How Green Tires are Manufactured

Producing tires the traditional way leads to high levels of pollution. The usage of unsustainable resources such as rubber and petroleum-based substances has a negative environmental impact. Additionally, with crude oil prices constantly changing, material costs are inconsistent and can cause higher manufacturing costs.

Green tires are manufactured in a way that reduces carbon dioxide emissions. They are specifically designed for lower rolling resistance, which leads to lower fuel consumption over a tire’s life. With a green tire, materials are made of recycled and sustainable materials. Green manufacturing practice thorough testing before the tire is sold and used on a car.

Planning & Design

The process starts with a computer calculation, which converts the car’s unique requirements into specifications. Afterward, a prototype is made to check the tire design’s capability. Designing a tire for a specific car or truck can take several months of screening, inspection, and testing by the tire manufacturer and the vehicle manufacturer. After all of that has been done, the vehicle’s manufacturer can commit to ordering tires.

Sourcing Sustainable Products

Finding and sourcing sustainable and recycled products is essential for any green tire to be produced. While several compounds are discovered in green tires, such as recycled plastics and rubber, silica has been the main commonality. It is a versatile and sustainable chemical compound that is found in sand, glass, and quartz. It’s important to know that when silica combines with a large quantity of natural rubber, this can be problematic. It is highly recommended that silica be combined with a specialized non-polar E-SBR rubber. Carbon black is typically used for traditional tires and is omitted when making a green tire. It has a harmful global warming impact, even worse than carbon dioxide.

The advantage of using silica in a green tire is that there is lower rolling resistance. Lower rolling resistance reduces fuel consumption. This reduces harmful emissions and reduces the cost of gas for the consumer. The disadvantage of a green tire is that it reduces the tire’s grip when it rains.

A Banbury mixer combines the different raw materials to create a homogenized gooey substance. The mixing procedure is computer-controlled and automated to guarantee uniformity. Then the compounded materials are sent out to machines for further handling.

Constructing the Tire

Constructing the tire takes place on the tire building machine. The first part to be put on the machine is the inner liner. It is a unique rubber that repels air and moisture, as well as adds strength to the tire. Then the plies and belts are cut to a specific size recommended by the engineer. These offer tire stamina and flexibility. Bronze-coated strands of steel wire are looped and implanted right into the tires’ sidewall to develop the bead, assuring an airtight fit of the rim. The sidewalls are taken into placement over the belt and body plies.

The green tire is now ready to be cured. The tire is positioned inside a mold to form a tread and the tire identification information. It is heated at least 300 degrees Fahrenheit for at least 12 minutes, stimulating a chemical reaction to bond the elements and cure the rubber.

 

Safety & Testing

After the tire has cooled, the tire is taken out of the mold and is ready to be evaluated. Each tire is thoroughly checked for imperfections. These could be bubbles, spaces in the rubber of the tread, sidewall, and the inside of the tire. Afterward, the tire is positioned on a test wheel, pumped with air, and rotated rapidly.

Random samples are pulled for safety tests. As part of these tests, tires are cut apart, x-rayed, operated on test wheels, road-tested to examine handling, mileage, and grip efficiency. If correctly taken care of, tires can last a long time- typically from 40,000 to 80,000 miles. When the tire has been adequately tested, it can be transferred to a distribution center and installed on a vehicle.

In Summary

Manufacturing green tires are produced in an environmentally friendly way, using sustainable and recycled products. They are designed for reduced rolling resistance, which is means lower gas consumption.  When getting a new set of tires, consider going green!

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How Automation is Helping E-Commerce Businesses

Online Shopping with Robot holding phone

E-commerce has boomed and transformed thanks to automation. With collaborative robotics, customer support, and data analytics, distribution centers are progressing to fulfill skyrocketing demands. 

With increased popularity in online shopping since the pandemic, demand for deliveries to be trackable in actual time is important for the business and for customers. From the minute an order has been placed to when it reaches somebody’s front door is paramount. With enormous e-commerce titans like Amazon and Walmart+ providing 2-day and same-day delivery for online orders, large retailers need to supply in-stock in multiple locations.

Automation with Help From Robotics

This fast change in online shopping has caused a boom in implementing automation systems within e-commerce businesses. Automation and robotics have helped services stay on-trend with expanding needs while being affordable. These advancements in innovation assist with order picking, tracking, customer assistance, data analytics, and more. Automated ordering systems are becoming more budget-friendly and readily available. Additionally, they are offered in numerous flexible setups so they can fit in a business’s distribution center accordingly.

Micro-Fulfillment

Micro-fulfillment includes making use of automated order-picking systems that are ideal for large warehouses. They can fulfill consumer orders for home delivery or store pickup faster and with less labor than a manual approach.

In Summary

Companies selling products of all kinds are embracing the e-commerce boom by incorporating innovative automation. With robotics, customer assistance, and data analytics, e-commerce businesses have incorporated automation to make their business more competitive and cost-effective. If you are an e-commerce business and have a need to automate your material handling, let UMD’s Engineering Group design an expert solution for your process.

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Warehouse Systems

UMD specializes in complete warehouse system design, creating solutions for whatever your specifications may be. Our proven modular design approach coupled with our standard conveyor components saves upfront engineering costs, reduces scrap and helps keep future upgrade costs low. With years of design engineering and manufacturing experience, UMD gives you the best overall value in the industry:

  • Lower overall investment
  • Best system design and highest quality components
  • Less time to implementation
  • Less and easier maintenance
  • Longer service life

Warehouse Solutions

Handling: This refers to all the motion that goes into a distribution center or warehouse. When a package is being moved into, out of, or throughout the DC, it falls under handling. It can also include labor to re-warehouse, repackage or refurbish damaged products.

Storage: This is usually for any product that isn’t moving and is being kept in a warehouse or distribution center. The costs are usually not as flexible because it’s based on the occupancy of the space whereas handling costs can be adjusted with better systems.

While each warehouse and distribution center function differently, we offer solutions for any business that could benefit from an updated warehousing or distribution center system.

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Benefits of Loading and Unloading Systems

Our loading (or unloading) systems help move trailers away from the dock faster, saving you time and money. The few minutes spent on prepping equipment for loading and unloading may seem insignificant, but you could be losing hours in your process. Our automated loading systems cut the time between unloading or loading a trailer and getting the products where they need to be.

Benefits of Loading and Unloading Systems

Save Time and Money

Automating your loading system saves your business money. It requires less manpower involved in the storage and handling process which saves on overall costs. Unloading systems with forklifts requires operators and the cost of purchasing and maintaining the forklifts. An automated loading and unloading system requires less maintenance and costs less to operate and its long lifespan creates a great overall savings.

Safety

By having employees using other equipment, the danger of forklift accidents is reduced. Keeping staff out of this unloading process gives the company a chance to adopt safer practices throughout the warehouse.

Versatility

All of our systems are modular and created uniquely for each organization. We will create your loading or unloading system based on your business’ specific needs. The versatility of our systems gives you the chance to make all parts work together.

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Vertical Conveyors

If you need to move tires or other products from one floor to another, or you’re trying to save space on the floor of your warehouse, a vertical lift may be a great fit for your business.

What is a Vertical Conveyor?

A vertical conveyor or lift is simply a machine that can be used to move products from one level to another, similar to an elevator. Vertical conveyors are meant to carry only products and not people. There are multiple types of vertical conveyors for different jobs. Some of the most common vertical lifts are reciprocating elevators, spiral conveyors, L-shaped lifts and scissor lifts.

Why Choose a Vertical Conveyor System?

Our vertical conveyor systems can be easily worked into systems where there may not be much space on the floor or in multi-level warehouses or distribution centers. By adding a vertical lift, the business can save space while still having an automated process. Vertical lifts can be used for processing, storage or moving materials.

Our Promise

We offer modular automated systems that can be easily upgraded, replaced and maintained so your business can continue production during repairs and upgrades.  We draw on broad experience across multiple industries and continuous research and development to create unique solutions designed around the overall needs of our customer, not just the specific application.  High quality service and products, improved production and maximum efficiency are our way of giving your business a competitive edge and we will continue to be the best choice for our customers. Find out more here.

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Retrofits and Aftermarket Services

A retrofit is a component or part added to something that did not have it when originally retrofit and aftermarket servicesmanufactured. A retrofit piece of equipment can make an outdated system feel and function like new. In manufacturing, retrofitting describes the measures taken to allow new or updated parts to be fitted to old or outdated systems. The production of retrofit parts is necessary when the design of a large system is changed. If a customer with an older system wants to update their system instead of replacing it all, retrofit parts and installation will be used to revise the older system.

Retrofitting can improve a machine or system’s overall functionality by using advanced and updated equipment and technology. If possible, retrofits should occur during scheduled downtimes to keep the cost efficient.  Replacing worn parts on a regular basis is one of the best ways to prevent unplanned downtime and protect your material handling equipment. UMD stocks a wide selection of replacement parts, conveyor belt assemblies and accessories ready to ship.

UMD provides replacement parts, customer service, and system services for all aftermarket parts. Our full range of services help keep your systems up and running so you don’t lose time or money.  If you’re looking to retrofit one of your systems or add aftermarket parts, contact us to see how we can help you.

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Structural Steel

Our customers have unique needs. We take pride in being able to help with more than sorters and movers. We also offer complete structural systems including mezzanines, platforms, stairs, catwalks, and handrails.

Structural steel is used in construction or building projects. Constructed with fabricated steel components, our structural steel fixtures are built to last through rigorous usage. We offer different pieces and systems as a whole or for a remote project.

There are different configurations that structural steel comes in, but it is usually made of the same things on the inside. The main components are iron and carbon. Sometimes other components can be added to increase the strength of the beams. Structural steel is a regulated category of steel that must meet industry standards for composition.

Our products can make the construction process easier and more efficient. UMD builds systems designed around the unique requirements of our customers. Because of our customized approach, we can achieve an exact fit between the application and objective every time.

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Automotive Industry: Tier One and OEMs

UMD Automated Systems has experience with material handling services tailored specifically for automotive OEM, Tier 1 Automotive Suppliers, transportation providers, and automotive assembly plants. While our expertise goes beyond one industry, we’ve broken down what each of these tiers consist of and how we can help make their businesses run smoother.

OEM

Original Equipment Manufacturer (OEM) automotive components are the official parts produced directly by your vehicle’s maker. The OEMs are the big names you hear that actually create and design vehicles. Some OEM pieces are sold and endorsed by a specific brand but are created by another plant. OEMs focus on overall design and production, or the big picture, of engine and drive train, leaving other components and accessory development to tier one companies.

Our systems can be used for moving people/equipment, assembly, sorting and more. We offer training on the equipment and a modular design that allows a manufacturer to adjust their system as needed without having to pay for a new system or large repairs.

Tier One

The companies that supply parts to OEMs are Tier one. Many Tier one companies make parts or products for one or two specific OEMs and keep a close relationship with them. We can consider Tier one distributors the most important in the industry because of their direct relationships with OEMs. While OEMs are focused on the “big picture,” Tier one companies are responsible for functions carried out by OEMs.

Our complete systems keep automotive components moving efficiently with material handling services tailored specifically for automotive OEM, transportation providers, and automotive assembly plants. Our comprehensive range of services include: tire and wheel handling, processing, JIT shipping, delivery and receiving.

We can provide service to almost any type of industry. Let us get your business running smoother.

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What is a Green Tire?

A green tire is simply a tire that has all the parts put together but has not been cured or had the treads added to them yet. There is a surprisingly lengthy process to tire production. Before the tire can be created, a mix of rubber, oil and additives must be mixed together. Once the mixture is the right consistency, the mixture will be moved throughout other machines to be made into the individual parts of the tire. The individual pieces consisting of an inner rubber liner, the plies, the belts, the bead, the sidewall and the tread meet back up on the tire building machine and is pressed together to create the tire shape we are familiar with.

Once that beginning process is finished, we’ve got a green tire. The green tire will then be placed in a mold and taken to be cured. A green tire is placed inside a large mold for the curing process which consists of the tire being inflated and heated to get the proper shape and tread. During the curing process the green tire is heated up about 300 degrees to bond each element. The curing process depends on the size of the tire and can take anywhere from 15 minutes to an entire day.

This is the end of green tires. Anything after the curing process is a cured tire and goes through inspection and then is ready to be used. UMD offers sorters for green and cured tires. Our DARB Sorters utilize non-contact diverter technology to avoid the potential alteration in green tire uniformity that can occur with standard sortation equipment.

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Tire and Wheel Systems

UMD modular tire & wheel systems ensure that newly manufactured tires and wheels move through the entire assembly process efficiently. While our systems are completely integrated, each piece can be replaced individually as well.

Tire and Wheel systems by UMD can consist of as many units as you see fit. We can include tire stackers/de-stackers, tire weight presses, tire rotators, conveyors and more. Each piece can be custom made to fit your businesses needs.

Tire rotators are a huge part of a tire and wheel system. UMD builds their tire rotators with durability for continuous use and provide valve stem orientation, tire weight orientation, and the ability to be bar code ready with line scanners. Tire rotators can be added separately or integrated with our modular tire & wheel systems.

Our tire weight presses provide offline dynamic balancing to assure that new tires are properly balanced before being mounted on vehicles. These can be used in the tire and wheel system or added separately as well.

Our stackers and de-stackers are part of a fully automated system and designed to provide efficient storage of processed tires maximizing square footage on the plant floor. UMD stackers also assure maximum use of space when loading trailers. And our intelligent automated system tracks the serial number of each tire.

If you’re looking for a wheel and tire system or upgrades to your current system, let UMD Automated Systems help you out.

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