CONTENTS

Overview ..................................................................................................................................................... 4
vision ........................................................................................................................................................... 5
mistion ........................................................................................................................................................ 5
Compound Mixing ....................................................................................................................................... 6
Calendaring ................................................................................................................................................. 6
Tread and Sidewall Extrusion ...................................................................................................................... 6
Bead Construction ...................................................................................................................................... 6
Tyre Building ............................................................................................................................................... 6
Curing .......................................................................................................................................................... 7
Final Finish .................................................................................................................................................. 7
Temperature Measuring Instruments ........................................................................................................ 8
Thermocouple ......................................................................................................................................... 8
RTD (Resistance Temperature Detectors) ............................................................................................... 8
Thermistor ............................................................................................................................................... 9
Proximity Sensors........................................................................................................................................ 9
Capacitive ................................................................................................................................................ 9
Inductive .................................................................................................................................................. 9
Photoelectric sensor................................................................................................................................ 9
Opposed (through beam) .................................................................................................................... 9
Retro-reflective .................................................................................................................................. 10
Proximity-sensing (diffused) .............................................................................................................. 10
Omron C200HX/HG/HE ............................................................................................................................. 11
Allen Bradley SLC 500 Controller .............................................................................................................. 12
Allen bradley PLC-5 ................................................................................................................................... 12
Allen Bradley 1756 ControlLogix (logix 5561) ........................................................................................... 14
Siemens Simatic S7-300 ............................................................................................................................ 14
Siemens Simatic S7-400 ............................................................................................................................ 14
Siemens Simatic S5 PLC............................................................................................................................. 15
Mitsubishi FX3U Series.............................................................................................................................. 15

Human Machine interface (hmi) ............................................................................................................... 15

MItsubishi Got 1000 series.................................................................................................................... 16
Mitsubishi Got 2000 series .................................................................................................................... 16
Area-1 Mixing Department ....................................................................................................................... 16
F270 and HF270 Mixer .......................................................................................................................... 16
Triplex and Dual Extruder...................................................................................................................... 16
4 Roll Calendar ...................................................................................................................................... 17
Area-2 Tyre Building department ............................................................................................................. 17
Lubrication and holing........................................................................................................................... 18
STOCK PREPARTION AND BEAD/BAND BUILDING ................................................................................ 18
Observation ........................................................................................................................................... 18
area-3 Tire Curing and Inspection............................................................................................................. 19
Tire curing.............................................................................................................................................. 20
Final Finish ............................................................................................................................................. 20
Observation ........................................................................................................................................... 20
DESCRIPTION ......................................................................................................................................... 22
Reference .................................................................................................................................................. 23

ACKNOWLEDGEMENT
I thank the company General tyre for giving me the opportunity to take firsthand experience with the
field work. I like to thank Mahmood Jamil for accepting my request for internship.
I owe a debt of gratitude to my instructors Sir Muneer, Sir Khurram, Sir Qayum Khan, Sir Tunveer, Sir
Affan, Sir Zeshan, Sir Umer, Sir Zubaar and Sir Furqan for helping me to understand the technical aspects
of the machines used.
It is also my duty to record thankfulness to Google.com, Draw.io and Microsoft for providing the tools
and services to complete this report.

Electrical Department General Tyre: ________________________________

GENERAL TYRE AND RUBBER

COMPANY
OVERVIEW
The General Tyre & Rubber Company of Pakistan Limited (GTR) came into existence in 1963, in Landhi
Karachi and commenced its production in 1964.
The Company was established by General Tire International Corporation (GTIC) of USA, with a total
capacity of only 120,000 tyres per annum.
GTIC sold 90% of their shares to the present owners M/s Bibojee Services Ltd (BIBOJEE GROUP OF
COMPANIES). In 1977 and retained 10% of the ownership. In 1985, the Company completed a major
expansion, which took the capacity to 600,000 tyres annually.
Continental AG, Germanys number one tyre manufacturer purchased GTIC in 1987 and thus became
10% owners in GTR. Continental provides technical assistance to GTR under a program, which includes
training of our people, formulations, recipes, selection of equipment from potential suppliers. GTR under
this agreement, is bound to follow all rules and regulations including the given quality standards. The
brand name GENERAL also belongs to Continental AG. This brand name is now synonymous with
quality as we have experience in the art of making tyres for last 50 years. The name GENERAL carries the
highest top of the mind brand recall in Pakistan when it comes to tyres.
Currently, the capacity of the Company stands at 2.3 million tyres approximately with potential to meet
one third of the countrys demand. GTR is producing tyre sizes and patterns that cover almost 85% of
the sizes in demand in Pakistan. GTR has been and still is the largest tyre manufacturer in the country

producing tyres for cars, light commercial vehicles, trucks / buses, tractors, CNG Rickshaw and now
Motorcycles.

VISION
To be the leader in tyre technology by building the Companys image through quality improvement,
competitive prices, customers satisfaction and meeting social obligations.

MISTION

To offer quality products at competitive prices to our customers.

To endeavor to be the market leader by enhancing market share, consistently improving

efficiency and the quality of our products.

To improve performance in all operating areas.

To create a conducive working environment leading to enhanced productivity, job satisfaction

and personal development of our employees.

To discharge its obligation to society and environment by contributing to social welfare and
adopting environmental friendly practices and processes.

TYRE BUILDING PROCESS

COMPOUND MIXING
Various grades of natural and synthetic rubber are blended in an internal mixer and mixed with carbon
black and other chemical products

CALENDARING
Textile fabric or steel cord is coated with a film of rubber on both sides. Steel cord is used for the belts.
Calendar are used to produce:

Body PLY

Belt

TREAD AND SIDEWALL EXTRUSION

The tread and sidewalls are constructed by forming two different and specifically designed compounds
into tread profiles by feeding the rubber through an extruder. Extruders produce continuous lengths of
tread rubber, which are then cooled and cut, to specific lengths.

BEAD CONSTRUCTION
The bead core is constructed by coating plated steel wires, which are wound on a bead former by a given
number of turns to provide a specific diameter and strength for a particular tire.

TYRE BUILDING
Tire building is a two stage process. It involves assembling all the components onto a tyre building drum.
The tyre building machines can be fully or partially automatic. The final product of the tyre building
machines is referred to as Green tyre.

CURING
The green tire is now placed in a mold inside a curing press and cured for a specific length of time at
a specific pressure and temperature. The finish tyre is then ejected from the mold to a conveyer.

FINAL FINISH
In this step excess rubber is removed from
the cured tire on a trimming machine and
the tyre is inspected visually for bulge and
other defects. Then it is placed to
uniformity machine to check tyre balance
and force variation by taking it on a road
trip (simulated by the machine).

FIELD INSTRUMENTATION
TEMPERATURE MEASURING INSTRUMENTS
THERMOCOUPLE
A thermocouple is

temperature-

measuring device consisting of two

dissimilar conductors that contact each
other at one or more spots, where a
temperature differential is experienced
by

the

different

conductors

(or

semiconductors). It produces a voltage when the temperature of one of the spots differs from the
reference temperature at other parts of the circuit. Thermocouples are a widely used type
of temperature sensor for measurement and control, and can also convert temperature into voltage
(millivolts). It is inexpensive and works on the principle of Seeback effect. Thermocouples have a range
of 180 to 2,320 C, which makes it perfect form industrial usage.

RTD (RESISTANCE TEMPERATURE DETECTORS)

A Resistance Thermometer
or Resistance Temperature Detector is a
device which

used

the temperature by

to

determine

measuring

the

resistance of pure electrical wire. This

wire is referred to as a temperature
sensor. If we want to measure temperature with high accuracy, RTD is the only one solution in

industries. They are slowly replacing the use of thermocouples in many industrial applications below
600 C, due to higher accuracy and repeatability. For temperatures between 200 to 600 C an industrial
RTD is the preferred option, for temperatures above 600 C Thermocouple are the only contact
temperature measurement device.

THERMISTOR
A thermistor is a type of resistor whose resistance is dependent on temperature, more so than in
standard resistors. The word thermistor is a combination the two words thermal and resistor. It has
temperature range of -30 to +150 oC. Thermistor is used in small temperature application, due to its
small temperature range.

PROXIMITY SENSORS
A proximity sensor is a sensor able to detect the presence of nearby objects without any physical
contact. A proximity sensor often emits an electromagnetic field or a beam of electromagnetic
radiation (infrared, for instance), and looks for changes in the field or return signal. The object being
sensed is often referred to as the proximity sensor's target. Different proximity sensor targets demand
different sensors. The main type include:

CAPACITIVE
Capacitive Proximity Sensors can be used to detect non-metal objects, such as liquids and plastics.

INDUCTIVE
For non-contact detection of metallic targets at ranges generally under 50mm (2 inches). Inductive
proximity sensors emit an alternating electro-magnetic sensing field. When a metal target enters the
sensing field, eddy currents are induced in the target, reducing the signal amplitude and triggering a
change of state at the sensor output.

PHOTOELECTRIC SENSOR
A photoelectric sensor, or photo eye, is a device used to detect the distance, absence, or presence of an
object by using a light transmitter, often infrared, and a photoelectric receiver. They are used extensively
in industrial manufacturing. There are three different functional types:

OPPOSED (THROUGH BEAM)

A through beam arrangement consists of a receiver located within the line-of-sight of the transmitter. In
this mode, an object is detected when the light beam is blocked from getting to the receiver from the
transmitter.

RETRO-REFLECTIVE
A retro-reflective arrangement places the transmitter and receiver at the same location and uses a
reflector to bounce the light beam back from the transmitter to the receiver. An object is sensed when
the beam is interrupted and fails to reach the receiver.

PROXIMITY-SENSING (DIFFUSED)
A proximity-sensing (diffused) arrangement is one in which the transmitted radiation must reflect off the
object in order to reach the receiver. In this mode, an object is detected when the receiver sees the
transmitted source rather than when it fails to see it.
Some photo eyes have two different operational types, light operate and dark operate. Light operate
photo eyes become operational when the receiver "receives" the transmitter signal. Dark operate photo
eyes become operational when the receiver "does not receive" the transmitter signal.

AECO

PHOTOELECTRIC SENSORS
PHOTOELECTRIC-SENSOR-CYLINDRICAL

FORM

HTTP://WWW.AECOSENSORS.COM

THROUGH-BEAM-SENSOR-

PC (Programmable Controller)
A PC (Programmable Controller) is basically a CPU (Central Processing Unit) containing a program and
connected to input and output (I/O) devices. The program controls the PC so that when an input signal
from an input device turns ON, the appropriate response is made. The response normally involves
turning ON an output signal to some sort of output device. The input devices could be photoelectric
sensors, pushbuttons on control panels, limit switches, or any other device that can produce a signal that
can be input into the PC. The output devices could be solenoids, switches activating indicator lamps,
relays turning on motors, or any other devices that can be activated by signals output from the PC.

OMRON C200HX/HG/HE
The C200HX/HG/HE PCs use a form of PC logic called ladder-diagram programming. The C200HX/HG/HE
PCs are Rack PCs, there is no one product that is a C200HX/HG/HE PC. To have a functional PC, you would

OMRON
XW2Z-200S-V
CABLE
need to have a CPU Rack with at least one Unit mounted to it that provides I/O points.
A C200HX/HG/HE CPU Rack consists of three components: (1) The CPU Backplane, to which the CPU Unit
and other Units are mounted. (2) The CPU Unit, which executes the program and controls the PC. (3)
Other Units, such as I/O Units, Special I/O Units, and Link Units, which provide the physical I/O terminals
corresponding to I/O points. Up to three Expansion I/O Racks. Software used to program and monitor
the C200H PLC is CX-One / CX-One Lite.

ALLEN BRADLEY SLC 500 CONTROLLER

Allen-Bradley is the brand-name of a line of Factory Automation Equipment manufactured by Rockwell
Automation. The series SLC 500 include SLC 5/01, 5/02, 5/03, 5/04, 5/05. 1747-CP3 network interface
cable to connect 5/03, 5/04 and 5/05 to computer. Use RSLogix 5 programming software to program
your SLC-500 system. The SLC 500 is a modular SLC. Extension up to three local chassis. The modules
include:

PS (Power Supply)

Analog I/O

Counter I/O

AC I/O module

Relay Output Module

Thermocouple Module

1747-CP3
SLC 500 IO CARDS

CONNECTING CABLE

FOR SLC 500

SERIES

A SLC 5/03 CPU

BASE PC

ALLEN BRADLEY PLC-5

The PLC-5 processors include PLC 5/30, 5/15, The PLC-5 processors are single-slot modules that are
placed into the left-most slot of a 1771 I/O chassis. They are available in a range of I/O, memory, and

communication capability. RSLogix 5 and RSView32 software are used to program this plc series.
Modules include:

Digital I/O Module

o TTL
o 24V DC Sink Source Load
o 48V DC Sink Source Load

Analog I/O Modules

o Voltage Only
o Current Only
o Thermocouple
o RTD
o Mixed

Intelligent Module
o Counter
o Positioning
o Flow
o Temperature
o Hydraulic

I/O Module

Flex I/O Module

Compact Block I/O Modules

Point I/O Modules

Ethernet Interface Module

Power Supply

ControlNet Network

ALLEN BRADLEY 1756 CONTROLLOGIX (LOGIX 5561)

Provides premier high-speed, high-performance, multi-disciplined application control. Provides modular
and scalable network communications. Offers broadcast range of communication and I/O options.
Software use to program 1756 controllogix family is RSlogix 5000.

SIEMENS SIMATIC S7-300

The SIMATIC S7-300 universal controller is specially designed for innovative system solutions in
manufacturing, specifically the automotive and packaging industries. A wide range of modules can
be used to expand the system centrally or to create decentralized structures according to the task at
hand, and facilitates a cost-effective stock of spare parts. SIMATIC STEP 7 is used to program S7
product line. The Modules include:

Power Supply Module

Digital input Module

Digital Output Module

Analog Input Module

Analog Output Module

Dummy Module

Position Decoder Module

Interface Module

S7-300

SIEMENS SIMATIC S7-400

Part of the SIMATIC process controller series, the S7-400 has been designed for system solutions in the
fields of manufacturing and process automation. This process controller is ideal for data-intensive tasks
that are especially typical for the process industry.

SIEMENS SIMATIC S5 PLC

The Simatic S5 PLC is an automation system based on Programmable Logic Controllers. This product
line is considered obsolete, as the manufacturer has since replaced it with their newer Simatic S7
PLC. However, the S5 PLC still has a huge installation base in
factories around the world. Most automation systems integrators
still have the ability to provide support for the platform. The S5
product line is usually programmed with a PC based software
programming tool called Step 5.

MITSUBISHI FX3U SERIES

Mitsubishi FX3U Series Logic Module 16 x Input, 16 x Output, 100 240 V ac Supply Voltage, is the most
powerful FX PLC yet. This compact PLC offers extremely fast program execution, accepts up to eight
special function modules and provides maximum flexibility and control power for all factory automation
applications. In addition to the features already listed, the FX3U also offers the following:

Choice of 5 I/O sizes from 16 to 80 I/O base units

Expandable up to 256 Local I/O, 384 combined I/O

High processing speed, 0.065s/basic instruction

249 applied instructions, 7680 auxiliary relays, 512

timers, 251 counters, 40768 data registers

64K steps battery-backed RAM memory

24Vdc 600mA output for sensors etc. (400mA for

16 & 32 I/O)

100% backward compatibility with older FX units.

HUMAN MACHINE INTERFACE (HMI)

MITSUBISHI FX3U-32M

A human machine interface (HMI) is an interface which permits interaction between a human being and
a machine.

MITSUBISHI GOT 1000 SERIES

The GOT1000 series offers six classes of terminals to fit any system or budget requirement.

MITSUBISHI GOT 2000 SERIES

The GOT2000 boasts advanced functionality, acts as a seamless gateway to other industrial automation
devices, all while increasing productivity and efficiency.

AREA-1 MIXING DEPARTMENT

In this area the raw rubber is mixed with oil, carbon and other chemicals to produce the material
required to build tire. All the ingredients are mix in a batch of rubber, the operation in named
compounding. Then it is feed to an extruder.

F270 AND HF270 MIXER

Mixers are equipped with two counter-rotating rotors in a large housing that shear the rubber charge
along with the additives. The ingredients are feed to the mixer where it is melted and mixed. The
shearing action generates considerable heat, so both rotors and housing are water-cooled to maintain a
temperature low enough to assure that vulcanization does not begin. The machine which perform this
operation in General Tires are the F270 and HF270. The batch is then pass to the extruder.

TRIPLEX AND DUAL EXTRUDER

The extruder machine consists of a screw and barrel, screw drive, heaters, and a die. The dual extruder
has two extruders, as the name implies, and is call hot feed extruder, as the material is further missed
as warmed, by extruder mill (XM), before it is feed to the extruders. Cooling is provided so that the
rubber shrinks before it is cut into size. Triple extruder is cold feed thus there is no requirement for mills
to warm up the feed as in the case of dual extruder. Its purpose is to form tread and sidewall of radial
tires. A cutter which runs according to the instructions fed in the PLC is provided at the end of the
shrinkage conveyor for cutting the sidewalls and treads into sizes.

4 ROLL CALENDAR
A machine for calendaring the fabric with rubber sheets on both sides.4 roll calendar produces
calendared sheet with fabric inside known as ply which is used in both radial and bias tires.
First, a pre-set number of fabric cords under proper tension are continuously pressed through two steel
rollers, and rubber compound is added to the opening area between the rollers. Then the rubber
compound is pressed into, on top of and on the bottom of the fabric or steel cords. A continuous sheet
of cord-rubber composite goes through several more rollers to ensure good penetration and bonding
between the rubber and cords. Quality is measured by the thickness of the sheet, spacing between cords,
the number of cords and the penetration of rubber into the composite sheet. The composite sheet is
then cut into appropriate sizes, shapes, and angles depending on the desired contour of the tire. Four
mills of large diameter prepare rubber feed for the calendar.

AREA-2 TYRE BUILDING DEPARTMENT

Building is the process of assembling all the components onto a tire building drum. Tire-building
machines (TBM) can be manually operated or fully automatic. Typical TBM operations include the firststage operation, where inner liner, body plies, and sidewalls are wrapped around the drum, the beads
are placed, and the assembly turned up over the bead. In the second stage operation the belt package
and tread are applied and the green tire is inflated and shaped.
The Radial tire building department includes different TBM for different tires. The PB and PR machine
for radial tire, TR machine for tractor, and TK machine for truck tire and MB for motorcycle Radial tire
building. The TR and TK machine are old and relay logic base, and PB, PR and MB are PLC base. The
machines movement is done by pneumatic piston and solenoid valve.
The Radial tire building process include the Passenger builder (PB) machine which is the 1st stage machine
and the Passenger Radial (PR) machine, which is the 2nd stage machine. All the other building machine
does not include the 2nd stage machine, the tread and belt package are applied in this single machine.

LUBRICATION AND HOLING

The Green tire is lubricated and holed before it is sent to the curing area. This lubricant soften the tire
and the holes provide a way for the air inside to escape during curing, thus removing the threat of air
bubbles in the tire which can weaken the tire.

STOCK PREPARTION AND BEAD/BAND BUILDING

The stock department include the machine that build inner linear, belt, body ply and bead. The machine
are Bead Builder (BD) machine, Band Builder (BB) machine, Fabric Cutter (FC) machine, Fabric Slitter (FS)
and the Steallastic Department which provides the steel belt.

OBSERVATION

Mitsubishi FX3U PLC

Allen Bradley PLC-5/10

Siemens S7-300 IM 365 PLC

Siemens S7-300 CPU 315

Siemens S7-400 CPU 414-2

Allen Bradley Logix5561

Relay logic, and contactor base system

Servo Drive and Servo Motor

Encoder

Retro-Reflective Proxy sensor

Limit switch

Solenoid valve

2ND STAGE MACHINE OF RADIAL TYRE

1ST STAGE MACHINE OF RADIAL TYRE

AREA-3 TIRE CURING AND INSPECTION

In this area the green tire is cured to its final form and then it is inspected for defects by humans and
machines. There are backup generators to power this areas curing machine in case main power failed.

TIRE CURING
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 other materials. In
this process the green tire is automatically transferred onto the lower mold bead seat, a rubber bladder
is inserted into the green tire, and the mold closes while the bladder inflates. As the mold closes and is
locked the bladder pressure increases so as to make the green tire flow into the mold, taking on the
tread pattern and sidewall lettering engraved into the mold. The bladder is filled with a recirculating heat
transfer medium, such as steam, hot water. Passenger tires cure in approximately 16 minutes and large
tire takes more time to cure properly. The tire may be placed on a PCI, or post-cure inflator, that will
hold the tire fully inflated while it cools.
The curing machines are divided into different rows. Q and R-Row for passenger radial tire, J and K-Row
for truck back tire, G-Row for truck forward tire, E and F-Row for tractor radial tire and M Rows for
motorcycle tire.

FINAL FINISH
After the tire has been cured, there are several additional operations. Tire uniformity measurement is a
test where the tire is automatically mounted on wheel halves, inflated, run against a simulated road
surface, and measured for force variation. This is done on a machine called uniformity machine.
In the final step, tires are inspected by human eyes for numerous visual defects such as incomplete mold
fill, exposed cords, blisters, blemishes, and others.
The curing machine had only one motor to open and close the press, all the other movement is done by
pneumatic power.
After the inspection process the tires are raped in bundles by the worker and are ready to be mounted
on care, tracker etc.

OBSERVATION

Allen Bradley PLC-5/15

Q-Row

Allen Bradley PLC-5/30

Q-Row

Allen Bradley SLC-5/03

N/G-Row

TYPICAL TIRE CURING MACHINE

Allen Bradley SLC-5/04

R-Row

Allen Bradley MicroLogix

K-Row

Omron C200HG

F-Row

Siemens S7-300 Uniformity Machine(New)

Siemens S5

Mitsubishi Got 2000 HMI

Mitsubishi Got 3000 HMI

Solenoid Valves

Capacitive proxy sensor

Inductive proxy sensor

Uniformity Machine(Old)

FIGURE 1 CURING MACHINE SINGLE PRESS

CURING MACHINE DOUBLE PRESS

POWER HOUSE
DESCRIPTION
The power house is the main power distribution area of the factory. It distributes the 3Phase supplied
by KE (Karachi Electric) in to the factory areas supports and its machinery. There are three 3phase
Feeders from KE. Each carry a line-to-line voltage of 11KV.Each feeder powers a part of the factory. The
3Feeders are interconnected so that when one line is down we can shift to the other line. The feeders
are also interlocked to prevent a short. The 11KV lines are step down by HT (High tension) & LT (Low
tension) transformer to 3KV and 420V, as some motor require 3KV to operate to reduce the current
drown. In the absence of the main supply from KE the backup generators are used to feed the needs of
the factory. These generators are:

CATERPILLAR

1.2MW

CUMMINS

1..2MW

SKODA

730KW

A synchronizer is used to synchronize the

generator and distribute the load evenly. The
circuit breakers used are namely:

Air Circuit Breaker (ABC)

Vacuum Circuit Breaker(VCB)

Oil Circuit Breaker (VCB)

The power house

section also have air

compressors. The compress air is used in to power all the pneumatic machines. It also include two huge
Water Tube Boiler. The steam generated by the boiler is used in the Area-3. The fuel used in the boilers
and electric generators is LPG.

REFERENCE
www.google.com.pk
www.draw.io/
en.wikipedia.org/wiki/Tire manufacturing
atrm.co/tires1.htm
www.advancetyres.com/tyre-bulges/
eng.com.au/products/rtd-sensors/
thesensorconnection.com/thermocouples/all-thermocouples/thermocouple-sensor-probe-industrialhead-assembly-type-k
www.aecosensors.com
www.gentipak.com/ContentPage.aspx?pageid=8
ab.rockwellautomation.com/Programmable-Controllers
www.rockwellautomation.com
www.mitsubishielectric.com/fa/products/cnt/plc_fx/items/index.html
w3.siemens.com/mcms/programmable-logic-controller/en/Pages/default.aspx
www.ia.omron.com/products/category/automation-systems/programmable-controllers/
www.scribd.com