1. Rubber mixing
June 1, 2007 saw the beginning of production of rubber mixtures using the new formula. KAMA-EURO tyre production is zero-cycle using Italian technologies.
The rubber mixture for KAMA-EURO tyres includes silica called carbon white used in tread production.
The presence of silica makes the rubber mixture more homogeneous, which improves the tyre's performance. Silica is widely used in production of winter tyres, since the tread made of silica as opposed to technical carbon does not change its properties – silica does not solidify below the freezing point!
The rubber mixtures for KAMA-EURO tyres have higher lump rubber content and use advanced types of series N technical carbon to improve durability.
Quality control at this particular stage of production includes homologation of raw materials by Pirelli, acceptance tests for incoming raw materials and components according to GOST and Specifications requirements.
There are 12 types of mixtures produced in the rubber mixing area.
2. Assembly
Polyester cord is widely used as the new constructional material, which improves the tyre elasticity, shock-absorbing properties as well as performance at high speeds.
The equipment by the world's leading manufacturers is used in production of tyres: automated assembly systems VRP 2020 by VMI of Holland; bead-making units by Bartell of USA; tread-making units by Troester of Germany.
The assembly – a key stage in tyre production – is done using a unique automated system.
Assembly using the assembly system by VMI ensures automated control of the dimensions of intermediate products being fed, the offset of parts during alignment with frame and breaker drums, the pressure during seam rolling, etc.
Automated assembly system by VMI of Holland is operated by only one person. Every 47 seconds a new tyre is born. Four such assembly systems installed at the new production line are able to manufacture around 30 000 tyres per day.
During manufacturing of intermediate products for tyre assembly numerous parameters are simultaneously monitored. For example during production of profiled components of tread and sidewalls with the triplex-head die system 8 parameters are monitored: extrusion rating, feedstock temperature when exiting the extruder, width of the feedstock, thickness, weight, etc.
The tyre manufacturing technology ensures tyre reliability under aggressive conditions of multidirectional load. It results in lowest radial and axial tyre runout at high speeds, durability and reliability of the components our lives depend on, lower noise, higher traction and grip, better behavior on snow, ice, and in wet conditions.
3. Vulcanization
New production systems almost completely eliminate manual labor, while high automation level enables quality control at all stages of production.
The polymerization of rubber is done in Herbert shaper-vulcanizers under very high pressure, high temperature and under automated control. Special equipment ensures proper duration and temperature of heating, which determines the quality of rubber.
During vulcanization the vulcanization and shaping parameters of tyres are automatically controlled.
4. Quality Inspection
Every stage of production employs its own automated quality control systems. The final product quality inspection is performed both visually by Quality Control inspectors and automatically using precision equipment by Hofmann of Germany. The tyres are inspected across 20-25 parameters including weight inhomogeneity, imbalance, force and geometrical consistency. If any deviation is found the tyre is automatically discarded. This allows only high quality products to reach the market.
In February 2008 Nizhnekamskshina successfully completed the quality management system audit according to ISO/TS 16949:2002 and GOST R 51814.1-2004. These certifications apply to companies, engaged in automobile parts manufacturing.
Environmental Safety of the Products:
In production of KAMA-EURO tyres modern materials are used, such as polyester cord, which improves elasticity and shock-absorbing properties, spiral breaker screen layering and automated assembly ensure high force and geometrical consistency of tyres. It minimizes the weight and improves dynamic properties of tyres, which reduces rolling loss, fuel consumption and consequently lowers emissions.
Environmental safety of the tyres is achieved by reduced content of materials emitting volatile matter, carcinogenic and other detrimental compounds. It is achieved by using silica filling, which simultaneously allows to reduce rolling resistance and to increase grip on wet surfaces, as well as to reduce environmentally harmful effects.
Optimal geometry of the tyre section, calculated patterns of tread blocks allocation and their sequence ensure lower noise when using KAMA-EURO tyres.