RJA June-July 2012 Industry News

Rubber Journal Asia Technology News

Recycled tyre-to-oil meets standards

Higher productivity from new press

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S firm Green EnviroTech Holdings (GETH) says its recycled tyre and plastic to oil samples surpassed all of the specifications and qualifications required by refineries enabling the produced oil to be sold commercially as crude oil.

The last round of tests confirmed that with the installation of the additional equipment that the samples were processed through, the oil was well within the limits set by refineries in order for them to purchase the oil. GETH utilised Intertek, a global testing laboratory that also works directly with the oil industry, and Cempro, to test samples over the past six months.

GETH is working in partnership with Ebbros Energy Partners with the latter to develop the tyre and plastic to oil plants and lease the same back to GETH. Ebbros will also purchase all of the oils produced at the plants, which is estimated to be as much as 10,700 barrels/ month at each site.

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rench maker of rubber injection moulding machines REP has launched a new machine in its RT9 series, said to match the Japanese standard and compatibility, according to Export Manager Pascal Consolaro. The so-called J model is made in conjunction with its eight-year partnership with Taiwanese machine maker Tung Yu. The new model is equipped with REP’s Tempinverter technology that enables users to increase and homogenise temperature; decrease the scorch risk; increase the flow ability; reduce cure and injection times; decrease energy consumption and reduce the reject rate.

According to Pascal, the RT9 has been sold mainly to the automotive and industrial sectors in China, India and South Korea. “Compared to competitor machines, there is no reduction of the section and it does not affect material properties, making it an uncomplicated machine.

The temperature is adjusted so that it is homogenous all over the material flow.”

He also said that for processing natural rubber parts, it offers gains up to 40% and for EPDM parts more than 30%.

Other milestones for REP include the introduction of its G9 energy saving press with a servodrive and dive

REP’s new RT9 J model that is said to be equal to Japanese standards

control to reduce heating power consumption.

Furthermore, its Fillbalancer technology from Turbocure is increasingly being used on moulds.

“Complementing Tempinverter, Fillbalancer decreases cure time while improving part characteristics and quality,” said Pascal.

The firm also launched its C-frame V19 press range available in 25 and 40 tonnes with a top closing unit for injection moulding of rubber or plastic.

In the horizontal range, it introduced a 300-tonne H59 model.

This press is equipped with special brushes and an air blow system.

Meanwhile, Pascal said that this year REP has expanded its reach to Thailand, where it has set up a technical centre together with its agent Centrewest. And after setting up subsidiaries in Germany, Italy, the US, Brazil and China, REP’s next stop was Russia, where it now has a presence.

Silicones for baby teats

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unich-based chemical group Wacker has introduced injection moulding silicone rubber grades for manufacturing pacifiers and bottle nipples for infants and toddlers.

The new grades include two liquid silicones of the Elastosil LR 3040 product line and two Elastosil R plus 4020 solid silicones. A feature of all four products is the high tear strength of the cured rubber, with the two 4020

solid grades exhibiting even higher tear strength, over 50 N/mm, measured as per ASTM D 624 B, which until now, has been unattainable with silicones in baby care applications.

Hence, the 4020 enables the manufacture of thinwall products which, at the same time, exhibit practical bite resistance.

Low wall thicknesses make for greater freedom of design and facilitate the manufacture of orthodontically correct products.

Industry News

NBR in growth mode

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rom automotive and aerospace to industrial and consumer goods, nitrile butadiene rubber (NBR) will enjoy limitless uses from these applications, says Global Industry Analysts (GIA) in its latest report. Demand for NBR is closely tied to strong GDP growth, which is reflective of gains in the manufacturing and industrial sectors, fuelling need for synthetic rubber.

Although the NBR industry displayed dormancy in recent years owing to poor economic conditions, it is now in a growth mode. For instance, consumption of NBR in automotive parts is poised to grow, especially in developing countries since manufacturers are moving production to low cost countries. Thus, automotive parts manufacturers from low-cost countries are expected to address over 40% of the global parts market by 2015.

In the medical industry,

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Rubber Journal Asia production shortages in raw materials like vinyl and the declining role of latex, which until now was the dominant material used in the manufacture of medical gloves, is helping trigger demand for NBR in this sector. Plus, nitrile gloves are puncture-resistant in comparison to gloves made from natural rubber.

China, Japan and the US continue to be the leading consumers, with China, in particular, being the epicentre, owing to robust growth in domestic production of industrial goods and vehicles. Other regions in Asia-Pacific are also expected to clock up significant growth, owing to healthy economics, growth of vehicles and increasing number of tyre plants.

Thailand to clear illegal rubber farms

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he Natural Resources and Environment Ministry of Thailand will invest US$1.58 million to clear extensive illegal rubber plantations in headwater areas in the south.

According to the ministry, there has been extensive encroachment into national forest reserves and wildlife parks because parawood is retailing at a higher price.

Three years ago, 22.4 million sq m of restricted land was encroached upon and replaced by rubber plantations, while 4.9 million cu m of wood from trees was felled illegally and is still unaccounted for. To date, 552 suspects have been arrested in 1,515 cases.

Lanxess’s rubber plant in Belgium

Lanxess beefs up rubber plant in Belgium

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erman speciality chemicals company Lanxess has strengthened its butyl rubber plant in Zwijndrecht, Belgium, expanding its capacity by 10% and building two new pilot plants for R&D for butyl rubber.

The biggest share of butyl rubber produced in Zwijndrecht is premium halobutyl rubber, used mainly in tyre inner liners to keep tyre pressure constant over a long period.

Butyl rubbers can also be used in the tread of a tyre allowing better grip and comfort. Special applications include protective clothing and medical devices as well as for chewing gum production.

With the EUR20 million expansion, the capacity of the facility is 150,000 tonnes/year.

Lanxess is also building a new butyl rubber facility on Jurong Island, Singapore, with a total capacity of 100,000 tonnes/year, to start up by 2013. Lanxess has another butyl rubber plant in Sarnia, Canada, with a capacity of 150,000 tonnes/year.

The new pilot plants at Zwijndrecht will test innovative production

technology since butyl rubber is highly complex and requires process steps at temperatures ranging between -95 to +200ÂşC. The new process, which the firm is developing makes use of fewer resources and this is more energy-efficient and environmentally friendly.

Automotive Tyre Manufacturers’ Association (ATMA), tyre production and exports increased by 6% and 24%, respectively, in the April 2011 to February 2012 period. Import and export of NR in 201112 was 205,433 tonnes and 27,145 tonnes, respectively.

Trelleborg gets a go signal for jv

Sibur/Sinopec to produce nitrile rubber

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he European Commission has approved the proposed joint venture between Trelleborg and Freudenberg in antivibration solutions for light and heavy vehicles. With the go signal at hand, the two companies will start the last phase of preparations to bring the joint venture to fruition by the end of this year.

Indian NR rubber on a high

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atural rubber production in India increased by 4.3% in fiscal 2011-12, according to the Rubber Board, with the growth to continue without much fluctuation.

Production and consumption of NR in 2011-12 was 899,400 tonnes and 966,750 tonnes, respectively.

NR consumption in the tyre sector increased by 6.3%, whereas in the non-tyre sector it declined by 5.4%.

According to the

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ussian petrochemicals firm Sibur and Chinabased Sinopec have entered into a joint venture to produce butadiene nitrile rubber in Russia.

Sinopec will have a 25.1% stake in the Russian rubber plant, which will have a capacity of up to 56,000 tonnes/year.

A final decision on the establishment of the joint venture is expected by end2012.

Early this year, Sibur entered into a joint venture with Indian conglomerate Reliance to produce 100,000 tonnes of butyl rubber in India, where the current demand of 75,000 tonnes/year is being met by imports.

Reliance will own 74.9% of the joint venture firm that will invest US$450 million to construct the facility, which will be commissioned by 2014.

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Rubber Journal Asia Tyre News

Sun ramps up capacity

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ndia-based Sun Tyre & Wheel Systems, a division of Sundaram Industries, plans to build a factory for making solid industrial tyres and related products at a new facility in South India.

Sun Tyre did not disclose information pertaining to the plant´s size or investment for the plant that will be operational end 2012.

After completing its acquisition of Watts Lanka in Sri Lanka in 2010, Sun Tyre has been expanding capacity for solid resilient and press-on band tyres at the plant and this year expects to realise additional capacity for solid skid steer tyres as well. The company goes to market under the Numa, Tantor and Talon brand names.

Continental takes over Malaysian jv

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erman firm Continental has purchased the remaining 30% interest from its Continental Sime Tyre joint venture in Malaysia from partner Sime Darby. Continental paid US$31 million in 2003 for a 30% in the unit, then increased its share to 51% in 2004 and then to 70% in 2006.

With full ownership, the tyre company will rename it Continental Tyre Malaysia. The firm says the transaction underlines its long term interest and commitment to the Asia Pacific region.

Continental operates two

tyre plants in Malaysia for truck, passenger and bus radials and agricultural, industrial and OTR tyres as well as motorcycle tyres, along with a technology centre.

a 17.1% year-over-year increase. Hankook’s global sales performance was driven by accelerated sales growth in major markets including the US, Europe, which make up 19.8% and 26.7% respectively of its total global sales. Additionally, sales in emerging markets including, South America and Southeast Asia, increased by 32.8%.

Meanwhile, Indian Apollo Tyres says its consolidated annual revenues across operations in Asia, Africa and Europe grew 37% for fiscal year 2011-12. Its Indian operations revenue grew 49% this year as compared to the previous year; Europe saw a growth of 27%, while the African operations also witnessed a 10% growth, despite challenging local circumstances. The total operating profit grew 18%.

Tyre makers report healthy revenues

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talian tyre maker Pirelli’s revenues in Q1 2012 reached EUR1.55 million, up by 11.1% compared to Q1 2011. The combined operating result after restructuring charges was EUR209.4 million, a 46.1% increase compared to Q1 2011. The firm also recorded a payment of EUR154.5 million for the acquisition of the Russian plants in Kirov and Voronezh.

Japanese firm Yokohama Rubber’s net sales in Q1 2012 increased 7.4% over the same period of the previous year and its operating income increased by 403% to reach US$117 million. The Q1 sales growth reflected strong gains in sales of tyres to automotive makers in Japan and progress in raising prices for tyres and other products in Japan and overseas.

Meanwhile, Nokian Tyres reported increased net sales of EUR384.3 million, a 32.9% boost from EUR289.2 million in Q1 2011. The company said the demand and order book for its car tyres are strong in all its core markets, especially in Russia.

Elsewhere, Hankook Tire continued strong sales growth for Q1 2012, with global consolidated sales of KRW1.71 trillion,

Truck tyre radialisation a focus

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ext year’s Tyrexpo India show in Chennai, to take place from 9-11 July, will focus on the increased radialisation of truck and bus tyres in India. According to ECI International, the show organiser, this is a reflection of the huge investments local and international tyre manufacturers are making in producing TBR radials for the domestic market.

Amongst the manufacturers are Indian tyre makers Apollo, BKT, Bridgestone India, Ceat, Dunlop India, Falcon Tyres and JK Tyre that are in the process of building new tyre facto-

ries, dedicated to producing truck and bus radials.

Industry analysts estimate that by 2013 there will be an additional 25% manufacturing capacity for TBR radial tyres.

External manufacturers are investing in the change, too. Michelin is to invest US$800 million in its new Chennai plant, which will have a capacity of 300,000 radial tyres and Continental is said to be spending EUR50 million to increase its truck radial capacity in India by 2013.

Although the market for TBR radials only account for a mere 15% of the huge commercial vehicle market, due to a variety of factors, including poor roads infrastructure, heavily overloaded commercial vehicles and a subsequent lack of OEM demand, the time is right now for growth. This is because the government plans to build 35,000 km of new roads over the next two years as well as a 2005 court ruling on the overloading of trucks has increased interest in radial tyres.

Industry sources estimate the Indian tyre industry’s annual turnover at Rs 300,000 million, with exports accounting for Rs 36,000 of this. During the year to the end of September 2011 an estimated 119.2 million tyres were produced in India by 39 tyre companies; the 10 largest manufacturers produced 95% of the total. Truck and bus tyres accounted for 65% of the tyre industry turnover, with the replacement market making up around 70% of this.

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Tyre companies seek financial support

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wo start-up companies, Galileo Wheel and SciTech Industries, are seeking support for their new tyre innovations: CupWheel and an airless tyre respectively.

According to Avishay Novoplanski, Founder and Chief Technical Officer of Israel-based Galileo, the firm’s CupWheel tyre eliminates some of the boundaries of traditional tyres because it requires very little air and has an integral run-flat capability. Other advantages of the tyre include a bigger footprint than pneumatic tyres, better load distribution, greater traction, higher efficiency, increased safety and a smoother ride, he said.

SciTech, meanwhile, has innovated a completely airless tyre and is very close to having it ready for commercial production, said Michael Moon, Vice-President of Engineering at SciTech. The design is based on the works of Gyula Subotics, the former R&D head of the now-defunct Taurus tyre company in Hungary.

Ten years of development work has produced a radical, patented new tyre design with supports made from a thermoplastic glass fibre composite that has never before been used in the tyre industry, the firm says. A tyre design was moulded at a contract tyre factory in Eastern Europe and tested successfully, on a standard rim, at a laboratory in the US. SciTech believes its tyre will improve vehicle fuel economy by as much as 2%, thanks to less sidewall flex than pneumatic tyres, according to Moon. The tyre never runs hot, and the absence of air eliminates slow leaks and tread separations caused by under inflation.

Tyre News The company also has successfully retreaded the airless tyre, using both pre-cure and mould-cure technologies.

Meeting OTR tyre shortage

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S-based Xtreme OTR Tire and Bridgestone Americas are launching OTR (off-the-road) tyre projects to help meet the global shortfall.

The worldwide shortage of giant OTR tyres is having a negative impact on production in the mining and construction industries, which consume a substantial amount of the OTR tyre supply.

Companies needing replacement tyres are said to be having a difficult time finding any substantial inventory of OTR radial or bias tyres for their heavy equipment and it is for this reason that Xtreme OTR Tires says it has entered the market with its wide range of tyres.

Meanwhile, Bridgestone is embarking on a US$19.5 million expansion project at its OTR plant. Expected to be completed in mid2013, the additional capacity will go primarily to the production of tyres used in the heavy industry. The investment follows a September 2011 announcement of a US$1.3 billion investment in tyre plants in Aiken County; Warren County and Des Moines as well as an expansion by parent company Bridgestone at its steel cord plant in Clarksville.