Calendering (Ply)

Compounding

Tread Extruder

Tyre building

Tyre moulding

Bead winding
Finishing and inspection

Tube manufacturing process

Strained rubber

Warming Mill

Compounding Mill

Water spray

Feeding Mill

Extruder
Cutting

Mouth fixing

Cooling conveyor

Chalk powder bath

Edge cutting

Splicing & Jointing Joint cooling

Dispatch

Inspection

Inflation

Leak test

Tube curing press

Inflation

Compressed air system

300 cfm
60 kW

Refrigerated
air dryer

300 cfm
60 kW

Loading - 50 kW
Unloading - 12 kW

Air
Receiver

Tyre plant

Loading - 50 kW
Unloading - 12 kW

600 cfm
110 kW

Loading - 20 kW
Unloading - 99 kW

Tube plant

Cooling water system : Air Compressors

10 HP
Actual -5 kW

100 TR
300 cfm
60 kW

HP - 10
Actual - 5.5 kW
H - 22 m
Q - 57.6 m3/hr

Refrigerated
air dryer

300 cfm
60 kW

HP - 7.5
Actual - 3.2 kW
H - 22 m
Q - 57.6 m3/hr
600 cfm
110 kW

Cooling water system : Tyre plant

10 HP
Actual - 3.2 kW

84 mill (1)
Falcon

200 TR

84 mill (2)
Dunlop

HP - 10
Actual - 6 kW
H - 29 m
Q - 17 m3/hr

60 mill
Kleinewerfers

HP - 20
Actual - 14 kW
H - 39 m
Q - 23 m3/hr

HP - 20
Actual H- m
Q - m3/hr

60 mill (2)
Manchester
42 (1)
Sonal mill
42 (2)
mill

4.7 m3/hr

1.4 m3/hr

5.3 m3/hr

8.4 m3/hr

3.3 m3/hr

8.4 m3/hr

4.2 m3/hr

8.4 m3/hr

8.4 m3/hr

25.5 m3/hr

3.4 m3/hr

5.6 m3/hr

4.2 m3/hr

5.6 m3/hr

0.746 m3/hr

9 m3/hr

Darwing mill

Return water sump

Extruder screw
cooling
4 1/2 Conveyor
cooling

HP - 10
Actual - 6 kW
H - 29 m
Q - 17m3/hr

HP - 20
Actual - 12 kW
H - 39 m
Q - 23 m3/hr

HP - 20
Actual - 16.2 kW
H - 56 m
Q - 15 m3/hr

4.2 m3/hr

8 extruder
mouth cooling
60 warming
mill (1)
60 warming
mill (2)
60 feeding
mill (3)
8 extruder
conveyor cooling
60 warming mill
(Calender
60 feeding mill
(Calender)
Calender
12 kg/hr
70O C Hot water 85O C Condensate - 12 kg/hr

Cooling water system : Tube plant & K4

10 HP
Actual - 6 kW

100 TR

Final
compounding
mill

8 m3/hr

2.5 m3/hr
2
1

Warming mill

HP - 20
Actual - 11 kW
H - 29 m
Q - 23 m3/hr

HP - 7.5
Actual - 4 kW
H - 22 m
Q - 16m3/hr

Feeding mill

K4

0.23 m3/hr
Extruder

Extruder
die cooling

Return water sump

HP - 10
Actual - 6 kW
H - 29 m
Q - 17m3/hr

HP - 20
Actual - 12 kW
H - 39 m
Q - 23 m3/hr

HP - 20
Actual - 16.2 kW
H - 56 m
Q - 15 m3/hr

0.4 m3/hr

Extruder
conveyor cooling

3 m3/hr

9.4 m3/hr

Closed circuit cooling water system

Make up water
from Sintex tank

Overflow for
recirculation

Spray
Pond
8 kW
High pressure pumps

Center piston water

Ejector

Condensate
Tank
HP steam +
Closed Circuit water

9 kW

Tyre curing presses

After HP steam inflation, High pressure water enters
and along with steam goes to condensate tank

Compressed air: Leak vs actual demand

Demand
1000
900
800
700
600
500
400
300
200
100
0

12

13

14

15

16

17

19

20

21

22

23

Leak

10

11

Anticipated Compressed air demand pattern

(After minimising leaks)

Demand

Leak

700
600

Cfm

500
400
300
200
100
0
12

13

14

15

16

17

19

20

21

22

23

Time (Hrs)

10

11

Existing cooling water system for tube plant

10 HP
Actual - 6 kW

100 TR

Final
compounding
mill

8 m3/hr

2.5 m3/hr
2
1

Warming mill

HP - 20
Actual - 11 kW
H - 29 m
Q - 23 m3/hr

HP - 7.5
Actual - 4 kW
H - 22 m
Q - 16m3/hr

Feeding mill

K4

0.23 m3/hr
Extruder

Extruder
die cooling

Return water sump

HP - 10
Actual - 6 kW
H - 29 m
Q - 17m3/hr

HP - 20
Actual - 12 kW
H - 39 m
Q - 23 m3/hr

HP - 20
Actual - 16.2 kW
H - 56 m
Q - 15 m3/hr

0.4 m3/hr

Extruder
conveyor cooling

3 m3/hr

9.4 m3/hr

Modified cooling water system for tube plant

10 HP
Actual - 6 kW

100 TR

Final
compounding
mill

8 m3/hr

2.5 m3/hr
Warming mill
1

HP - 20
Actual - 11 kW
H - 29 m
Q - 23 m3/hr

HP - 7.5
Actual - 4 kW
H - 22 m
Q - 16m3/hr

K4

HP - 3
Actual 1.4 kW
H - 22 m
Q - 17m3/hr

Feeding mill

0.23 m3/hr
Extruder

Extruder
die cooling

Return water sump

HP - 10
Actual - 6 kW
H - 29 m
Q - 17m3/hr

HP - 20
Actual - 12 kW
H - 39 m
Q - 23 m3/hr

HP - 20
Actual - 16.2 kW
H - 56 m
Q - 15 m3/hr

0.4 m3/hr

Extruder
conveyor cooling

3 m3/hr

9.4 m3/hr

Modified pumping system

Existing cooling water system for K4

10 HP
Actual - 6 kW

100 TR

Final
compounding
mill

8 m3/hr

2.5 m3/hr
Warming mill
1

HP - 20
Actual - 11 kW
H - 29 m
Q - 23 m3/hr

HP - 7.5
Actual - 4 kW
H - 22 m
Q - 16m3/hr

K4

HP - 3
Actual 1.4 kW
H - 22 m
Q - 17m3/hr

Feeding mill

0.23 m3/hr
Extruder

Extruder
die cooling

Return water sump

HP - 10
Actual - 6 kW
H - 29 m
Q - 17m3/hr

HP - 20
Actual - 12 kW
H - 39 m
Q - 23 m3/hr

HP - 20
Actual - 16.2 kW
H - 56 m
Q - 15 m3/hr

0.4 m3/hr

Extruder
conveyor cooling

3 m3/hr

9.4 m3/hr

Modified pumping system

Modified cooling water system for K4

10 HP
Actual - 6 kW

100 TR

Final
compounding
mill

8 m3/hr

2.5 m3/hr
Warming mill
1

HP - 20
Actual - 11 kW
H - 29 m
Q - 23 m3/hr

HP - 7.5
Actual - 4 kW
H - 22 m
Q - 16m3/hr

K4

HP - 3
Actual 1.4 kW
H - 22 m
Q - 17m3/hr

Feeding mill

0.23 m3/hr
Extruder

Extruder
die cooling

Return water sump

HP - 10
Actual - 6 kW
H - 29 m
Q - 17m3/hr

HP - 20
Actual - 12 kW
H - 39 m
Q - 23 m3/hr

HP - 20
Actual - 16.2 kW
H - 56 m
Q - 15 m3/hr

0.4 m3/hr

Extruder
conveyor cooling

3 m3/hr

9.4 m3/hr

Modified pumping system

Idle running of cooling water pump and fan

even when mill is not in operation
10 HP
Actual - 6 kW

100 TR

HP - 20
Actual - 11 kW
H - 29 m
Q - 23 m3/hr

Water keeps circulating

through the mills even
when they are not in
operation

HP - 7.5
Actual - 4 kW
H - 22 m
Q - 16m3/hr

K4

Compressed air: Leak vs actual demand

Demand
1000
900
800
700
600
500
400
300
200
100
0

12

13

14

15

16

17

19

20

21

22

23

Leak

10

11

Anticipated Compressed air demand pattern

(After minimising leaks)

Demand

Leak

700
600

Cfm

500
400
300
200
100
0
12

13

14

15

16

17

19

20

21

22

23

Time (Hrs)

10

11

Existing cooling water system for tube plant

10 HP
Actual - 6 kW

100 TR

Final
compounding
mill

8 m3/hr

2.5 m3/hr
2
1

Warming mill

HP - 20
Actual - 11 kW
H - 29 m
Q - 23 m3/hr

HP - 7.5
Actual - 4 kW
H - 22 m
Q - 16m3/hr

Feeding mill

K4

0.23 m3/hr
Extruder

Extruder
die cooling

Return water sump

HP - 10
Actual - 6 kW
H - 29 m
Q - 17m3/hr

HP - 20
Actual - 12 kW
H - 39 m
Q - 23 m3/hr

HP - 20
Actual - 16.2 kW
H - 56 m
Q - 15 m3/hr

0.4 m3/hr

Extruder
conveyor cooling

3 m3/hr

9.4 m3/hr

Modified cooling water system for tube plant

10 HP
Actual - 6 kW

100 TR

Final
compounding
mill

8 m3/hr

2.5 m3/hr
Warming mill
1

HP - 20
Actual - 11 kW
H - 29 m
Q - 23 m3/hr

HP - 7.5
Actual - 4 kW
H - 22 m
Q - 16m3/hr

K4

HP - 3
Actual 1.4 kW
H - 22 m
Q - 17m3/hr

Feeding mill

0.23 m3/hr
Extruder

Extruder
die cooling

Return water sump

HP - 10
Actual - 6 kW
H - 29 m
Q - 17m3/hr

HP - 20
Actual - 12 kW
H - 39 m
Q - 23 m3/hr

HP - 20
Actual - 16.2 kW
H - 56 m
Q - 15 m3/hr

0.4 m3/hr

Extruder
conveyor cooling

3 m3/hr

9.4 m3/hr

Modified pumping system

Existing cooling water system for K4

10 HP
Actual - 6 kW

100 TR

Final
compounding
mill

8 m3/hr

2.5 m3/hr
Warming mill
1

HP - 20
Actual - 11 kW
H - 29 m
Q - 23 m3/hr

HP - 7.5
Actual - 4 kW
H - 22 m
Q - 16m3/hr

K4

HP - 3
Actual 1.4 kW
H - 22 m
Q - 17m3/hr

Feeding mill

0.23 m3/hr
Extruder

Extruder
die cooling

Return water sump

HP - 10
Actual - 6 kW
H - 29 m
Q - 17m3/hr

HP - 20
Actual - 12 kW
H - 39 m
Q - 23 m3/hr

HP - 20
Actual - 16.2 kW
H - 56 m
Q - 15 m3/hr

0.4 m3/hr

Extruder
conveyor cooling

3 m3/hr

9.4 m3/hr

Modified pumping system

Modified cooling water system for K4

10 HP
Actual - 6 kW

100 TR

Final
compounding
mill

8 m3/hr

2.5 m3/hr
Warming mill
1

HP - 20
Actual - 11 kW
H - 29 m
Q - 23 m3/hr

HP - 7.5
Actual - 4 kW
H - 22 m
Q - 16m3/hr

K4

HP - 3
Actual 1.4 kW
H - 22 m
Q - 17m3/hr

Feeding mill

0.23 m3/hr
Extruder

Extruder
die cooling

Return water sump

HP - 10
Actual - 6 kW
H - 29 m
Q - 17m3/hr

HP - 20
Actual - 12 kW
H - 39 m
Q - 23 m3/hr

HP - 20
Actual - 16.2 kW
H - 56 m
Q - 15 m3/hr

0.4 m3/hr

Extruder
conveyor cooling

3 m3/hr

9.4 m3/hr

Modified pumping system

Idle running of cooling water pump and fan

even when mill is not in operation
10 HP
Actual - 6 kW

100 TR

HP - 20
Actual - 11 kW
H - 29 m
Q - 23 m3/hr

Water keeps circulating

through the mills even
when they are not in
operation

HP - 7.5
Actual - 4 kW
H - 22 m
Q - 16m3/hr

K4

Provide interlocks to avoid idle running of

pump and cooling tower fan
10 HP
Actual - 6 kW

Interlock between pump &

cooling tower fan and dump
mill will ensure that pump
and fan are switched off
when mill is not in
operation
1

100 TR

HP - 20
Actual - 11 kW
H - 29 m
Q - 23 m3/hr

HP - 7.5
Actual - 4 kW
H - 22 m
Q - 16m3/hr

K4

Existing cooling water supply

system for 8 Extruder
Extruder

Cracker mill

Warming mill

Feeding mill
Return
Supply

Proposed series cooling water

supply system for 8 Extruder
Extruder

Cracker mill

Warming mill

Feeding mill
Return
Supply

Existing hot air blowing system

for moisture removal
Electric heater 4 kW

Hot air

Extruder
Cutting

Chalk powder bath

Cooling conveyor

Modified system with more surface

contact between air and tube

Ambient air

Extruder
Cutting

Chalk powder bath

Modified air
blowing arrangement

Cooling conveyor

Existing hot air system for tread

cooling in 8 extruder

Electric
heater 9 kW

Hot air
Cutting

Extruder
Cooling conveyor

Modified ambient air system with

change in air blow angle

Ambient air
Cutting
Extruder
Cooling conveyor

Existing steam supply to canteen

18 kW

18 kW

Steam jacketed vessels

Electric Boilers

Proposed steam supply to

canteen
Steam supplied
from boiler house
Hot water tank
Proposed extension of steam line to canteen

Workers bathroom
Steam jacketed vessels