Tyre Retreading Machine

Retreading Process

Retreading is a process through which we can use our old tires. In this method, the worn cover of a tire which has a good structural property is unloaded and placed through a process in which it is completely refurbished and holds the rubber sideways. After that, the modified tire is pushed forward for an improvement process, in which the new rubber is vulcanized into the original cover and, therefore, the tire gets a new fabricated trade pattern. Over the years, there has been a lot of development in the tire manufacturing industry worldwide. High standard tires are being manufactured using premium technologies, so that they can perform not only in their 'first life', but also in their second and third lives. So, along with this, the retread tire industry is also growing, as stronger tire coverings, enhanced re-manufacturing technology and higher quality rubber compounds are being used.
A retread tire starts its life as a tire malfunction. When you find out that the trader is down to 2-3mm or if it is already re-waistned, or if your tire has punctures and needs repair, it needs to be stretched. In these cases, you will need to take your tire to an experienced technician, who will examine and inspect the tire to see if it is in a recoil position. If the specialist finds it okay, you can go to get your tire back.

 1. Collection of casings

Wern tires are collected to select the appropriate casings for the tire retread.

2. Initial inspection

Each tire received at a retread plant is subjected to rigorous visual inspection. Inspectors are assisted by the use of non-destructive sophisticated inspection equipment such as the 540/2 Spectra or Nevera inspection machine.

3. Buffering after inspection

The older tread of the tire has been mechanically removed on high-speed buffers. Today's buffers are highly accurate and will remove the appropriate amount of rubber, turning the tire to a precisely specified diameter and radius. The collaboration with international leaders such as MATTEUZZI enables Navira to make computerized world-class equipment under license for Asia.

4. Segment repair and skiing

With advances in state-of-the-art repair materials and repair methods, many of these tires can be repaired regularly and in most cases worn while running the original. The repair station is where any surface injury is treated using effective materials and equipment for grinding and patching.

5. Cement and Filling

Even in minor injuries, it is important that the injury is cleaned and filled. If this is not done, severe corrosion, separation and steel cable loosening can be taken out of service. The injury should be inspected, and then cleaned with a carbide cutter. After the injury is reinforced, a vulcanizing rubber stem must be applied to "fill" the injury. This will create a permanent repair that maximizes tire life.
With Nevera's designed and built spray booth, your cement operation can be executed in a clean, efficient and environmentally responsible manner.

6. Building rubber

In the pre-curing system, the tread rubber is already vulcanized with the new tread pattern design. Buffed tires require a thin layer of cushion gum to be wrapped around their crown area. The pre-cured rubber is then applied with the building machine. This is called the manufacturing process.

7.

A) envelope and rim mounting or

Manufactured tires are again fitted with envelopes and rims to prepare them for curing.

B) double envelope system

For envelopes, the tires are first fitted into an outer envelope on the envelope-mounting table, before the inner envelope is fitted into them. The covered tires are vacuumed again to prepare for curing. In modern plants their veils are flanked by monorail systems. With professional planning from the engineers at Nevera, you can be assured of workstations that are designed to maximize output and make workflow easier.

8. Treatment by Chamber

The tire is placed in a curing chamber and the pre-cured tread is followed by the tire through a vulcanizing process.
Our extensive engineering capabilities and experience enable us to shape the different preferences of our customers, creating steam heating, electric heating or building new for double heating systems, semi-automatic and automatic chambers.
Monorail and hook systems increase productivity by cutting the possibility of contamination and allow for faster loading and unloading of tires. This increases the safety and productivity of your work space.

9. Final Inspection and Painting

Retread tires have been subjected to final inspection. This inspection states that only tires that meet industry quality standards are allowed to leave the retread plant. All retired tires are encouraged to return along the pavement painted using a light coat of black tire paint.

1.Tyre Testing System

The Shearography Tire Test System has been developed for non-destructive testing of new tires in R&D and quality control, as well as for inspection of tire carcasses in the retreading industry. The technical basis of the system is the phase shearography system.
During the test cycle, a pressure difference (vacuum, for example 50 m) is generated in the vacuum chamber, causing distortion, which is caused by
Expansion of air pockets occurs in defective areas in the carcass of the tire. With the phase shirography technique - a holographic measurement method that detects physical deformation in the micron range - the defective areas can be clearly and reproducibly

2. Buffing Machine

The method of computer programming and operation of RAS 90-DC is very simple and does not require any special preparation
      The computer will accept up to 1,000 programs to give any buffer profile to spread "hot" or "cold"
      high productivity
      low power consumption
      Suitable for tires from 12 ″ to 24 suitable (including 18-22.5 tires) - minimum external tire dismeter 515 mm., Maximum 1250 mm.

3.Tyre Repair Station

 Ideal for truck tire repair or inspection
      Handles all passenger, light truck and truck tires
      Tires built in lifters lead to work height
      Optional track for monorail system
      Lifting capacity: 250 kg
      Lifting height: 750mm
      Air supply: 8-10 times

4.Retrax Extruder Machine 

Computer controlled / Simple / Robust / Effective
Save cushion gum costs by using single size of feed strip
Save cement spraying costs with correctly formulated cushion gum
Save labor costs by automatic skive filling

5. Tire Building Machine 

Suitable for purchase process and camel
      Applicable for light truck and truck tire sizes from 15 ”to 12.00 - 24
      Double selection of sewing pressure for cushion gum, liner and camelback
      Rotation motor: 2 hp / 1.5 quid with fast / slow speed selection
      Stitcher Motor: 2 HP / 1.5 Quad with fast / slow speed selection
      Voltage: 415/3/50
      Total amperage: 10 Amp (approx)
      Air supply: 8 times

6. OTR Envelope Spreader 

Convenient installation and removal of outer envelopes
      Applicable for sizes of tires from 14.00 - 24 ”to 2400 R35
      Motor power: 2 hp / 1.5 quad
      Voltage: 415/3/50
      Total amperage: 5 Amp (approx)
      Air supply: 8 times

6.Rim Mounting Station 

Tilting table handles truck tires easily
      Designed to handle all 20 ″ and 22.5 all preacher rims. Other rim sizes may be specified.
      Air powered
      Pressure required: 8 bar

7. Ferlex chamber 

Ferralex is continuously working to supply the market with premium quality products. For this reason, its policy focuses on production growth and improvement.

The experience of producing over two thousand autoclaves for various purposes is a proof of our customers' satisfaction and loyalty. At least, this is the result of 30 years of continuous work and learning.

Ferralex manufactures light trucks ranging from 6-tires to 30-tires and OTR tires from autoclaves.

With safety, quality and breakthrough technology, Ferralex autoclaves provide high quality and uniformity to your production. They can be manufactured in many different sizes and configurations, according to the characteristics of the customer and production versions.

    Radial locking door: Easy, fast and light opening and closing movement to require no lever, piston or other maintenance generating mechanism. Radial system avoids friction with trim, and reduces wear
    Encapsulated motor: Since the motor is installed externally encapsulated, it is operating at low temperatures, but under the same pressure; The motor does not require any mechanical seal, motor winch and fan belt, thus the autoclave fan is running more efficiently and at lower maintenance costs
    Internal thermal insulation: Since the device body does not require heating, its operation time is short, and this process is accelerated, thus increasing output, and enabling larger power or vapor economy goes.
    Electric control board: Set up with high quality components, it provides high reliability and easy replacement. The electrical control board subsequently provides precise control of vulcanization magnification, thus securing the repetition of conditions in all working cycles.
    Kit EPS (Third Pressure): Introduces a positive pressure in the movable design, allowing it to set the casing more firmly. Envelopes extend life time, distribute connections evenly, and prevent connection distortion
    Double heating (optional): The autoclave can be supplied with double heating means, and can be worked with electric resistance or steam heat exchangers

final inspection

8. High pressure testing Machine 

Handles tires from 15 ″ to 22.5 Hand
     Tire inflation predetermined at 2, 4 and 8 times (maximum) for better QC inspection
     Attached as security by steel cage
     The test cycle ended automatically to reduce supervision work
     Light well within the cage for better visual inspection
     Driving motor: 2Hp / 1.5 Kw with programmable fast / slow speed
     Power: 110V / 3Ø / 60 Hz / 40 Amp
     Air supply: 10 times

 

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