Maxride Tyres & Tubes: Redesign of Boiler & curing presses

REGA association with

Maxride Tyres & Tubes

Max Ride (India) Rubber Private Limited, is a leading manufacturer and exporter of various ranges of High Quality Tyres & Tubes. REGA Consultancy was hired in 2016 for expansion of their existing tube manufacturing to tyre manufacturing facilities. Also, REGA worked on shortcomings in the existing facility in boiler & curing area along with recommendations to overcome them.

Here are a few major benefits of Maxride Rubber Pvt. Ltd. By partnering with REGA Consultancy Services:

Challenges

There were many challenges in machine selection & design layout as the current tube facility has restricted space and in the space the tyres manufacturing facility has to be incorporated with efficient production.

Machineries Selection for Business expansion from Tube to Tyre Manufacturing Plant.
Design Layout finalization of Curing Presses for new plant setup in the small, covered area.
The minimum steam & pressure from the existing boiler was was not sufficient for efficient production.
The minimum temperature from existing curing press was not sufficient for efficient production.
Higher Steam Consumption.

Findings

The Chief Consultant and Project Engineer visited the plant for 2 days. A very detailed inspection was done in the boiling & curing presses area.

The minimum steam & pressure from the existing boiler was 10kg, while required was 13-14 kg.
The minimum temperature from curing presses was 150 Degree, while required was 175-180 Degree.
Steam ratio was higher (4:1), i.e, 4 kg of steam required for 1 kg of required tyres due to which steam consumption was higher.

Solution Provided

Corrective action was taken on these while onsite visit and solutions were provided for each challneges. Also, Best Machineries recommendations with their dealer’s information was provided for the tyre manufacturing facilities.

Cleaning of tubes of boilers & water softener parameter checked &
Faulty Steam Traps rectified/Replaced at boiling & curing area.
Steam pipeline design correction was provided.
Complete steam pipeline from boiler to curing presses and return were properly insulated.
Steam condensates were collected & feed to boiler back to reduce fuel efficiency. (15%)

Results

Recommendations were provided for the shortcomings in the existing facility to overcome them and helped in machineries selection & finalization with machine design layout.

Proper Design Layout of Curing presses was finalized in the given small covered area.
The minimum steam & pressure was achieved to 14 Kg.
The minimum temperature was achieved to 180 Degree.
The steam ratio was achieved to 3:1, i.e., reducing steam consumption.
Steam Consumption reduced to 15%.