INTRODUCTION

Retreading of damaged tyre is done

by conventional hot matrix curing in
most cases. But recently a new
technology has been developed called
Precured Tread Rubber Retreading
Process which is commonly known as
Cold Process Retreading. In this
process, the Precured Tread Rubber
already has a tread pattern on it
eliminating the need for a tread matrix
at vulcanizing stage. Tread Rubber is
precured along with other raw materials
and manufactured in the factory under
controlled conditions and given a well
researched pattern ensuring that the
transporter gets a reliable perfectly finish
product. Retreading Tyre by precured
method gives 50% more mileage than the
tyre retreaded by conventional process.
Tyre Retreading (By Cold Process)
PRODUCT CODE : 300401000
QUALITY AND STANDARDS : Manufacturers own specifications
PRODUCTION CAPACITY : 1. LCV Tyre Retreading
Size-70015-2400 Nos.
2. Passenger Car Tyre Retreading
Size-59015-3600 Nos.
3. Truck Tyre Retreading Size 300x20-3000
Value : Rs. 91.8 Lakhs
MONTH AND YEAR : December, 2002
OF PREPARATION
PREPARED BY : Small Industries Service Institute
P.O.-Tadong, Gangtok - 737102 (Sikkim)
Telephone Nos. : (03592)-231262/231880
Telefax :03592-231262
E-mail-slg sisigtk@sanchar.net.in
MARKET POTENTIAL
The market demand of tyre retreading
by cold process is increasing day by day.
There is a good scope for setting up
units for tyre retreading by cold process
using procured tread rubbers.
BASIS AND PRESUMPTIONS
This project profile has been prepared
based on the following presumptions:
1. Production capacity is calculated
on single shift of 8 hours a day
for 300 working days in a year at
75% efficiency.
2. Capacity utilization is 60% during
first year 80% in second year and
full capacity utilization from 3rd
year onwards.
21
108
3. The salaries and wages, cost of
raw material, utilities, rent of the
shed etc. are based on prevailing
rates in and around local region
hence cost factor is likely to vary
with location of the units.
4. Interest on ter ms loan and
working capital has been taken @
16% on an average. The rate may
vary depending upon policy of
financial institutions and agencies
from time to time.
5. The cost of machinery and
equipments refers to particular
make and model and prices are
approximate to those ruling at the
preparation of the same.
6. The project preparation cost, non-
refundable deposits, may be
considered under the head of pre-
operative expenses.
7. The break even point is calculated
on full capacity utilization.
8. Shed rental charges are Rs.
10,000 per month. The rate is
likely to vary depending upon the
location of the units.
9. Power at the rate of Rs. 3.50/KW
is taken.
10. The operation period of this
project is estimated to be about
10 years considering technology
obsolescence.
IMPLEMENTATION SCHEDULE
Sl.No. Activity Period
1. Site selection preparation of 6 months
project report and other formalities,
application for loan and finance/
disbursement and,
DIC registration etc.
2. Seeking quotation for machines, 3 months
purchase, installation and power
Sl.No. Activity Period
connection, obtaining clearances
from Pollution Control Board
and other Govt. bodies and
agencies.
3. Procurement of raw material, 3 months
recruitment of staff and labour
and commercial production
4. Total period required for 12 months
commencing commercial
production.
TECHNICAL ASPECTS
Process of Manufacture
The t yr e coming f r om t he
customers is cleaned dully. Dust and
mud are removed. The casi ng i s
i nspect ed f or cut s, pl y sect i on,
condition of beads etc., and based
on the condition of the casing, the
tyre is selected or rejected. Under
inflated conditions the selected tyres
crown area is buffed to the required
texture and contour. This is for better
bonding of procured rubber to the
casing. The buffed casing is mounted
on t he t read bui l di ng machi ne.
Cushion compound is applied on the
buffed tread area over which the
procured tread rubber is applied and
sti ckl ed usi ng rol l ers. The j oi nt
portion of the procured tread rubber
is stepped to avoid possible opening
during curing of the tyre. The build
up of the tyre is covered by a rubber
envelope and placed in the bonder
and the bonder steam is passed at
specific temperature, which cures the
cushion compound to complete the
bonding of the tread on the casing.
Quality Control and Standards
No such standard is available but the
treading will be done as per the
specifications fixed by tyre manufacturers.
TYRE RETREADING (BY COLD PROCESS)
109
Sl. Particular Ind/ Qty. Price Total
No. Imp Nos. (Rs.) (In Rs.)
bonder with
curing rims and
Electric hoist
2. Work bench Ind. 1 35,000 35,000
Envelope/Tyre
stand Gantry
3. Boiler cap. do 1 2,25,000 2,25,000
300 kg/hrs.
4. 100 Ibs working do 1 40,000 40,000
pressure Air
compressor
fitted with 5 H P
Motor
5. Air conditioner do 1 50,000 50,000
Total 9,50,000
Electrification and Installation at Rs. 95,000
10% of the above cost
Office Equipments and Furniture. LS Rs. 50,000
Cost of Auxiliary items. i.e. Rs. 1,50,000
pipe erection Electric fittings,
Retreading, Tools, Mechanical
Hoist with Trolley etc.
Total 12,45,000
(iii) Pre-operative Expenses Rs. 50,000
Total 12,95,000
Total Fixed Capital Requirement Rs.12,95,000
B. Working Capital (per month)
(1) Personnel
Sl. Description Nos Salary Total
No. (Rs.) (In Rs.)
1. Manager 1 8,000 8,000
2. Supervisor (Technical) 1 6,000 6,000
3. Skilled Workers 5 3,500 17,500
4. Semi-skilled Workers 6 3,000 18,000
5. Un-skilled Workers/ 3 2,000 6,000
Helper
6. Clerk cum Typist 1 2,500 2,500
7. Salesman 1 2,500 2,500
8. Office Assistant- 1 2,000 2,000
cum-peon
9. Watchman 1 2,000 2,000
Total 64,500
Production Capacity (per annum)
1. LCV Tyre retreading Size-70015 2400 Nos.
2. Passenger Car Tyre Retreading 3600 Nos.
Size-59015
3. Truck Tyre Retreading Size-30020 3000 Nos.
Motive Power 20 HP.
Pollution Control
Tyre Retreading work generally should
not be done in public place and NOC
from Pollution Control Board may be
obtained.
Energy Conservation
All efforts are to be put in for optimum
utilization of power. The following
measures can be adopted to conserve
power and save energy:
1. Proper maintenance of power
operated equipments and
machinery and fuel operated
boiler and their judicious use.
2. Shed to be properly ventilated and
covered with transparent sheet to
have enough light in day time with
minimum requirements of lighting.
FINANCIAL ASPECTS
A. Fixed Capital
(i) Land and Building (In Rs.)
Covered area for workshop, office, 10,000
stores etc. and open Area -
2000 sq feet (per month).
(ii) Machinery and Equipment
Sl. Particular Ind/ Qty. Price Total
No. Imp Nos. (Rs.) (In Rs.)
1. Buffing machine Ind 1 6,00,000 6,00,000
with dust collector
builder tyre truck
bonder/three
tyre LCV/Passenger
TYRE RETREADING (BY COLD PROCESS)
110
(ii) Raw Material (per month)
Sl. Description Qty. Ind/ Price Total
No. Imp (Rs.) (In Rs.)
a) For Retreading 200 LCV Tyre
in Precured System
i) Precured Tread 1,000kg Ind 85/Kg 85,000
Rubber
ii) Cushion 100 Kg do 84/Kg 8,400
Compound
iii) Vulcanising 60 Ltr. do 60/Ltr. 3,600
Solution
iv) Envelope 200 Nos. do 5/Nos 1,000
v) Curing Bag 200 Nos do 5.5/Nos 1,100
Total 99,100
b) For Retreading 300
Passenger Car Tyre in Precured System
i) Precured 900 kg Ind 85 Kg 76,500
Tread Rubber
ii) Cushion 105 Kg do 84 Kg 8,820
Compound
iii) Vulcanising 75 Kg do 60/Ltr. 4,500
Solution
iv) Envelope 300 Nos do 5/Nos. 1,500
v) Curing Bag 300 Nos do5.5/Nos. 1,650
Total 92,970
c) For Retreading 250 Nos.
Truck Tyre in Precured System
i) Precured 2375 kg Ind 85 2,01,875
Tread Rubber Kg
ii) Cushion 252 Kg do 84 Kg 21,168
Compound
iii) Valcanising 250 Ltr. do 60/Ltr. 15,000
Solution
iv) Envelope 250 Nos. do 5/Nos. 1,250
v) Curing Bags 250 Nos. do5.5/Nos. 1,375
Total 2,40,668
Total Raw Material 4,32,738
Say 4,32,800
(iii) Utilities (per month) (In Rs.)
Power @ Rs. 3.50 for 3600 units 12.600
Fuel for Boiler 20,000
Total 32,600
(i v) Other Contingent Expenses (In Rs.)
1. Rent 10,000
2. Postage and Stationery 2,500
3. Insurance and Taxes 2,000
4. Telephone 1,500
5. Repair and Maintenance 2,000
6. Publicity and Advertisement 2,500
7. Travelling and Transport 6,000
8. Renewal and Replacement 1,500
9. Other Miscellaneous Expenses 5,000
Total 33,000
(v) Total Recurring Expenses (In Rs.)
1. Staff and Labour 64,500
2. Raw Material 4,32,800
3. Utilities 32,600
4. Other Contingent Expenses 33,000
Total 5,62,900
Say 5,63,000
(vi) Total Working Capital for 3 Months
Rs. 5,63,000 x 3 = Rs. 16,89,000
C. Total Capital Investment
1. Fixed Capital Rs. 12,95,000
2. Working Capital (for 3 month) Rs. 16,89,000
Total Rs. 29,84,000
FINANCIAL ANALYSIS
(1) Cost Of Production (per annum) (In Rs.)
1. Recurring Expenses 67,56,000
2. Depreciation on Machinery @ 10% 95,000
3. Depreciation on tool and 30,000
Fixtures @ 20%
4. Depreciation on Furniture and 10,000
Office Equipments @ 20%
5. Interest on Total Capital 4,77,450
Investment @ 16%
Total 73,68,450
(2) Turnover (per annum)
a) Precured Retreaded Charge for LCV
Tyre size -70015, 2400 Nos. Rs. 900
= Rs. 21,60,000
b) Passenger Car Tyre Size - 59015,
3600 Nos. x Rs. 700 = Rs. 25,20,000
TYRE RETREADING (BY COLD PROCESS)
111
c) For Truck Tyre Size - 300 20,
3000 Nos. x Rs. 1500 = Rs. 45,00,000
Total Rs. 91,80,000
(3) Profit (per annum)
Sales Cost of Production
= Rs. 91,80,000 73,68,450 = Rs. 18,11,550
(4) Net Profit Ratio
=
Profit (per annum) 100
Sale (per annum)
=
18,11,550 100
91,80,000
= 19.7%
(5) Rate of Return
=
Profit (per annum) 100
Total Capital Investment
=
18,11,550 100
29,84,000
= 61% Appx.
(6) Break-even Point
Fixed Cost (In Rs.)
1. Rent 1,20,000
2. Depreciation on Machinery @ 10% 95,000
3. Depreciation on Tools and 30,000
Fixtures @ 20%
4. Depreciation on Furniture and 10,000
Office Equipments @ 20%
5. Interest @ 16% 4,77,450
6. 40% of Salary and Wages 3,09,600
7. 40% of Utilities and Other 2,66,880
Contingent Expenses
Total 13,08,930
B.E.P.
=
Fixed Cost x 100
Fixed Cost + Profit
=
13,08,930 x 100
13,08,930 + 18,11,550
= 42%
Addresses of Machinery Suppliers
1. M/s. Security Equipment
Engineers
48, Chetla, Road,
Kolkata- 700027
2. M/s. Industrial Rubber Products
20, Khanpara Road,
Kolkata - 700065
3. M/s. Nandi and Co.
125, Belilious Road,
Howrah - 711101 (WB)
4. M/s. Chand and Co. Engineering
Pvt. Ltd.
3/18, Mahendra Road,
Kolkata-700025
5. M/s. Die Hard Polimer Products
117, Ghorkha Basi Road,
Kolkata - 700028
Addresses of Raw Material Suppliers
1. Local Market
2. M/s. H. K. Agarwal and Co. Sevoke
Road,
Siliguri734401
3. M/s. Beekay Hardware
Tadong, Gangtok,
Sikkim737102
4. M/s. Cherry. Pvt. Ltd.
31-A National Highway, Gangtok,
Sikkim737101
5. M/s. Vinod Enterprises
Near Convey Ground, Tadong,
Gangtok,
Sikkim737101.
TYRE RETREADING (BY COLD PROCESS)