Tire Manufacturing

Yes, it is true; a bad attitude and a flat tire have much in common, as both prevent one from moving forward in life.  With that said, there was a time thousands of years ago when the concept of a tire did not exist, much less a rolling wheeled object.

To fully appreciate the tire, one must first appreciate the wheel.  The creation of the wheel is one of humanity’s most ancient and greatest inventions; so valuable that it continues to transform our modern world.  Some 5,000 years after its discovery, the wheel is as influential today as it was with that first wheelbarrow.  Without the wheel, we wouldn’t have automobile tires to help us get us from point A to point B.

The automobile tire is a ring-shaped rubber cushion that fits and surrounds a wheel’s rim and is filled with compressed air.  The next couple of images help visualize how the wheel and tire are linked.

Ancient Wheel

Modern Wheel and Tire

The U.S. tire manufacturing industry is made up of companies that manufacture tires and inner tubes from natural and synthetic rubber.  Tire are manufactured for a wide range of moving vehicles: automobiles, trucks, business, aircraft, tractors, shopping carts, bicycles, and motorcycles.

Below, we highlight the history of tires, the manufacturing process, types of tires, and their economic impact.   Most importantly, we highlight the hazards workers face when manufacturing tires and the PPE they should consider wearing while on the job.

The Rubber Tire's History

First pneumatic bicycle tire found at the National Museum of Scotland

The wheel, on its own, when rolled across surfaces, begins to wear and tear.  As the 19th century ended and bicycles were becoming popular, an outside layer added to the wheel was needed to absorb damage and minimize wear.  This is where the tire debuted on the world scene, providing strong absorption and a smooth ride.

Early tires took on the appearance of leather bands wrapped around a wooden wheel.  The solid rubber tires that followed after these initial designs owe their existence to Charles Goodyear, who discovered vulcanization in 1839, which is the process of curing rubber with sulfur and lead.  It turns sticky rubber into a stable material, perfect for manufacturing tires.

By 1888, the tire industry was set, when John Boyd Dunlop created the first successful pneumatic tire, an air-filled tire rather than one made of solid rubber.  It reduced vibration and improved traction with the road, providing users with a smoother overall ride.

Radial tire, which dominates today’s tire industry

Today, two different types of pneumatic tires are constructed: bias and radial construction.  The tire’s belt is what separates the two, with radial tires being strengthened by steel fabric.

Modern Tire Products

Over 200 raw materials makeup a tire’s composition, ranging from the following: wire, rubber, chemicals, carbon black, oil, nylon, polyester, and steel.  Ultimately, the material that goes into a tire impacts worker safety.  For example, different chemicals require different glove polymers, and sharp metal may require higher ANSI-rated cut gloves.

Here are the core materials that make up a rubber tire:

1. Chemical Products - 37.3%
2. Rubber - 12.1%
3. Metal - 4.6%

Even though a tire is made up of these three core materials, not all tires manufactured are the same.  Different tire treads are crucial to performance in different types of driving conditions.

Tires are broken up into a couple of major product categories, and then a variety of tires are made within each category.  Passenger car tires make up the bulk of tire production, with 45% of all tires made, followed by truck and bus tires with 30%.  Industrial tires are the smallest category of tires produced.  Below are the types of tires manufactured for different vehicles and environments:

Passenger Tires

Passenger tires are engineered for a variety of driving experiences.  In 2018, the U.S. Tire Manufacturers Association (USTMA) reported that 46.2 million tires were shipped for OEM and 214.9 million were shipped as replacement tires.  Here are some types of passenger tires:

• All-season tires - manufactured for a variety of road conditions, including mud and show
• Touring tires - designed for a comfortable ride and more responsive handling
• Performance tires - larger circumferential and lateral grooves provide better grip in wet weather
• Summer tires - designed for wet and dry conditions

SUV and Truck Tires

Truck and SUV tires need to meet a wide selection of driving needs and end uses. In 2018, the U.S. Tire Manufacturers Association (USTMA) reported that 11.5 million tires were shipped for OEM and 52.6 million were shipped as replacement tires.  Here are some tires specific to SUVs and trucks:

• All-terrain tires – used on four-wheel drive vehicles
• Highway tires – all-season tread patterns designed for heavier loads
• Mud-terrain tires – designed for traction in deep mud and sand
• Ribbed tires – ultimate tire for highway handling and long-lasting mileage

 

Specialty Tires

Tires fit a wide variety of vehicles, from ATVs to trailers. Here are some specialty tire types:

• ATV tires – designed for mud, sand, and all-terrain
• Trailer tires – carry heavier weight for longer periods
• Winter tires – manufactured for deep snow and harsh winter conditions
• Summer tires – warm weather tires, not designed for snow or ice

There’s a ton of important information located right on your tires.  That’s right, those side numbers do mean something.  Just click the images below to learn more.

A tire’s date means something.

Economic Impact

The U.S. Tire Manufacturers Association (USTMA) reported that a total of 325.2 million tires were shipped in 2018.  The overall industry is forecasted for $19 billion in revenue in 2019.

Demand for tires is ultimately impacted by new vehicle sales and the need for replacement tires.  As we highlighted on our Motor Vehicle Manufacturing page, worldwide production for automobiles is at an all-time high.  The increased production has, in turn, increased demand for tires.

Companies

The largest tire manufacturing companies operating in the U.S. are Bridgestone, Goodyear, Michelin, and Cooper Tires.  These top four tire manufacturing companies generate more than 70% of tire manufacturing revenue.

Out of 62 plants operating in the U.S., yearly tire capacity for all North American tire manufacturing plants was 334.8 million tires in 2018.  Here is a list of some of the largest operating plants within each state.

Yearly tire capacity for all of North America totaled 334.8 million tires.  The new Giti Tire plant located in South Carolina is helping prop up U.S. total production numbers is projected to produce 5 million tires annually.

State Employment

According to the Bureau of Labor Statistics (BLS), the Rubber Manufacturing Industry employs a little over 134,000 individuals.  Of that, the tire industry itself employs roughly 70,000 workers.  Out of this number, around 22,000 are referred to as tire builders.  Here is a snapshot of the states employing the most tire builders:

Data USA maps out the counties in each state with the highest rates of tire manufacturing employment.

County Employment According to Data USA

Pneumatic Tire Manufacturing Process

Manufacturing a tire involves multiple steps. Here is a breakdown of the overall process:

Step 1

Weighing

Raw materials are measured before being moved into the mixers.

Step 2

Laboratory

Samples are tested.

Step 3

Mixing

The Banbury mixer (compounder) prepares the ingredients and the raw materials are mixed to specific tire recipes. These recipes call for rubber, carbon filler, chemicals, and oil.

Rubber trees producing one of the core material found in tires.

Step 4

Material processing and Tire Making

It begins on a revolving drum.  Several operations occur during this stage to produce a tire’s key components.  Here are primary activities found at this stage:

• Bead Wire - bead wire must be made to hold the tire to the trim.
• Extruder – for inner liners, casing ply and sidewalls, the warmed stock is fed into the barrel and forced by screw out through a die.
• Rolled – the mixed rubber must be rolled into sheets and worked until proper consistency is achieved.

• Calendar – used to produce body piles and belts. Stock, such as nylon, polyester and steel, is used in the carcass of the tire. Rubber is then squeezed around the cords to insulate them.
• Cutting - All components require splicing. Treads and sidewalls are cut with a skiver to exact lengths.

Step 5

Tire Building Machine

Components from the above steps are sent to the green tire building machine and assembled.   Previously calendared fabric (called a ply) wraps around the drum and a bead bundle is placed on the edge.

Tire Building Machine

Step 6

Curing (Vulcanization)

The green tire is put over the bladder, using steam to heat up the curing press platen.  This provides for a resilient and durable finished tire.

Image from the Library of Congress, showing a mid-20th century worker placing a tire in the mold before vulcanization.

Step 7

Quality Inspection Control

Tires are inspected for specific level requirements.

Multistrada, a producer of tires, has created the visual aid below to illustrate the tire manufacturing process.

Occupations

The top three occupations found in this industry are the following:

1. Tire builders
2. Extruding operators
3. Metalworkers

To manufacture tires, you need workers. Based on the Bureau of Labor (BLS) statistics for Rubber Manufacturing, which includes Tire Manufacturing, here is a snapshot of the main occupations:

• Tire Repairers and Changers 

  A vehicle requires tires to be occasionally changed once the tread wears down.  There are around 1,220 members of this occupation in the rubber and tire manufacturing industry.  You will find these workers remounting wheels, removing puncturing objects, and assisting mechanics.

• Tire Builders 

  An automobile has at least four tires, which means a lot of rubber tires are needed for a vehicle to run.  This worker operates machines to build tires.  There are around 22,000 members of this occupation in the rubber and tire manufacturing industry.  You will find these workers trimming excess rubber, cutting plies, and painting solvents.

• Mixing and Blending Machine Setters, Operators, and Tenders 

  Machines are operated to crush, grind, and polish materials.  There are around 3,300 members of this occupation in the rubber and tire manufacturing industry.  You will find these workers crushing and grinding materials, along with mixing chemicals.

• Metal and Plastic Workers  

  Metalworkers are needed across the entire automotive industry, creating individual parts and repairing metal structures.  There are around 11,000 members of this occupation in the rubber and tire manufacturing industry.  You will find these workers welding, cutting, shaping, and forming metal pieces.  Vehicles have metal everywhere across their bodies, which means a lot of metal must be shaped to the correct size.

• Machine Tool Cutting Setters and Operators  

  A multitude of automotive parts are shaped to different dimensions.  There are around 3,100 members of this occupation in the rubber and tire manufacturing industry.  You will find these workers inspecting metal workpieces and operating machines such as lathes, cutters, and shears to make metallic and plastic workpieces.

• Laborers and Material Movers by Hand 

  The entire automotive industry has many objects moving at all times.  There are around 4,130 members of this occupation in the rubber and tire manufacturing industry.  You will find this occupation loading docks, moving parts, moving materials to production areas, and moving finished vehicles to warehouses.

• Industrial Maintenance Workers  

  Automotive factories have many machines that need to be maintained and repaired.  There are around 9,690 members of this occupation in the rubber and tire manufacturing industry.  A maintenance worker must be skilled in electricity, welding, and mechanical systems.  You will find these workers repairing equipment and cleaning machines and machine parts.   Cleaning solvents, oily parts, and metalworking fluids are a definite concern for these workers. 

• Industrial Machinery Mechanics  

  Industrial Mechanics repair and maintain industrial production and processing machinery.  There are around 2,800 members of this occupation in the rubber and tire manufacturing industry.  You will find these workers cutting and welding metal to repair broken metal parts. 

• Extruding and Drawing Operators 

  Automotive parts are needed in all shapes and sizes, including rods and other structural shapes.   There are around 15,000 members of this occupation in the rubber and tire manufacturing industry.  You will find these workers operating machines to extrude or draw thermoplastic or metal materials into tubes, rods, hoses, wire, and bars.

• Cutting and Slicing Machine Setters, Operators, and Tenders 

  The rubber used in tire manufacturing needs to be cut to exact lengths.  There are around 2,000 members of this occupation in the rubber and tire manufacturing industry.  These workers operate machines that cut/slice materials, such as glass and rubber.

Work Activities

The workers in the tire manufacturing occupations listed above engage in a wide range of activities.  Here are just a handful of the hundreds of activities performed across this industry.

1910 Akron Tire Workers

Assembly

• Assemble components
• Clean and maintain work area
• Conduct quality checks
• Depress pedals to collapse drums after processing is complete
• Fit inner tubes and final layers of rubber onto tires
• Start rollers that bond tread and plies as drums revolve
• Trim, shim, and cut materials

Tire Repairers and Changers

• Remove puncturing objects
• Remount wheels

Metalworkers

• Cut, shape, and form metal
• Fabricate metal parts

Extruding, Forming, and Press Operators

• Apply parting agents
• Clear equipment jams
• Cut industrial materials
• Inspect plastic composite products
• Mount attachments
• Move material between work areas
• Operate metal or plastic forming equipment
• Remove products from production equipment
• Stack finished items

Tire Builders

• Brush or spray solvents onto plies to ensure adhesion
• Pull plies from supply racks
• Roll camelbacks onto casings by hand, and then cut camelbacks, using knives
• Align parts or workpieces
• Align plies with edges of drums
• Assemble tires
• Brush or spray solvents onto plies
• Cut industrial materials
• Inspect worn tires for faults, cracks, cuts, and nail holes
• Load materials into production equipment
• Mount attachments or tools onto production equipment
• Place tires into molds for new tread
• Position rollers that turn ply edges
• Roll hand rollers over rebuilt casing
• Trim excess rubber and imperfections during retreading

Safety

Worker safety is important to the tire manufacturing industry.  It is a dangerous industry, with about 22% more injuries per year compared to the average for all industries.

Manufacturing tires is hazardous primarily because it involves humans interacting with numerous dangerous operations, as we highlighted in the Activities section.  When working with rubber, many injuries occur due to manual handling, such as loading materials into production equipment.  In addition, because chemicals make up the main material in tires, you can bet workers come into contact with hazards substances.  Thankfully, MCR Safety makes gloves that protect against harsh chemicals.

The good news is the U.S. Tire Manufacturers Association (USTMA) recognizes those companies advancing occupational health and safety.  MCR Safety assists safety managers in advancing safety in their production areas by offering the most advanced PPE found in the marketplace.  Below, we highlight the hazards workers face in the industry.

Let us keep you safe when building tires. We Protect People!