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See how a tyre is recreated!

Retreading is not only a cost effective procedure but also environment responsible. It is the process of coating the worn away tyre with a tread or mould so as to remodel it and make it work exactly like a brand new one.

Retreading not only saves a bulk of your money that you spend on buying a new tyre but also helps in saving gallons of oil, thus, resisting new carbon emissions in the atmosphere.

Material Used for Tyre Retreading are as follows:

  1. Tread Rubber
  2. Cushion
  3. V-Cement (Vulcanizing Cement)
  4. Patch
  5. Envelops and AirBag (Tube)
  6. Buffing Blades ; Rasping Blades
Tyre retreading process | Tyre retreading in udaipur, Tyre retreading in Rajasthan, Tyre retreaders Udaipur | Highway Tyre Retread

The Tyre Retreading Process flowhart

PROCESS:

Mainly two procedures are followed to carry out retreading:

  1. Cold Process
  2. Hot Process

Terms used:

Tread Rubber (TR)                      : Rubber Belt

Casing                                             : Tyre to be retreaded

Cushion                                          : Semi-solid form of rubber used to stick tread rubber on tyre

Solution                                         : Liquid form of rubber used to stick cushion and tread rubber

 

Basic steps for both the processes is almost same. The only difference is that, in Cold Process, we use a procured belt (Tread Rubber) with particular design or pattern that is made to stick to the tyre and then the whole tyre is heated in a furnace for final shaping and strengthening. While in Hot Process, we use a Plain Tread Rubber which, after sticking to the tyre is put in a mould cum conveyor to heat up and turn into a proper shape.

  • Checking: The first and the basic step include checking of any wear and tear in a tyre. There are Nylon Plys overlapping each other in a tyre. Sometimes, there causes an air separation between these plys. Thus, one can detect the air separation in a tyre by the change in its sound while hitting on the wall from inside and outside through a hard metal tool. Similarly, one should check for cuts in tyre. If there is no air separation and the cuts are small or repairable, then the tyre is passed to get retread, otherwise, it gets rejected.
  • Cleaning and Vending: After finding the worn away areas, the tyre is then cleaned with water so that all the dirt or any other material present on the tyre gets washed off. This is basically done so that any type of polishing or oiling on the tyre can be carried out easily.

Vending is done only on Nylon tyres and not on radials. It is done to eliminate any left proportion of unwanted air. The side walls of a tyre are drilled by 2mm so that at the time of curing the air between the plys can pass through it to avoid air separation.

  • Buffing: After vending, the tyre is buffed on a machine so as to remove the old tread and replace it with new finishing. Also, the small patches on the surface and the condition of tyre are checked for.

In case of cold process, only top surface gets buffed but, in case of hot process, we have to buff it from side walls as well.

  • Rasping: This is mainly done to smoothen the buffed surface’s roughness and make it planer. The cuts or any similar damages present on the tyre’s surface are rasped and left till they loosen up. This process makes sure that there are no loose cuts and the cuts are properly visible.

Highway Tyre Retread

  • Building : Building is a process in which four things happen,
  1. Solution: After rasping, a solution named Vulcanizing Cement (Liquid form of rubber) is spread on the tyre’s surface and is kept untouched for 1 hr. It works as an adhesive.
  2. Filling and Patching: The cuts and the damaged areas are filled with cushion and made equal to the surface. Different sized patches are used to cover different cuts.
  • Tread Rubber Building: Tread rubber is then built on the cushioned tyre and is pressed mechanically against high pressure to properly stick to the tyre. After this, the tyre is covered by a cover before leaving it for curing in an electric chamber.
  • Curing: Finally, the complete tyre gets cured in the electric chamber for 2 to 3 hours at 150 0 Centigrade at about 110 PSI Pressure.

After completion of the process, the cured tyre is rechecked and eventually sent to the customer.

MACHINES USED:

  1. Electric Chamber
  2. Buffing & Rasping Machine
  3. Building Machine
  4. Moulding Machine (For Hot Process)
  5. Aluminium Moulds
  6. Boiler
  7. Compressor
  8. Generator