Off-Road Solid PU Tire Solution
Plan off-road solid polyurethane tire production with material preparation, metering, two-component mixing, mold casting, curing and inspection. Match the equipment and tooling to tire dimensions, service conditions and production targets.
Automated Production Line for Solid PU OTR Tires
Traditional semi-manual casting methods have limited capacity, leading to significant variations in tire performance due to manual ingredient mixing. It is difficult to quickly adapt custom formulations for complex conditions like heavy mining, low temperatures, and corrosion resistance. Open casting processes result in high material waste and emissions. Matching formulas with automated equipment presents a significant technical barrier, making large-scale, standardized production challenging for small and medium-sized enterprises. This turnkey line utilizes proprietary high-pressure PU casting machines, modular tire molds, and an online post-curing inspection station, enabling fully automated precision casting, two-component mixing, tire casting, and online performance testing. The system achieves a ±1% measurement accuracy. It can be customized to create durable, low-temperature, and corrosion-resistant PU formulations for use in mining, ports, and steel plants. The equipment features a modular, expandable design, allowing for flexible addition of workstations and inspection modules. Integrated AI visual sorting reduces material waste and emissions through a closed-loop feeding system. Different tire specifications and operating conditions require adjustments to molds and formulations, and a single set of hardware cannot cover all OTR (Off-the-Road) solid tires.
Customized formula system for harsh working conditions
Developed specifically for demanding mining conditions – heavy loads, low temperatures, and corrosive environments – Accelon tires offer extremely low wear rates, as low as 0.15 cm³/1.61 km. Tire durability and load-carrying capacity are verified through third-party testing reports.
Fully automated, closed-loop, environmentally friendly production.
Fully automated pouring process with integrated machine vision defect detection and alarm; closed-loop feeding system that improves raw material utilization by 20%, suitable for large-scale, heavy-duty tire production.
The equipment provides stable casting conditions, but the durability, load-bearing capacity, and impact resistance of the finished product are not directly guaranteed by the equipment itself. The quality of the finished product is determined based on reports from a recognized third-party laboratory. Operation for more than 6000 hours without failure is considered the standard for mine loading conditions. The machine vision system only provides defect detection alerts; the physical sorting mechanism is a separate component. Project acceptance is based on a signed technical agreement between the parties.
Complete project implementation steps
We offer a comprehensive, end-to-end service, from initial on-site condition assessments and formulation validation, through equipment customization and production, on-site installation and commissioning, small-scale trial production and optimization, to full-scale production. This ensures a smooth and successful launch of the OTR-PU solid tires production line.
Factory site condition assessment and evaluation
A specialized technical team conducts on-site assessments, gathering information on existing equipment layouts, target production capacity, tire load specifications, and any specific operating conditions. This data is then used to develop a customized handover plan.
Formula development and laboratory validation
The R&D center developed a suitable polyurethane formulation and a complete production process. Before commencing equipment design, laboratory performance testing and feasibility validation were completed.
Pre-commissioning within the manufacturing facility
We offer factory-specific casting machines or upgrade existing production lines for our clients. Our engineers perform pre-installation and testing on-site before shipping the equipment.
Technical specifications and performance analysis
The following represents a benchmark for the proposed solution: operation with no failures for over 6000 hours under standard mine loading conditions; machine vision is only used for defect detection and alerting, with physical sorting being an optional feature. The final configuration will be determined based on tire specifications, raw materials, and production capacity, and will be subject to a signed technical agreement between the parties.
| Parameter specifications | Fully automated, continuous production line for solid polyurethane tires (OTR-PU). |
|---|---|
| Applicable products | Mining vehicles, port equipment, construction machinery, and heavy-duty steel transport – all requiring OTR (Off-the-Road) solid tires. |
| Material measurement accuracy | ±1% (as a reference, under stable mass production conditions) |
| Core process flow | Precise metering – two-component mixing – pouring – curing – online performance monitoring – fully automated transfer |
| Reference acceptance rate | ≥99% (based on standardized molding + reference values from formulation control) |
| Durability | The Akron compound exhibits a very low abrasion rate of 0.15 cm³/1.61 km (ASTM D4060, formulation-specific, third-party testing). |
| Device Architecture | The design is modular and scalable, allowing for the addition of new pouring stations and testing modules. |
| Environmental features | The closed-loop feeding system minimizes the release of hazardous substances, resulting in a 20% improvement in raw material utilization. |
| Configuration settings | Machine vision detects visual defects; physical sorting mechanism is part of the selection module. |
| Equipment reliability | Standard mine loading conditions, continuous operation without failure for more than 6000 hours. |
| Adaptability | Support for upgrading and modifying existing production lines. |
| Contents of delivery | Key manufacturing process, fully automatic casting machine, custom tire molds, online inspection unit, on-site installation and commissioning, formulation process, personnel technical training, lifetime spare parts support. |
| Warranty Information | Executed in accordance with the terms of the formal contract and the technical agreement. |
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Key advantages of the plan
Addressing the challenges of low production capacity, inconsistent performance, difficulty in developing new formulations, high environmental impact, and high technical barriers associated with traditional OTR tire manufacturing.
Custom-designed, highly durable formulations for harsh working conditions.
Customized PU formulations for demanding mining conditions: heavy loads, low temperatures, and corrosive environments. Akron tires offer extremely low wear rates, as low as 0.15 cm³/1.61 km. Actual wear and load-carrying performance are verified through third-party testing reports.
Fully automated, closed-loop, environmentally friendly production.
Fully automated pouring process with integrated machine vision defect detection and alarm; closed-loop feeding system that improves raw material utilization by 20%, suitable for large-scale, heavy-duty tire production.
Modular and flexible expansion, with controlled investment.
The modular equipment design allows for the addition of pouring stations and testing modules later on, increasing capacity without requiring a complete replacement of the entire system. This design is adaptable to fluctuating order volumes.
Closed-loop, environmentally friendly production + comprehensive technical support
Closed-loop feeding systems improve raw material utilization and reduce emissions; they also provide a comprehensive package of support, including formulas, equipment, processes, and training, thereby lowering the technical barriers for tire manufacturers entering the market.
Related PU Tire and Wheel Projects
Related project records for PU tires and industrial wheels. Each record has its own material, equipment and application scope.
PU Caster Production Line Upgrade Project in Poland
OTR Solid PU Tire Production Line Upgrade Project in China
Frequently Asked Questions
Questions about solid PU OTR tire production, equipment configuration, formulation trials and project acceptance.
Does the +1% measurement accuracy apply under all operating conditions?
Can 6,000 hours of trouble-free operation be achieved under any conceivable condition?
specifications, load, and routine maintenance are all closely related.
Can machine vision be used to directly and effectively sort and remove defective tires?
sorting and removal mechanism is an optional module and requires separate evaluation and configuration.
Can the device directly ensure that the tires meet the required standards for durability and performance under heavy loads?
bearing capacity of the tires depend on the customzed formula, raw materials, and molds. The final products performance
must be verified by a third-party laboratory testing report.
Can existing production lines be upgraded?
Request a customized solution and a quote.
Please provide us with information about the operating conditions for your tire application, tire specifications, and production targets. This will allow us to provide you with a detailed production line layout diagram and a customized pricing proposal for the OTR PU solid tire manufacturing line.
