WASTE TYRE RECYCLING PROJECT UNDERSTANDING 1 1.1. 1.2. 2 2.1. 2.2. 2.3. 2.4. 2.5. 3 4 4.1. 4.2. 4.3. 4.4. 4.5. 4.6. 4.7. 4.8. 4.9. 4.10. 5 5.1. 5.2. 6 6.1. 6.2. 6.3. 6.4. 7 7.1. 7.2. 7.3. 7.4. 8
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OVERVIEW OF THE INDIAN TYRE INDUSTRY: Introduction Key Influencers MAJOR PLAYERS MRF Ltd. Ceat Ltd. Apollo Tyres Ltd. J.K. TYRES Bridgestone India Private Limited TYPES OF TYRES BEING CONSUMED IN INDIA TYRE RECYCLING IN INDIA TYRE LIFE CYCLE USES BUSINESS OPPURTUNITY MARKETS PRESENT SCENARIO LANDFILL DISPOSAL STOCKPILES AND ILLEGAL DUMPING FACTS AND FIGURES LEGISLATION ENVIRONMENTAL CONCERNS SCOPE FOR TYRE RECYCLING PROJECT IN INDIA: REPLACEMENT MARKET TYRE COMPOSITION AND STAGES IN RECYCLING WASTE MANAGEMENT OPTIONS REDUCE REUSE RECOVERY Pyrolysis Flow chart of the process followed in pyrolysis CASE STUDIES - INTERNATIONAL EXAMPLES V.PROMPT THE NETHERLANDS CHINA PIRELLI TYRES - ITALY STARTING UP OF WASTE TYRE BUSINESS
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WASTE TYRE RECYCLING PROJECT REPORT as a SEPERATE DOCUMENT ( Included)
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WASTE TYRE RECYCLING PROJECT UNDERSTANDING
1. OVERVIEW OF THE INDIAN TYRE INDUSTRY:
1.1.
Introduction
The Rs.20,000 crore Indian Tyre Industry, is highly raw material intensive and predominantly a Cross Ply (or Bias) tyre manufacturing industry. It is highly concentrated wherein 10 large manufacturers for over 95% of the total tonnage production of 11.35 lakh M.T. It produces all categories of tyres, except Snow Tyres and Aero Tyre for which there is no demand domestically. The Indian tyre industry s for around 5% of the global demand as well as global supply of tyres. Domestic tyre industry has witnessed a remarkable recovery in FY10, after a slowdown in FY09. This growth was driven by strong revival in automobile demand on the back of resurgence in economy, rise in employment levels, and easing of interest rate scenario. Although strong demand growth is an encouraging scenario for the domestic industry, rising imports has become key concern factor off‐late. On an average, 55% of the production is for replacement market, followed by 29.8% sold to OEMs directly and the remaining is exported. Turnover of Indian Tyre Industry Rs. 25,000 Crores Tyre Production (Tonnage)
13.50 lakh M.T.
Tyre Production – All Categories (Nos.)
971 Lakh
Tyre Export from India (Value)
Rs. 3000 (est.) crores
Number of tyre companies
36
1.2.
Key Influencers
The level of economic activity, performance of domestic automotive industry, and the faring of the transport sector directly influence the performance of the tyre industry in India. With the replacement segment dominating the overall tyre demand, the industry remains inherently vulnerable to economic cycles. While radialisation has become the norm in the enger car segment, in the bus and truck tyre segment, its acceptance is still limited. Bus and truck radialisation could emerge in the long term as the quality of roads improves and the restrictions on overloading are better enforced. The practice of re‐treading, which is 2
WASTE TYRE RECYCLING PROJECT UNDERSTANDING
gaining increasing acceptance, could pose a challenge to replacement demand in the medium term. The ability of the re‐treading sector to capture potential replacement demand would depend on the awareness among customers (of the benefits of retreading) and also the quality of retreading done. Given the low levels of penetration of two‐wheelers and enger cars in the country, OEM demand is likely to increase, which in turn would ush up replacement demand with a lag. Slowdown in automotive industry and global economy in general negatively impacted the Indian tyre industry in 2009. The industry tonnage growth was only 2.19% during first nine months of FY 2009, compared to 7.38% growth experienced during the same period last year. Demand side was also severely affected as almost all auto manufacturers were forced to adjust their production last year. A major relief for tyre manufacturers was provided by the government by reducing the excise duty on tyres from 14% to 10% in December 2008, and further to 8% in February 2009.
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WASTE TYRE RECYCLING PROJECT UNDERSTANDING
2. MAJOR PLAYERS
MARKET SHARE ‐ INDIAN MARKET 5%
4% MRF
22%
APOLLO
18%
CEAT GOODYEAR BIRLA
10%
21%
JK TYRE BRIDGESTONE
7%
OTHERS 13%
While the tyre industry is mainly dominated by the organised sector, the unorganised sector holds sway in bicycle tyres. The major players in the organised tyre segment consist of MRF, Apollo Tyres, Ceat and JK Industries, which for 63 per cent of the organised tyre market. The other key players include Modi Rubber, Kesoram Industries and Goodyear India, with 11 per cent, 7 per cent and 6 per sent share respectively. Dunlop, Falcon, Tyre Corporation of India Limited (TCIL), TVS‐Srichakra, Metro Tyres and Balkrishna Tyres are some of the other players in the industry. MRF, the largest tyre manufacturer in the country, has strong brand equity. While it rules supreme in the industry, other players have created niche markets of their own
2.1.
MRF Ltd.
MRF Limited (MRF) is a well known India s No. 1, which was incorporated on 5th November 1960. The Company manufactures the largest range of tyres in India and is the market leader with the largest market share in almost every segment of the tyre industry, product portfolio of the company includes Tyres, Pretreads and Conveyor Belts. MRF has six manufacturing plants in India. It has a distribution network of over 2,500 outlets in India and also has overseas offices in United Arab Emirates, Bangladesh and Vietnam. Apart from the domestic, the company exports its products to over 75 countries worldwide. 4
WASTE TYRE RECYCLING PROJECT UNDERSTANDING
2.2.
Ceat Ltd.
Ceat Ltd. is a part of the RPG conglomerate. The company offers the widest range of tyres to leading Original Equipment Manufacturers across the world. They manufacture a range of tyres catering various segments. The company operates two plants in Maharashtra. The company has a robust national network consisting of 34 regional offices and over 3,500 dealers. The company has their presence in 110 countries.
2.3.
Apollo Tyres Ltd.
Apollo Tyres Ltd is engaged in manufacturing automobile tyres and tubes. They are having their manufacturing facilities at Trichur in Kerala and Vadodara in Gujarat. They are the first Indian tyre company to launch exclusive branded outlets for truck tyres and also the first Indian company to introduce radial tyres for the farm category.
2.4.
J.K. TYRES
J K Industries Ltd. (JKI), the leader in the Indian Tyre Industry and manufacturers of well‐ known J K TYRE. J K Tyre along with its subsidiary Vikrant currently holds the No.1 position in the 4 Wheeler tyre segment with a market share of 20.8 %. J K Tyre and Vikrant continue to be the leaders in the commercial tyre segment which constitute 70% of the Tyre Market with the highest market share in the Indian Tyre Industry. J K Tyre maintains its dominant position in the enger Car Radials. J K Tyre is a preferred supplier with most of the OEMs. J K Tyre has launched several new products including recently launched Tractor Radial Tyre. J K Tyre is in the process of further expanding its enger Radial capacity to strengthen its position further. • • • •
First manufacturer to launch "T" rated tyres in 1994‐Ultima. First manufacturer to launch "H" rated tyres in 1996‐97‐Ultima 210 H. First manufacturer to launch Dual High Traction Steel radials‐ Aqua sonic First manufacturer to introduce India's first range of eco‐friendly coloured tyres.
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WASTE TYRE RECYCLING PROJECT UNDERSTANDING
2.5.
Bridgestone India Private Limited
Bridgestone Corporation, Japan was established in the year 1931. Today, the company is a US $23.2 billion Corporation with its headquarters at Tokyo. It controls 18.2% of global market and sells products in over 150 nations. The company has 47 tyre plants and 93 non‐ tyre plants, 3 technical research and development centres and 10 proving grounds. Today, Bridgestone has a worldwide work force of more than 110,000 employees. It is a global tyre manufacturing company, which emphasizes on Japanese traditions. It is still growing and expanding and aiming at increasing its share in the world tyre and tubes, industrial rubber products like belts, hose, chemical products, sporting goods, automotive parts, electro materials and marine products etc.
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WASTE TYRE RECYCLING PROJECT UNDERSTANDING
3. TYPES OF TYRES BEING CONSUMED IN INDIA
CATEGORY WISE TYRE SALES IN INDIA BUS / TRUCK
18%
LCV ENGER CAR 7%
47%
JEEP TRACTOR FRONT TRACTOR REAR
21%
TRACTOR TRAILER OTHERS
1%
2% 2%
2%
Categorywise Tyre Production in India Financial Year 2007‐08 & 2008‐09(April‐September) (In Lakh Nos.) Tyres for: 2007‐08 Truck & Bus 65.57 enger Car 80.06 Jeep 7.40 Light Commercial Vehicle 25.17 Tractor Front 9.17 Tractor Rear 6.30 Tractor Trailer 4.42 Animal Drawn Vehicle 1.49 Scooter / Moped 55.65 Motor Cycle 134.11 Industrial 3.31 Off the Road (OTR) 0.69 Total 393.34
2008‐09 67.93 88.36 7.38 27.86 10.32 7.28 4.29 1.51 50.95 153.49 3.44 0.77 423.58
% Change 4 10 0 11 13 16 ‐3 1 ‐8 14 4 12 8
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WASTE TYRE RECYCLING PROJECT UNDERSTANDING
Category wise Tyre Production in India Financial Year 2007‐08 & 2008‐09(April‐September) (In Lakh Nos.) Tyres for: Truck & Bus
2008‐09 128.39
2009‐10 148.11
% Change 15
enger Car
165.7
200.47
21
Jeep
14.69
14.02
‐5
Light Commercial Vehicle
52.98
57.39
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Tractor Front
18.42
23.86
30
Tractor Rear
13.15
16.34
24
Tractor Trailer
7.58
9.03
19
Animal Drawn Vehicle
2.81
2.94
5
Scooter / Moped
108.83
135.57
25
Motor Cycle
301.48
356.64
18
Industrial
301.48
5.38
‐5
Off the Road (OTR)
5.68
1.61
18
Total
821.07
971.36
18
The above two tables clearly indicate a rise in tyre production in India from 8 % in 2008‐09 to 18 % in 2009‐10.
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WASTE TYRE W E RECYCLING G PROJECT U UNDERSTANDING
4. TYR RE RECYCL LING IN IN NDIA portation mo ore efficientt and travel more comffortable sincce Tyres have been maaking transp 5. Early tyres were mad de they werre first invented for horse‐drawn ccarriage wheeels in 1845 from lateex which is aa natural extract of the rrubber tree. These days tyres are maade in several stages ussing many diifferent materials as sum mmarized be elow: •
•
Rubber The ccomposition is dictated b R by the end u use requirem ments of the tyre. A blen nd of natural and a synthetic rubber is mixed with carbo on black an nd chemicaals or vulcanizattion. A typiccal car tyre u uses about 40% natural rrubber and 6 60% synthettic fo ru ubber. Te extiles and steel wire LLayers of teextiles make up the cassing of the tyre, t which is reeinforced with steel wirre. Most mo odern tyres use steel w wire to reinfforce the tyrre w where it mee ets the rim of the wheeel (called beeads). In higgh performaance, or trucck tyyres steel wiire is also used to reinforce the textiile casing.
tyre is placced in a mould and inflated. Heatin The constructed c ng under prressure in th he mould sh hapes the trread and vulcanizes thee rubber. Tyres are desiigned to acccommodate a variety of vehicles, surfaces and weather conditions. For example, ttruck tyres teend to have a higher peercentage of steel to reinforce the structure. TTyres still havve the samee basic desiggn and, despite variatio on, there is enormous potential fo or reuse or rrecovery due to the vast quantitiees of waste ttyres generated each yeaar.
The n number of vvehicles hitting the roads is increasing everydayy and so is th he number o of tyres. Th here is a bussiness oppo ortunity up ffor grabs an nd it’s in reccycling them m. With morre than 33 million vehiicles added to the Indiaan roads in last three yyears, can you y guess th he uld have incrreased maniifold leadingg to some graave problem ms? other items that wou 9
WASTE TYRE RECYCLING PROJECT UNDERSTANDING
TO BUY THE FULL INDUSTRY REPORT ALONG WITH DETAILED PROJECT REPORT FOR RECYCLING WASTE TYRE including the financials and technology supplier SEND DRAFT OF RS. 2999/‐ IN NAME OF “ NEPRA ENVIRONMENTAL SOLUTIONS PVT. LTD” Payable at AHMEDABAD, In case of Outstation Cheques please issue for Amount RS.3250/‐ Courier it to along with your details to NEPRA Environmental Solution Pvt Ltd. 404. ATRIA, Lane Opp Atithi Resturant Bodakdev, Ahmedabad GUJARAT INDIA.
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