Pumping Up Efficiency In The Tyre Manufacturing with Acoustic Imaging Cameras For Compressed Air Leaks
Tyre Manufacturers Challenge
Tyre manufacturing is a complex and intricate process, consisting of multiple stages such as chemical mixing, calendaring, extruding, bead making, tyre building, and curing. These stages heavily depend on compressed air systems, which are crucial to the operation of tyre manufacturing plants. Regrettably, air, steam, and gas leaks are prevalent in tyre manufacturing process lines, where they contribute to increased expenses, energy waste, and production interruptions if left undetected.
Tyre Manufacturers Solution
The FLIR Si124 acoustic imaging camera, an advanced ultrasonic solution for air leak detection, finds even minor leaks effortlessly and from a distance, making inspections safer to conduct. The lightweight, portable device is easy to use with only one hand and provides real-time leak size and cost estimates using AI-driven analytics, which make determining the urgency of repair actions easy.
The addition of FLIR Thermal Studio Suite desktop software can help tyre companies gain a further advantage by integrating thermal and acoustic imaging in a single report. This dual functionality enhances maintenance decision-making while eliminating the need to learn multiple software platforms.
Furthermore, the complimentary FLIR Acoustic Camera Viewer web-based reporting software enables rapid image uploads via Wi-Fi for immediate analysis. This service provides users with valuable insights, such as the dimensions and energy costs of compressed air, enabling maintenance departments to prioritise repairs. In addition, the ingenious software generates ISO 50001-compatible reports that automatically present in-depth information on the problem and suggestion for how to proceed with repairs and maintenance.
Equipped with 124 microphones, the Si124 enables exceptional sensitivity and accuracy in finding even small leaks in noisy industrial settings, such as tyre manufacturing plants.
By deploying the FLIR Si124 acoustic imaging camera, mills can locate pressurised leaks in compressed air systems up to 10 times faster than point scanning methods.
The FLIR Si124 can also save tyre plants money. To estimate the potential energy a plant could save from detecting and repairing air leaks, in relation to the cost of the camera itself, the Si124-LD ROI Calculator can be used.
Additionally, the added benefits of report generation and cloud storage offered by the ultrasonic camera helps tyre companies keep records of planned repairs and maintenance work for the tyre plant machinery, ensuring cost-efficient operational continuity in the future.
The benefits of using an acoustic imaging camera for air leak detection in tyre manufacturing include the following:
- Automatically detects leaks by the sound they emit, even in loud industrial environments
- Allows for leak detection in a wide field of view and from an extended range, thanks to its 124 microphones
- Locates leaks up to 10 times faster than traditional methods for greater efficiency
- Analyses leaks in real time, utilising the processing power of its built-in AI
- Saves up to 20–40% of all energy used for compressed air
- Saves inspection time and costs
- Provides safe and easy usage in industrial settings
- Delivers ISO 50001-compatible reporting
Equipped with 124 microphones, the Si124 enables exceptional sensitivity and accuracy in finding even small leaks in noisy industrial settings, such as tyre manufacturing plants.
"Compressed air systems are used throughout the entire tyre-making process and require regular inspections"
Deeper Dive: Turning Insight into Action on the Factory Floor
In the highly competitive world of manufacturing, efficiency is not just a bonus; it is a necessity. One of the most commonly overlooked sources of energy loss in manufacturing plants is compressed air leaks. Despite the high cost of generating compressed air, many facilities lose thousands of pounds each year due to undetected leakage. This is where acoustic imaging cameras provide a practical and transformative solution for maintenance teams.
Acoustic imaging cameras work by using arrays of microphones that capture sound and convert it into a visual representation. This enables engineers and technicians to see sound in real time, making it possible to pinpoint the exact location of compressed air leaks, even in noisy or complex manufacturing environments. Unlike traditional methods that require close contact or the trained ear of a technician, acoustic imaging cameras allow for quick and safe surveys of large areas from a distance.
For engineers working on the manufacturing floor, the ability to identify compressed air leaks without halting operations can make a significant difference. These cameras turn leak detection into a proactive task, allowing maintenance staff to stay ahead of potential problems. Leaks that would typically go undetected for weeks or months can be found and resolved in hours, improving overall plant efficiency and reducing wear on equipment.
Another key advantage of acoustic imaging cameras is their ability to generate digital reports. These reports quantify each leak, including estimates of cost and severity. This data helps prioritise repair work, justify maintenance budgets, and support long-term energy-saving strategies. In the wider context of manufacturing efficiency and sustainability goals, this information becomes a valuable asset.
Addressing compressed air leaks using acoustic imaging cameras is more than just an energy-saving initiative. It is a way to create a more responsive, data-driven maintenance culture. As energy costs rise and pressure increases to meet environmental targets, reducing air waste has never been more important.
By using acoustic imaging cameras, manufacturing facilities can finally gain visibility into a problem that is often invisible to the naked eye. This technology gives maintenance teams the tools they need to turn compressed air into a controlled, measurable, and cost-effective resource.
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