RJA April 2012 Industry news

Rubber Journal Asia Tyre News

Yokohama has released its second tyre series made from orange oil

Second orange oil tyre from Yokohama

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apanese firm Yokohama Tyre’s Avid Ascend tyre features its orange oil technology. Made at its US plant, the tyre is suited to a variety of applications ranging from crossover vehicles and passenger cars to minivans.

It is said to possess a good mix of extended tread life and fuel economy.

Test results show that the Ascend can last up to 6,000 more miles and has lower rolling resistance, rolling 11% easier than a competitive tyre, says the firm. This feature translates into fuel savings of about 58 gallons and more than US$200 savings over the tyre’s useful life. Available in sizes ranging from 15 to 18 in., the Ascend follows in the footsteps of the company’s dB Super E-spec, the world’s first orange oil tyre introduced in the US market in 2008.

Conti forecasts higher tyre sales and buys Indian firm

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erman automotive firm Continental expects its sales to rise

GTC recalls tyres

more than 5% in its current fiscal year while its sales last year rose 17% to EUR30.5 billion.

Its tyre division had combined sales of EUR8.8 billion from passenger and light truck tyres and commercial vehicle tyres, 7% up on the previous year. The company is also banking on global demand for replacement car/light truck and commercial vehicle tyres to grow 3% and 4% respectively.

Continental’s tyre unit also plans to invest more than US$1.3 billion in the BRIC countries. It is doubling capacity in Camacari, Brazil, while the construction of a new plant in Kaluga, Russia, commenced in November 2011. In India, following the acquisition of Indian tyre manufacturer Modi Tyres, Continental plans to invest EUR50 million to establish in-house passenger and light truck tyre production as well as expand truck tyre production. In the US, the construction of a new plant is set to commence in South Carolina while an existing plant in Illinois is being expanded.

In related news, Rico Auto Industries is now a fully owned subsidiary of Continental that has acquired Rico’s 50% equity in the Indian joint venture Continental Rico Hydraulic Brakes. This acquisition reinforces Continental’s growth plans and investments in both development and manufacturing to introduce future technologies to both of its automotive and rubber industries in India.

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ore than 12,000 advance extra grip AR215 radial light truck tyres were recalled by GTC North America, an Ohio-based marketing arm of Chinese tyre maker Guizhou Tyre.

The recall was due to sidewall blistering or bubbles that could lead to tread chunking, belt edge separation and air loss. The recalled tyres were manufactured between September 2008 and December 2009. GTC has notified tyre owners and is offering replacement of the recalled tyres with similar tyres free of charge.

Sibur sells tyre plant to Pirelli

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ussian petrochemical company Sibur has finalised the transfer of its Voronezh tyre plant to Pirelli and Russian Technologies joint venture. This follows the transfer, also from Sibur, in December 2011 of the Kirov tyre plant.

The joint venture has invested a total of EUR222 million in the transfer operations and will spend a further EUR200 million from 2012 to 2014 on plant improvement and business development.

Annual revenues are expected to reach about EUR300 million in 2012 and more than EUR500 million by 2014.

Goodyear’s record earnings

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S Goodyear Tyre recorded higher sales and income of US$1.4 billion worldwide and US$276 million in the North American market last year. The company says this success is due to its improved price/mix and higher branded share in targeted market segments.

Despite a lower unit volume in the fourth quarter of 2011, its sales were up 12% to US$5.7 billion compared to last year. Tyre unit volumes totalled 43.2 million, down 5% from 2010, reflecting decreasing replacement industry volumes in mature markets along with business challenges in Latin America and the flooding in Thailand.

Sales in Q4 2011 showed a strong price/ mix performance, which spiked revenue per tyre up 19% year-onyear. Unfavourable unit volume and foreign currency translation reduced sales by US$174 million and US$49 million respectively.

Rhein Chemie positioned in bladder market

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erman firm Rhein Chemie, a subsidiary of speciality chemicals firm Lanxess, has purchased US-based Tire Curing Bladders (TCB), a manufacturer of bladders for the tyre industry.

Rhein Chemie entered bladder production last year when it bought

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Rubber Journal Asia Argentina-based Darmex.

TCB has a capacity of 400,000 bladders with sales of US$21 million last year. It primarily serves the North American market.

Bladders are used in the manufacturing process of tyres. A non-vulcanised tyre is placed in a press.

Once the press is shut, the internal pressure forces the tyre against the internal wall of the tyre mould. This is done using a butyl rubber bladder that is then inflated under high pressure and at high temperatures to give the tyre its final shape.

The demand for bladders is expected to grow parallel to global tyre production, which is expected to grow on average by 5% a year in the coming years. The size of the global bladder market is estimated at more than EUR300 million.

Bridgestone enters guayule and Thai markets

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apanese tyre maker Bridgestone’s US operations is researching on the viability of using guayule as an alternative to natural rubber in tyres.

The plant is native to the deserts close to Mexico and southwestern parts of US but can also be grown in parts of Europe, North Africa and in other arid, dry zones. Funded by Bridgestone Japan, most of the research project will be carried out in the US and the firm will leverage its resources from two of its research and technical centres.

The company expects to finalise a location, establish a pilot farm and begin constructing the process research centre in South-West US by this year. The facility is expected to be operational in 2014 and trial rubber production will commence in 2015. It says it is also working to develop tyres using 100% sustainable materials (renewable and recyclable resources), which it will reveal information about “in the near future.�

In other news, Bridgestone plans to build a 50 billion yen plant in Rayong, Thailand, for the production of offthe-road radial tyres for construction and mining vehicles (ORRs) and for steel cords used in ORRs. To start up by 2015, the facility will have a capacity of 85 tonnes/day by 2019, when scheduled capacity increases are completed. Until now, Bridgestone has produced these tyres in Japan and the US.

facilities, Apollo Tyres is also planning to acquire a Latin America tyre manufacturer.

NZ seeks solutions for old tyres

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very year, 4 million tyres are disposed of in New Zealand, posing a grave long-term risk to the environment.

Hence, the government will provide funding of US$133,000 to the Product Stewardship Foundation to establish economic and eco-friendly ways in which the used tyres can be put to better use.

Possibilities include recycling tyres for road surfacing, converting them into floor tiles, useable fuels and recycling the steel.

The foundation will work with the Motor Trade Association and 3R Group to bring together vehicle and tyre industry importers and retailers and will look at schemes in other countries to develop guiding principles for New Zealand. The government expects to receive results

by April 2013.

Apollo Tyres strengthens position

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o increase its global footprint, Indian firm Apollo Tyres will build new facilities in Eastern Europe and Brazil. The venture is expected to amount to a total of EUR400 million with both the facilities to be operational in two to three years time.

The plants will produce passenger car radial tyres with an initial production capacity of 7-10 million units/year. Aside from establishing new

Old tyres may find new uses in NZ

Industry News

Trelleborg changes its strategy

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wedish firm Trelleborg is divesting its automotive operation to allow it to focus and develop its automotiverelated operations.

Based in France, the operation produces hightechnology rubber, plastic and foam components and systems for the light vehicles industry.

It was acquired by Germany-based Bavaria Industriekapital, said to be a highly technical centre with a strong European customer base. The divested operation had a yearly revenue of US$81.2 million and employed around 570 workers.

Growth in India for firms

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apanese firm Tokai Rubber Industries has officially opened a factory for producing anti-vibration systems for cars and light trucks in Bangalore, India.

Operating as Tokai Rubber Auto-Parts India, the 8,000 sq m factory began operations in January.

Prior to this, Tokai was leasing a plant where it was assembling the products. It also has another facility in India for producing automotive hoses, which it started up in 2005.

In other news, US silicones maker Momentive Performance Materials is expanding its facility and application development centre in Chennai. Spanning more

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Rubber Journal Asia than 15 acres, the facility, which opened in 2009, focuses on manufacturing high-end speciality silicones.

AIRIA wants antidumping duties removed

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he high price of locally-made products over imported ones has made the All India Rubber Industries Association (AIRIA) to seek the removal of anti-dumping duties on imported raw materials, imposed by the Indian government. It also says the industry needs 100,000 tonnes of natural rubber to be imported to keep up with growing demand. According to the association, consumption of natural and synthetic rubbers is constantly increasing and availability is an issue even at high prices.

Aside from high interest cost and energy rates, the levy on carbon black and rubber chemicals has made products more expensive, causing small and medium-sized firms to close shop. Nontyre industries, such as footwear, have also felt the blow, as the levy on styrene butadiene rubber has made products more expensive, leading to a surge in imports from Nepal, Sri Lanka and China, says AIRIA. Due to this, AIRIA has sought a waiver of customs duty on raw materials, such as butyl rubber, SBR grade 1500/1700 and other synthetic rubbers and polyester tyre cord.

Sino Legend marks presence in Europe and the US

higher than at end Q4 2010.

Global rubber demand is forecast to reach 26.8 million tonnes in 2012.

Global SR demand is expected to grow by 3.6% in 2012, while global NR demand is forecast to rise by 3.4% in 2012. The global NR production is forecast to rise by 3.2% to 11.3 million tonnes in 2012.

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n line with its plans to establish its presence in the US and Europe markets, Chinese resin manufacturer Sino Legend has started showcasing its facility in Zhangjiagang, in Jiangsu province, China.

The company has a 70% share of the Chinese market and a 30% share for the rest of Asia.

Built in 2007, the plant was designed to meet future global expansions and standards. The facility is equipped with automated systems, QA assurance protocols and monitoring and rigid environmental controls.

According to the company, the facility utilises water and energy efficiently, and follows a process flow that optimises efficiency in manufacturing and distribution.

Cambodia prioritises rubber

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ubber plantations in Cambodia are expected to multiply as the country’s government is making rubber a priority sector. The Council for Development of Cambodia approved rubber projects worth USS674 million in 2011. Over 82% of these investments came from Indonesia, Vietnam and Malaysia. According to CDC, due to the country’s great potential for rubber cultivation, investment jumped by a whopping 256%. The country saw US$189 million invested into rubber plantations in 2010.

Higher rubber demand expected

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ccording to the latest report released

by Singapore-based International Rubber Study Group (IRSG), annualised global rubber consumption reached 25.8 million tonnes by end Q4 2011, 4% higher than at the same point in 2010, reflecting a decelerating increase in the demand for vehicles and tyres.

Global synthetic rubber (SR) production was 6% higher than at end Q4 2010, in line with the relatively strong growth seen in SR consumption supported by competitive prices, while global NR consumption was 1.4%

Technology News

Yulex and Cooper tie-up for guayule

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he continuous decline of natural rubber is driving companies in the tyre industry to identify alternative sources.

US-based Cooper Tire & Rubber has teamed up with another US company Yulex to evaluate

and develop guayule polymers and resins for tyre applications. In this joint venture, Cooper will provide materials, testing, development and design expertise whereas Yulex will provide its experience with engineered biopolymers from the guayule plant. Results of this research may help decrease Cooper’s reliance on off-shore raw material sources as well as come up with next-generation tyre production.

New asphalt technology from Kraton

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S-based producer of styrenic block copolymers Kraton Performance Polymers partnered with the National Centre for Asphalt Technology (NCAT) to test its HIMA technology on a pavement test track.

According to Kraton, the findings show that a modified binder using its HIMA technology has achieved the highest and most adequate performance, compared to competing asphalt pavement technologies.

This new technology proves that it is possible to reduce total pavement thickness. To produce this, Kraton kept the same gradation and mix design and replaced the binder, which allowed an 18% reduction in thickness.

To test its durability, an analysis based on actual pavement strain was conducted by NCAT. The findings show that the thinner section with HIMA outperforms the control section in bottom up fatigue cracking.

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Rubber Journal Asia Gevo to set up isobutanol plant

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evo, a US-based renewable chemicals and biofuels company, has received a patent to enable commercially viable production of isobutanol from yeast.

Since yeast naturally produces isobutanol at low yields, the new technology allows production for commercial applications by eliminating barriers in the process. The end result is an improved yield of isobutanol by 20%.

With its new technology, the company also plans to set up a plant. The new patent adds to its already existing 300 patents and applications for the economic production of isobutanol, process innovations and downstream product applications.

Safe production of rubber The European SafeRubber project has reached the halfway point of its three-year research. Since June 2010, the European Community-funded SafeRubber project has been working on on a suitable and safer alternative to ETU. Thiourea-based accelerators, of which ETU is the most common, have been used for more than 80 years in the vulcanisation of polychloroprene rubber as they facilitate the rubber curing system by speeding up the creation of molecular crosslinks, decreasing process duration and increasing

PAHs primarily occur in complex mixtures; many are classified as carcinogenic/mutagenic environmental toxins with the potential to cause negative long-term effects both in humans and in the aquatic environment.

Findings of this study suggest that tyre tread-wear could be a larger contributor of PAH than diesel vehicle exhaust and residential oil heating. Still in its preliminaries, the findings require further research to better understand tyre-particle generation and distribution in the environment in order to assess the implications to human health and environment.

physical properties.

However, ETU is classified toxic to reproduction and thereby a CMR within Europe.

Under the REACH regulations,in due time, its use could either be prohibited or drastically limited. The initial work is focused on research into the chemical mechanism of the vulcanisation of polychloroprene using ETU, a mechanism which has never been fully understood or proven. This enabled the consortium to design and synthesise several alternative molecules, which it hopes will be safer than ETU. These molecules are now being optimised in polychloroprene compounds before being scaled up to an industrial process. Project results to date are available at: www. saferubber.eu

Zymer to enhance end-product performance

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nano-engineered rubber technology is set to add new strength and conductivity to rubber compounds.

Called Zyvex molecularly engineered rubber (Zymer), the technology comes from US-based Zyvex Technologies.

Zymer uses a new chemical process to allow carbon nanotubes to be inserted into synthetic rubber compounds to enhance the mechanical and electrical properties of the material without compromising elasticity.

With nanotubes inserted, the material gets improved tear strength and tensile properties.

The technology is expected to open up new possibilities as makers can create tyres made of lightweight materials

Tyres source of carcinogens

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yres may be a potential source of carcinogenic dibenzopyrenes – a type of high molecular weight polycyclic aromatic hydrocarbon (PAH) – to the environment, according to researchers from Stockholm University. The goal of the Swedish research was to determine the level of dibenzopyrenes in tyres and its impact to the environment.

Eight types of tyres of high molecular weight for PAH were evaluated using pressurised fluid extraction.

PAH is a class of organic compounds produced by incomplete combustion or highpressure processes.

Zyvex’s rubber technology has been tested to show improved tear strength and elasticity

with increased durability and performance, says Zyvex.

Lab line for rubber profiles

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erman firm KraussMaffei Berstorff’s LabStar line is suited for rubber profile production in laboratory applications.

With a material use of 8 kg/hour, it is suited for low output rates and single component profiles. It is targeted at compound development applications, test specimens and sealing profiles with a size of below 1 cu cm. The core of the line is a GE 25 x 18D rubber extruder for continuous material shaping equipped with a mobile operating panel for line control. A downstream shock channel ensures prevulcanisation of the profile by means of short-wave infrared radiation.

The firm says the compact combination of microwave and hotair channel is based on production-scale equipment design and allows for optimum energy input. The cover flaps can be easily opened and facilitate material threading at line start-up and rapid cleaning of the processing chamber.

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