Manufacturing a tyre not only requires the latest technology, precision instruments and qualified people but also requires qualified suppliers.
Working together with our customers and leading research institutions, we have developed a full range of belting products for the Tyre Industry.
With the unique product portfolio of fabric based Process and Conveyor Belts, as well as uni Modular Belts, Ammeraal Beltech provides the best technical belting solutions for all tyre manufacturing processes.
Explore Tyre Manufacturing processes and our recommended products
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Este infográfico apresenta apenas um exemplo geral de referência.
As configurações reais das fábricas e dos processos podem variar, mas nossos especialistas conhecem as diferentes possibilidades.
Components per tyre type recipe needs to be weighed and transported into the mixer.
Principais desafios
- Mistracking of the belt due to heavy load (load not always spread over the entire belt width)
- Sliding of raw materials on the belt surface
- Belt elongation due to heavy load causes more maintenance
Soluções
- Ammeraal Beltech Synthetic Belts with folded edges against fraying and v-ropes for better tracking
- uni Modular Belts to solve all issues
Raw materials are mixed into a homogeneous rubber compound. There are two different mixing types in the market:
- ‘Banburry’ – material mixed between 2 big drums (3-4 stages)
- ‘Continuous mixing’ – material mixed between two belts (sandwich) for 15-20 minutes
Principais desafios
- The rubber compound is very sticky
- Compound temperatures between 120 °C to 180 °C
- More change over due to multiple recipes
Soluções
- Ammeraal Beltech Synthetic Belts with Silam coatings for very good non-stick characteristics and resistance against the high temperatures
- Felt or Fabric Belts for the infeed and outfeed conveyors
- Mill to mill transport with our plastic modular solutions (available as metal detectable)
The mixed rubber compound needs to be stored on pallets before the next manufacturing steps are coming. To avoid that the rubber sticks together it is dipped in a soapy water bath, cooled and stored with a wig wag unit on pallets.
Principais desafios
- Very dirty environment (soap, water, temperature ~80° C)
- Rubber can be very sticky (bad release properties of the chosen belt)
- Belts in the dip tank are difficult to change
Soluções
- Ammeraal Beltech Synthetic Belts with impregnation have non-stick characteristics
- Our Modular Belts with the biggest open structure in the market to guarantee a good soap / water penetration in the dip tank
- Unique ZipLink® range for easy installation and less downtime
This is a mechanical process by which rubber is pressed into textiles (cloth, fabric) or steel cords to form composite sheets. Calendered textiles are used for casing, cap plies and chafers. Calendered steel cord is used for belts.
Principais desafios
- Rubber can be sticky (bad release properties of the chosen belt)
Soluções
- Ammeraal Beltech Synthetic Belts with impregnation have non-stick characteristics
- Our Modular Belts for longer lifetime and less maintenance
- AmWind liner solutions
inished steel cord (for Breaker Belt, Body Ply) and textile cord (Body Ply, Strip) is cut into appropriate sizes, shapes, and angles depending on the desired contour of the tyre.
There are three different cutting methods:
- Guillotine
- Rotary
- Hot blade
Principais desafios
- Conveyor belts can be damaged from the cutting device
- Vacuum is necessary for easy transport
- Replacement of timing belts on the feeder lines
Soluções
- Ammeraal Beltech Synthetic Belts with different covers specially chosen for the used cutting methods
- Quick fastener solution or welding solutions for timing belts
- Our AmWind liner solutions
Extrusion is the process by which heated rubber (80 °C – 120 °C) is pushed, under high-pressure, through an extruder head, to pre-shape the rubber. The next step is the cooling line where the rubber (tread, sidewall) is cooled and the dimensions are stabilised. The new semi products need to be stored before the next production step (TBM) and this is done via winding units (liner) or other storage systems.
Principais desafios
- Friction on the feeder belt must work perfect (no slippage but still good release)
- No mechanical fasteners allowed due to possible imprint on the rubber
- Long cooling lines are needed to cool down the rubber
- Pollution or waste due to damaged liner materials
Soluções
- Ammeraal Beltech synthetic belts with impregnation to have non-stick characteristics
- Our plastic modular belts with an open structure to guarantee a good water penetration in the cooling lines
- Non fraying liner material to avoid rubber pollution
- AmWind liner solutions
This is a mechanical process by which multiple rubber layers are pressed in a multi-roll calender towards one homogeneous rubber layer. An alternative is rollerhead equipment. The rubber compound plasticised in the extruder is conveyed via a wide extrusion die directly into the roll nip of a two-roll calender.
Principais desafios
- Rubber can be sticky (bad release properties of the chosen belt)
Soluções
- Ammeraal Beltech Synthetic Belts with impregnation to have non-stick characteristics
- Our Modular Belts for longer lifetime and less maintenance
- AmWind liner solutions
The first step in final finishing involves the tyre-building machine (TBM), with over 40 components that work to form the green tyre.
Principais desafios
- Rubber does not release from belt
- Low coefficient of friction between belt and rubber causes rubber to slip
- Many parallel running timing belts to accommodate extra-wide rubber leads to different elongation and mistracking
Soluções
- Ropanol Belts offer good release of sticky rubber
- Grip covers available
- Ultrasync Belts with widths up to 1000 mm
Curing is the process of applying pressure to the green tyre in a mould in order to give it its final shape, and applying heat energy to stimulate the chemical reaction between the rubber and other materials.
After the tyres are cured in the press, they are often cooled down on a conveyor belt and then transported to the trench line (collector line).
Principais desafios
- Temperature impact during cool down phase
- Mistracking of the conveyor due to temperature impact and wrong material combination
Soluções
- Ammeraal Beltech heat resistant Modular Belts
- Our roller top belts for the trench line
After the curing presses, the tyres are cooled before going for inspection and collecting. Finished tyres need to be handled with care, so transfer roller belts are used for conveying.
Principais desafios
- Tyres can jam on the belt, requiring manual intervention
Soluções
- Gentle handling from Felt NPF Belts and uni Modular Belts RTB M1 and M2 eliminate jams
Finished tyres need to be stored (short term) before they are transported to the hubs of the sales channels.
This storage has a demand of intralogistics where conveyor belts are often used.
To quickly load and unload trucks it is common to use telescopic loading systems.
Soluções
- Ammeraal Beltech Modular Belts for longer lifetime and less maintenance
- Our Synthetic Belts with easy connection solutions (ZipLock)
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| Código do Artigo | Descrição | Baixar |
|---|---|---|
| LWSB560008 |
SBR EF 16/2 00+C37 black
|
|
| SBFE000045 |
Felt NPF 40 black HC
|
|
| SBFL574552 |
Flexam EX 10/2 0+A42 black AS
|
|
| uni_rtb_m1_8_open |
uni RTB M1 8% Open
|
|
| uni_snb_m2_34 |
uni SNB M2 34%
|