Case Study 03 · Tyre Mounting Paste
Case Study 03 · Tyre Mounting Paste
India’s largest tractor manufacturer faced a visible quality problem: permanent flow stains and corrosion on the steel rims of new tractors. At the dealership, these defects affected the customer experience and cost sales. The manufacturer turned to Compac to identify the cause and resolve the issue.
The customer manufactures tractors and agri-equipment in North India, supplying dealers across the country and shipping to export markets. Wheels are assembled inside the plant, where tyres are mounted onto steel rims before the completed wheels are fitted to the tractors.
The rim lies flat on the tyre mounting station, held in place by a special jig. The operator places the tyre over the rim, and the mounting equipment stretches the tyre onto it. The customer previously applied a soap solution, made by mixing soap with water, to help the tyre slide into place.
The soap solution used in the mounting process was leaving permanent flow stains on the visible rim face. At the contact point between the tyre and the rim, the paint had been coming off, and the exposed steel was corroding. Damage to the tyre bead, the reinforced inner edge of the tyre, was also leading to quality complaints of air leakage from the market.
New tractors reached dealerships with permanent flow stains, peeling paint and visible corrosion on their steel rims. The loss of paint exposed the steel to rust, compromising the condition of the rim before the tractor was sold. Buyers expected a new machine in sound condition; these defects undermined confidence in its quality, created a poor customer experience and cost sales. Air-leakage complaints extended the quality concern into service.
Tyre mounting · The application surfaces
Apply a thin coat to the tyre bead and rim flange before mounting.
Compac traced the rim defects back to the tyre mounting operation, examining how the soap solution was applied, the quantity used and its movement across the tyre and rim during mounting. Inspection covered both the visible flow stains and the damage at the tyre–rim contact: paint loss, corrosion and deterioration of the bead rubber. This assessment connected the customer’s concern at the dealership to the lubrication and material compatibility requirements of the mounting process.
The tyre must stretch enough to pass over the rim during mounting and then recover its shape. Effective lubrication helps the bead slide over the rim flange with less force, protecting the rubber from splits and excessive stretching. The mounting medium therefore needs to provide adequate lubrication throughout that movement.
The mounting medium remains between the tyre bead and rim for a long duration, in contact with rubber and painted steel. Its effect on those materials matters alongside its sliding properties. The inspection identified water-related corrosion, paint damage and hardened bead rubber as concerns the replacement material needed to address.
The quantity applied and the area covered determine where the mounting material ends up. Compac’s solution required a thin, even coat on the tyre bead and rim flange. Achieving that coverage with a thick paste called for a compatible brush, expert initial application and training in the technique and quantity required.
The problem with the quality of the tyre rims began in the mounting process. The soap solution provided inadequate lubrication, while retained water promoted corrosion and the soap damaged paint and hardened bead rubber. Compac therefore addressed the material and its application together: a paste with good sliding properties and rubber and rim care, applied in a controlled quantity with the correct tool and technique.
Compac streamlined the process used to mount tyres by specifying a tyre mounting paste and establishing how to apply it. The team supplied the compatible brushes, carried out the first few applications on the production wheels, refined the quantity needed and trained the plant’s operators to repeat the method.
Compac selected the paste for its sliding properties, compatibility with rubber and painted steel, and protection against corrosion. These properties addressed the damage identified during inspection and the demands of the mounting operation.
Good sliding properties. The paste allowed mounting with low force and minimal time, minimal use of materials and low machine wear. It protected the tyres and the rim flange and improved centring of the tyre on the rim.
Rubber and rim care. The paste kept the rubber soft, supported lasting sealing between the rim and tyre bead, prevented rust formation and prevented the tyre from sticking to the rim. These properties addressed the need to protect both materials during mounting and after assembly.
A pH-neutral formulation. The paste is pH-neutral and not aggressive on rubber or the rim. It is gentle on the skin, environmentally friendly and not harmful to health. The formulation is silicone-free and free from harmful solvents.
A short drying time. The paste dried quickly after application, helping establish a firm connection between the tyre and rim soon after assembly. This helped reduce subsequent complaints and re-balancing costs.
Care during storage. The paste kept the tyre bead soft and ready for use during summer and winter storage.
Specified the paste against the inspection findings. Compac selected a mounting material that combined the required sliding properties with care for the rubber and painted steel it would contact.
Provided the special applicator. The paste’s thick consistency requires a controlled application technique to achieve a thin, even coat. Compac supplied the compatible brush and provided expert guidance on coverage and quantity at the tyre bead and rim flange.
Carried out the initial expert application. Compac applied the paste on production wheels at the plant, established the coverage and worked on the quantity each wheel required. This application work brought down the paste consumption, improved mounting performance and ensured protection of the rim finish.
Trained the operators to continue the process. Compac showed the plant’s team how to handle the paste, use the brush and repeat the application. The operators now carry out the work themselves.
The customer reported that the change resolved the rim-quality problem. The plant’s operators now carry out the paste application following Compac’s demonstration and training.
Rim-quality problem, as reported by the customer
New tractors reach the dealership with clean rims
Application technique and paste usage refined on production wheels
Plant operators now carry out the application themselves
A visible finish defect can begin in a process that also affects the condition of the tyre. Following the problem back to the mounting station connected the customer’s concern with lubrication, material compatibility and application practice. Compac carried that diagnosis through to the paste, the brush, the first expert application and the operators who now run the process.
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