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Presenter M.S.NanaiahS C RameshMohd. Sohail

Date: 27.06.2018

PROJECT TITLE“Modify methodology of Natural Rubber packing from conventional to Eco Friendly method”

START DATE : 20.01.2016

END DATE : 03.10.2016

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NATURAL RUBBER MANUFACTURING PROCESS

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BRIEF INTRODUCTION ABOUT PROJECT

Over the last few decades Natural Rubber(NR)

producers have been using talc powder slurry to

avoid jamming or sticking together of NR bales

(stacking of layers of Natural Rubber).

This was causing spillage of talc powder all over the

NR bales and also on floor, causing pollution and

contamination, during each stage of handling.

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BRIEF INTRODUCTION ABOUT PROJECT

The highlight is that, LDPE film due to its low melting point and characteristics of blending

very well seamlessly with rubber, becomes a integral part of compound in the rubber mixing

process and eliminates dust and contamination in subsequent process.

This has improved the working environment and also the processing of rubber, without any

impurities / dust in the process / environment

After critical review, analysis and brain storming, we identified a material which can serve

the purpose of

a) avoiding jamming / sticking of NR bales

b) avoid dust or contamination.

After several trials with various types of packing & packing materials, we worked out usage

of LDPE film of 6 micron is found feasible technically and commercially viable. Hence we

decided to implemented LDPE packing in place of talc power slurry for packing NR bales.

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UNIQUENESS OF THE PROJECT – HOW AND WHY IS THE PROJECT UNIQUE

(CONCEPT, APPLICATION, ETC.)

LDPE film (6 micron) which is presently used as packing material completely eliminated the usage of talc powder slurry.

Uniqueness of the Project : The new packing material i.e. LDPE film selected after critical review and trials, which has low melting point and characteristics of blending very well with rubber becomes a integral part of compound without affecting any of the quality parameters.

This innovative idea was conveyed in structured manner and benefits were explained to all rubber producers. After they convinced about the benefits, all NR Suppliers readily adopted this LDPE packing material which is cost effective and environment friendly.

With this kaizen, overall working environment (SPM level at Mixing and Raw Material storage area and also at supplier end) improved as the bales are without any impurities / dust at all stages, our end and at rubber producers / handlers end.

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MAJOR THRUST/TRIGGER OF THE PROJECT – NEED FOR THE PROJECT

AND CONDITIONS PREVAILED BEFORE PROJECT IDEA CONCEPTION

Over last many decades NR producers were using talc powder slurry as a packing which

was causing the dust menace during loading, storage (Raw Material godown), bale

cutting & mixing area. This talc powder dust was causing poor housekeeping, increased

SPM level and suffocation to the persons handling Natural rubber.

This innovative idea helped both Rubber producers & JK Tyre to overcome all the above

problems. This idea is eco friendly & cost effective for both the parties.

Company Vision & Mission – Be a Green Company

Pleasant Workplace - TPM & HSE Policy

ISO 14001 & OHSAS 18001 – EMPs & HMPs

Statutory Requirement - SPM level at RMS & Mixing area

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PROJECT VIDEO – BEFORE IMPROVEMENT – SPILLAGE OF DUST

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PROJECT VIDEO – AFTER – LDPE PACKING

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BENEFIT – TANGIBLE & INTANGIBLE

Direct Cost Savings of Rs 54 / bale. Total savings of around Rs 2.2 crores / annum

• Slurry coating on 50 Kg NR bales is around 400gms.

• Cost of NR is aprox Rs135 / Kg & powder is around Rs 10 / kg.

• We were paying rubber cost for talc slurry this resulting in loss of Rs 54 / bale.

• Cost of LDPE packing is Rs 2.50/ bale

• Total NR bales consumption is 4.11 lacs / annum

Getting extra 400gm of raw material (rubber) in each bale.

SPM level in RMS godown reduced from 115 to 80 µg/m3

Dust free environment, supply chain – Production – Transportation – storage - Usage

Improved housekeeping in RMS & Mixing area

TANGIBLE

INTANGIBLE

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REPLICATION POTENTIAL OF THE PROJECT

THE PROJECT CAN BE

REPLICATED BY ALL RUBBER &

TYRE INDUSTRIES.

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ACHIEVING NATIONAL BENCHMARK / STANDARDS

JK Tyre & Industries Ltd., became 1st tyre industry in India to implement this idea with

Natural Rubber suppliers.

This idea is benefitting the rubber industries in reducing the SPM level & improved

working environment.

BEFORE AFTER

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EMPLOYEE INVOLVEMENT, TRAINING AND CAPACITY BUILDING

We have given extensive awareness & training programs for all our employees involving in

handling & processing of Natural rubber in our plant.

This improvement horizontally deployed in all out sister concerned tyre plant in India &

Mexico.

We gave extensive awareness & training programs to Natural Rubber bale manufacturer to

done away with chalk powder dusting & go for LDPE packing. This is improvement is

horizontally deployed by all our supplier.

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CHALLENGES / BOTTLENECKS FACED DURING PROJECT IMPLEMENTATION

To develop suitable packing material – which should become the part of tyre – No deviation

in performance of tyre is acceptable

More number of trial & error / process optimization

Repetitive checking of compound parameters at every stage of tyre manufacturing

Assessing the performance of compound with LDPE – Tyre performance study

Changing mindset of Natural Rubber bale manufacturer to adopt new technique – the

dusting was done since so many decades

Cost impact

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FUTURE TARGETS AND ACTION PLANS

Introduction of non fossil fuel based reinforcement filler for Bias tyre ( 2020)

Tyre weight optimization to improve performance & life (Continuous)

100% usage of REACH compliance chemicals (2019)

Increase usage of Eco friendly curing media (2020)

Increase the share of RE in overall plant energy consumption (2020)

Implement identified energy savings projects in fast track (Continuous)

Reduce scope 3 emission 50 % from 2017-18 level by 2020

Reduce steam consumption thru employee involvement (Continuous)

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Thank You