilities have adopted extensive emergency rescue procedures for workers trapped in mills. Unfortunately, mill operators are exposed to unavoidable noise and heat.

Step Three: Building Process

In the building process, the tyre is constructed from the inside out. The rolls of sidewall rubber, the tread rubber as well as the racks of beads are sent to a skilled assembler at the tyre building machine.

The assembler begins to build a tyre by wrapping the rubber-covered fabric plies of the body around the machine drum. The beads, tread and other components are placed in a tyre-building machine.

This is almost a relatively finished product and is termed a green tyre.

Step Four: Curing Process

Post the preparation of the green tyre, it is then vulcanised. It is placed in a mould for curing activity and further inflated with hot water or steam. This activity makes the tyre press against the mould. The heating process is termed the vulcanization of the tyre.

The tyre is placed over the balloon and the mould closes. Moving on, the steam is pumped into the balloon. This helps in expanding it to shape the tyre against the sides of the mould. During this process, the tyre gets its final shape, including the tread pattern and sidewall markings of the manufacturer.

After cooling, the tyre is inflated and passed on for testing.

Did you know that each and every tyre is thoroughly inspected for errors such as bubbles in the rubber of the tread, flaws in the sidewall and defects in the interior of the tyre? Post-inspection, the tyre is placed on a test wheel. Upon final approval, the tyre is ready for your vehicle.
Manufactures have been focussing on constant and non-stop improvements in rubber sciences and upgrading tyre designs. Customers always look for personal road safety along with greater and better mileage of the vehicle as well as advanced tyre performance in different weather conditions.
If you are a driver, you must keep in mind to select the right tyres for your vehicle based on the weight, size and usage of your vehicle. One must resolve tyre breakdown issues with timely maintenance of the tyres.
The concept of smart tyres is also being introduced by some of the tyre manufacturers. Yes, you heard it right! Your vehicle’s tyres are getting smart with the rising technology. With inbuilt smart sensors and cutting-edge technology, such tyres provide you with real-time information and timely alerts on the tyre pressure and temperature. Fascinating isn’t it?

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