The manufacturing process begins by creating the carcass, or the inner skeleton of the tyres Blandford. This is done by weaving synthetic and natural fibres together using a special loom. The resulting fabric is then cut into long strips, layered on top of each other, and bonded together.
Next, the tread pattern is embossed into the rubber compound. This is done by pressing a mould against the rubber sheet, which creates an impression of the desired design. The rubber is then cut into small pieces and heated until it liquefies. It is poured into the mould and allowed to cool and harden.
The newly formed tyre undergoes a series of tests to meet all safety standards. These include inflating the tyre to ensure that it holds air and performing a load rating test, which is done by stacking weight onto the tyre until it bursts.
The next step is to apply protective chemicals and fabric patches to the inside of the casing and insert steel or textile belts made of polyester, nylon, or rayon. These belts give strength and stability to the finished tyre so that it will not develop bulges and weak spots over time.
After this, the tyre’s interior is coated with a lubricant/coating solution. This allows for smooth operation and makes various adjustments easier later on during assembly. The exterior of the casing then undergoes clearance checks using a giant vernier calliper device to make sure that the tyre is not out of tolerance in any way.
Before the tyre is ready for assembly, the final stage is to run it through a scuffing machine, which helps remove any contaminants that might stick to it during production. The carcass is then inspected once again and readied for assembly.
Assembling The Tyres
When all the components arrive at the factory, they are unloaded and divided according to their type (e.g., steel belts, polyester belts) and destination (front, rear). Each component has specific characteristics (thickness, width) that determine where it should be installed on the wheel. Assembly begins with mounting all steel belts into place around the inner circumference of the wheel.
From there, each component is mounted in order: first the inner and then the outer bead, sidewall, and tread. Each layer is coated with lubricant before insertion into the mould to be easily inserted without damaging them or the tyre.
As soon as each component hits its designated spot, it begins heating up because of friction against all other components until it reaches a temperature that can bond together naturally with the rest of the tyres. Once this has occurred, the assembly process is complete.
Tyre Quality Control
Once a tyre has been assembled, it goes through a series of quality control tests that ensure that each component performs within predetermined specifications. These include checking ply separations, measuring cold inflation pressure and verifying the tread depth. The tyre is rejected and sent back to the factory for further inspection and possible repair if any issues are found.
Only tyres that pass quality control tests are stamped with the “Made in Japan” seal of approval and shipped off to retailers. The entire process, from start to finish, takes about two weeks. This is why it is important always to replace both tyres simultaneously; doing otherwise can cause an imbalance in the overall quality of the new tyre set.
Now that you know how a Blacklion Tyres Blandford is made, you can appreciate them more and maintain them well.