Tyres are ubiquitous, an integral part of our daily landscape. We see them lining the streets, whirling past us on highways, and even stacked in garages. Whether you're behind the wheel, riding a bus, or simply observing the flow of traffic, tyres are a constant presence, silently facilitating our journeys.

But amidst the familiarity, have you ever paused to consider the journey they undertake? The intricate process of transforming raw materials into these robust, reliable circles that carry us forward? If so, prepare to be enlightened. Today, we are sharing a detailed look into the fascinating world of tyre manufacturing.

Raw Materials Needed

Tyre manufacturing begins with a blend of various raw materials, each contributing specific properties to the final product. The main ingredients include:

• Rubber: Primarily used in the form of synthetic rubber (styrene-butadiene rubber (SBR) and polybutadiene rubber (BR) are common), but natural rubber is also used, especially in truck tyres for its superior heat dissipation and durability.

• Carbon Black: A fine, black powder that acts as a reinforcing agent, enhancing the tyre's strength, wear resistance, and UV protection.

• Sulfur: Used in the vulcanization process to crosslink rubber molecules, making the rubber strong and elastic.

• Steel: Used in the form of wires and belts to reinforce the tyre's structure and provide strength, stability, and puncture resistance.

• Textiles (Fabric Cords): Made from nylon, polyester, or rayon, these are used to build the tyre's body plies, providing flexibility and strength.

• Chemicals and Additives: A variety of chemicals, including oils, resins, antioxidants, and accelerators, are used to improve processing, performance, and longevity.

These ingredients undergo factory processes to make the tyre compound. While the overall process remains similar, every brand has their own way of doing it.

Mixing the Compound

The tyre compound is made in three steps:

Step 1 - Batching: The raw materials are weighed and measured precisely according to specific formulations for different tyre components (tread, sidewall, inner liner, etc.).

Step 2 - Mixing: The materials are combined in a large, powerful mixer called a Banbury mixer or an internal mixer. This process involves intense kneading and heat generation to create a homogenous rubber compound.

Step 3 - Milling: The mixed compound is then passed through a series of rollers to further refine the mixture, cool it, and form it into sheets or strips.

Thus readied, the compound is moulded into making the various components of a tyre.

Building the Tyre Components

Tyres are built in layers, starting from the inside out. Each component is carefully assembled to create the desired tyre structure.

Inner Liner: This is an impermeable layer made of synthetic rubber that holds the air inside the tyre.

Carcass Plies: Layers of rubber-coated fabric cords that form the tyre's main body and provide strength.

Beads: Hoops of steel wire wrapped in rubber that help secure the tyre to the wheel rim.

Sidewalls: The outer rubber layers that protect the carcass plies and provide flexibility.

Belts: Layers of steel cords encased in rubber that lie beneath the tread and provide puncture resistance and stability.

Tread: The outermost layer of rubber that makes contact with the road surface, providing grip, traction, and wear resistance.

Tyre Assembly

In this step, all the components come together on a specialized machine called a tyre-building drum. It happens in two stages:

First Stage Building: The inner liner, carcass plies, beads, and sidewalls are applied to the rotating drum in a specific sequence.

Second Stage Building: The belts and tread are then applied over the first-stage components.

Curing a.k.a. Vulcanization

This crucial step transforms the soft, pliable "green" tyre into a strong, durable finished product. In manufacturing terminology, "green" often denotes an unfinished or uncured state of a product. It doesn't refer to the color. In this context, a "green tyre" is a tyre that has been assembled from its various components (inner liner, carcass plies, beads, sidewalls, belts, tread) but hasn't yet been vulcanized in the mold.

The green tyre is placed in a mold that has the tyre's tread pattern and sidewall markings engraved inside. The mold is heated under high pressure, causing the sulfur to react with the rubber molecules and create crosslinks, a process known as vulcanization. This process also cures the rubber and molds the tyre into its final shape.

Inspection and Finishing

In the final step, the finished product is inspected for any defects or irregularities. Uniformity Testing Machines are used to measure tyre uniformity and balance. Some brands also use X-rays to check the finished tyres for internal defects. Lastly, any necessary trimming, cleaning, and marking are done to apply the finishing touch before shipping them to tyre shops near you.

Tyre variations

The basic manufacturing process outlined provides a fundamental understanding, but it's crucial to recognize that tyre construction and design vary immensely, tailored to specific vehicle types, performance needs, and driving conditions. This isn't simply a matter of size; it's about engineering a tyre that optimizes performance, safety, and efficiency for its intended purpose.

1. Types of Passenger Car Tyres:

Passenger car tyres are designed for the everyday journeys – the commute to work, the weekend road trip, the quick errand run. Built for comfort and efficiency, they strike a balance between performance, durability, and affordability.

Radial Tyres: Dominating the market, these feature plies that run radially (at a 90-degree angle) to the direction of travel. This construction leads to less heat build-up, longer tread life, improved fuel efficiency, and superior handling compared to bias-ply tyres.

All-Season Tyres: The versatile choice for most drivers, offering a balanced performance in dry, wet, and light snow conditions.

Touring Tyres: Prioritizing ride comfort and quietness, making them ideal for long drives. They typically feature a longer tread life and improved fuel efficiency.

Performance Tyres: Geared towards driving enthusiasts, these tyres provide enhanced grip and handling at higher speeds, often at the expense of tread life. They feature softer rubber compounds and specialized tread patterns for maximum contact with the road.

2. Types of SUV Tyres

SUVs demand more from their tyres. These vehicles, often tasked with carrying heavier loads, venturing onto rougher terrain, and tackling a wider variety of weather conditions, require a more robust and versatile tyre. So, SUV tyres are engineered to provide enhanced grip, increased load capacity, and greater durability than their passenger car counterparts.

All-Terrain Tyres: Designed for a mix of on-road and off-road driving, featuring more aggressive tread patterns for enhanced traction on gravel, dirt, and uneven surfaces.

Mud-Terrain Tyres: Optimized for serious off-roading, these tyres have large, deep tread blocks and reinforced sidewalls for exceptional grip in mud, sand, and rocky terrain.

Highway Tyres: Focusing on on-road performance for trucks and SUVs, prioritizing ride comfort, noise reduction, and long tread life.

3. Specialized Tyres

Beyond the mainstream, there exists a world of tyres crafted for very specific purposes. From the aggressive tread of mud-terrain tyres that conquer off-road obstacles, to the winter tyres designed to maintain grip in ice and snow, specialized tyres push the boundaries of performance and safety. These tyres aren't for every driver, but for those with particular needs or demanding conditions.

Winter Tyres (Snow Tyres): Featuring unique rubber compounds that remain flexible at low temperatures and aggressive tread patterns designed for maximum grip in snow and ice. They are essential for safe driving in winter conditions.

Run-Flat Tyres: Designed to allow a vehicle to continue driving for a limited distance even after a puncture, providing added safety and convenience. They feature reinforced sidewalls to support the weight of the vehicle with reduced air pressure.

Competition Tyres (Racing Tyres): Employing advanced rubber compounds and tread designs for maximum grip and performance on race tracks. They are often not street legal due to their limited lifespan and specialized characteristics.

Agricultural Tyres: Designed for tractors and other farming equipment, featuring large, deep lugs for optimal traction in fields and other agricultural settings.

Aircraft Tyres: Engineered to withstand the extreme conditions of takeoff, landing, and high speeds, with robust construction and specific tread patterns.

Also Read: Guide to Tyre Recycling: Everything You Need to Know

Beyond design, the materials used in tyre construction also contribute significantly to their performance characteristics. For example, the silica-based tread material in Apollo Alnac 4GS offers superior grip on dry and wet surfaces for excellent vehicle control. Adding silica to the rubber compound also reduces rolling resistance, contributing to improved fuel efficiency.

So, now you too know about the fascinating journey of a tire, from raw materials to road-ready companion. We hope you found this information insightful. Keep following Apollo Tyres for more intriguing insights into the world of tire technology and innovation!