There couldn’t be any industry that isn’t implementing, or at least knowing about, automation. And if there’s actually one, then it has probably been living under a rock. The tyre industry has already opened its doors to automation, and this helps make tyre manufacturing more sophisticated and reliable. The tyre manufacturing process itself has been experiencing constant changes – from different tyre sizes and constructions to targeting less usage of energy. Automation must be on every tyre company’s to-do list, if it hasn’t adopted it already. Don Heelis, Sales Manager, Cimcorp, gave Tyre Trends more insights on the different aspects of automation in the tyre industry and its absolute requirement, when we met him at the Tire Technology Expo 2022 in Hannover, Germany. Read on…

The philosophy of tyre manufacturing has changed dramatically. A part of the change in that philosophy relates to automation implementation in the tyre manufacturing process. However, we also find more technical perspectives being adopted and taken into account at new, modern tyre factories today.

This technical perspective can be considered to be coming from a few different areas, one of them certainly being from the actual production part of the tyre factory. Therefore, with production machinery, mixers, extruders and tyre building machines, the level of technology being implemented in these processes is increasing. Moreover, these processes are getting more sophisticated.

The other aspect of this is integrating the production across all the different areas (another factor for the dramatic change in the modern tyre factory). In the past, the different areas of production were not necessarily well connected. However, today we see them getting connected a lot more – and this is being driven and enabled by technology.

This is where companies like Cimcorp come in – who happen to provide material handling and automation technology so that different tyre manufacturing processes are better integrated.

Explaining this, Don Heelis, Sales Manager, Cimcorp, said, “When you produce your work in process, what you’re producing is in synchronisation with what’s being produced in other areas of the factory. This helps minimise the work in process and have a manufacturing process that’s more efficient.”

Going the modular way
But how does one integrate different machines and processes in the plant with all the different machines and manufacturing processes involved? Heelis let us in on this.

“The trick is to implement the automation and connectivity in a modular way,” he revealed and went on, “That way, the connectivity is physical and mechanical but involves software as well. Thus, we take an approach where the modules are flexible and can connect to various inputs and outputs; however, the module is in itself standardised. Hence, the modules can work for different factories – only the interconnection needs to be flexible.”

The green tyre
While implementing automation, one, of course, would want to implement it where they get the biggest value. “Traditionally, that has been in the palletising area – in managing and handling the finished product. Basically, palletising, storing and retrieving the finished product,” Heelis informed us and continued, “This is where everyone has traditionally looked in the past. However, a lot of focus has been put on the green tyre area in the past 10 years. That includes green tyre handling, storage and retrieval and its automatic delivery to the curing process.”

A green tyre is work in process – simply put, a tyre that has not been cured. “A green tyre is made up of a number of components. It’s built on a tyre-building machine,” Heelis further told us. “Once a green tyre is built, it is buffered, followed by being cured – and automation machines are required in order to do this. Hence, this is a key element of the modern tyre factory.”

He added, “This has been an area of key focus where productivity and simplicity can be gained. In fact, the whole process can be done with less plant floor space. Ultimately, factories that want to be competitive have to implement automation technologies in that area.”

Increased efficiency
There are many brownfield factories out there that have to modernise and be viable for the future. One of the key areas that they need to modernise and automate in is green tyre handling. Heelis asserted, “By having an automated storage and retrieval system, one can track and trace all of the work in process. Plus, one is able to store in a manner that maximises the quality of the green tyres. And then, one can deliver them from the storage system to the curing process in a very systematic and accurate way. This way, when a particular green tyre is needed in the curing area, it can be delivered there in the appropriate amount of time.”

“In this methodology, when the green tyre arrives at curing, it is at that point in time when it is needed, and the production does not have to stop,” Heelis further shared. “If this can be achieved, then the curing process can be run more efficiently; the efficiency can go from 80 percent to over 95 percent. In theory, one can increase the output of their factory by 10 percent. In such a case, one can imagine how many tyres can be produced in a factory by following this methodology.”

Automation – its role during the pandemic and inflation
While automation tends to bring in efficiency, how have companies managed to keep up their competence and productivity during the thorny period of the Covid pandemic? The pandemic has definitely brought some insights to the tyre industry from a management point of view, like it did to many other sectors. According to Heelis, automation has come to the rescue of the tyre industry in the pandemic as well.

“One important thing that the industry learnt from the pandemic was that it has a risk to its ability to produce products,” he mentioned and went on, “The absence of automation will make any company in the industry highly dependent on the labour force, which might not be available to keep the production going. On the other hand, with automated processes, a company is less at risk to events like a pandemic.”

Another issue we are dealing with right now in the global economy is inflation. Inflation equals to costs going up – from the cost of materials to the cost of labour. “Nonetheless, a company can mitigate some of the impacts of inflation if it has embraced automation. In fact, the ones who automated their brownfield factories three to four years ago are in a much better position today than their competitors who had not,” Heelis pointed out and went on, “This is because the former can mitigate some of the inflation costs, is less dependent on the workforce and is able to produce better-quality products – and at a higher level of efficiency at that. We know that there is a tremendous shortage of people in the workforce in the US right now. Therefore, automated companies have a significant competitive advantage.”

From the tyre industry’s challenges due to the pandemic and inflation, we turned to the challenges Cimcorp itself faces on the commercial side. Heelis responded that, commercially, the current challenge for them is being a low-cost, high-quality producer – which one has to be in order to compete in the market. “Furthering this challenge is how we become a low-cost, high-quality producer and stay that way. And from our perspective, the way to get there is through innovation and technology,” he stated.

Automation in the Asian tyre industry
CIMCORP opened up an office in India roughly three years ago. With its presence in the country and Asia, Heelis told us that the tyre companies in Asia are no stranger to automation and are implementing it. “As a move forward, the mentality is that if you want to be a world-class manufacturer and build a new factory, then you build the factory with automation. And this is a global perspective,” Heelis asserted.

Cimcorp’s customers in Asia range from traditional tyre manufacturers to new manufacturing entrants in the industry, so it’s a mix. Throwing further light on this, Heelis said, “We all know the traditional manufacturers like Bridgestone, Michelin, Goodyear, Continental and more. But beyond these, there are new companies emerging. And these new companies have an advantage in some ways because they are not constrained by the old ways of thinking. They are forward thinking, with a clearer mindset to do things in the current environment – the environment of automation and technology.”

“Moreover, the manufacturers who don’t invest in automation, and try to run the company with practices that were developed in the 1960 and 70s, will not be able to survive or compete,” he further added. “Their market will eventually consider them to be non-competitive, non-global and unable to produce the quality expected of them.”

Cimcorp has plans for India as well. “Our strategy is to continue to grow our business in India with the domestic tyre manufacturers, and we have been successful at that,” Heelis shared and went on, “When I say domestic, that goes for manufacturing facilities within India, from Apollo Tyres to MRF to JK Tyre to Goodyear to Michelin. Thus, we plan to continue to build our business with those factories and customers from an automation perspective, and then from a full customer service point of view.”

The other aspect comes to brownfield factories. Heelis averred, “With brownfield factories, whether in North America or Asia, the cost of automation is the same; there may be different payback scenarios between the two. However, it stands true that no matter where a company is present in the world, if it is operating a brownfield factory, then it needs a strategy to modernise. And the strategy to modernise is based on implementing automation.”

Automation in brownfield factories – what will it take?
The strategy to modernise when automating a brownfield factory is especially challenging in an already existing system. Therefore, when automating a brownfield factory, one of the most important considerations is to not interrupt their day-to-day production, Heelis cited. He mentioned that the factory has to continue making its certain number of tyres each day. Hence, a strategy that enables the factory to do that is needed – while concurrently implementing automation there.

“Besides, when you implement automation, you have to be able to do it in a standardised way,” Heelis further enlightened and continued, “This can be done with the help of flexible automation modules that can work in a lot of different scenarios. Therefore, you can deal with different brownfield factories depending just on how you arrange your automation modules. Thus, you can come up with a custom solution for every different brownfield factory out there with the help of a modular approach and on the basis of how you connect those automation modules together.”

Service provided
From providing standard modular systems to hardware to software, Cimcorp strategically has a service aspect to its business – Success Services. Therefore, the approach from its service side is to enable its customers to be as successful as possible.

“That could be achieved by providing a 24/7 support. So if the customers contact us due to an issue they are facing in the solutions provided by us, we are available at any time of the day or night to support them,” Heelis revealed and added, “We can do it remotely. In fact, as technologies emerge further, we’ll see how we can do this more remotely with virtual techniques. Here, their serviceperson could be using special tools, which enables our people (who are remote) to actually be in virtual situations in our customers’ plants. In such wise, we can be more responsive and be as if we are in place in real-time in order to provide a service.”

Tyre warehouse automation or manual operation – making the choice
Nevertheless, Cimcorp does not just stop at its 24/7 services or providing its automation solutions for tyre manufacturing processes. It goes beyond that – to the finished product warehouses. However, interestingly, that depends to a degree on which part of the world the automation is needed in; while some areas will need automation that is well advanced, some areas will use a more manual operation.

Heelis explained, “There are some key factors that determine whether the facility/area in question needs to be automated or not. For example, the cost of real estate. If it’s a manual operation, then that typically involves a very large warehouse, say around 100,000 sq mt.”

“For automating, on the other hand, you require lands that are much smaller,” Heelis further highlighted. “For instance, land is very expensive in Japan. Thus, one wouldn’t want a very big footprint warehouse over there. Which means, you go vertical wherever land is expensive.”

“On the flip side, land is very cheap in some areas and inexpensive to build the generic building (like in some areas of the US). So there is less incentive to go vertical with automation there,” he added. “But there might be other factors that could dominate.”

Choosing automation over manual operation – why?
While some main factors do influence the decision if a warehouse is going to be a fully automated one or a semi-manual one, an automated one is always preferred. For clear reasons.

“The benefit of an automated warehouse is that everything is extremely well controlled,” Heelis informed. “What’s more, you have complete control of your product – you know exactly where it is, how much of it you have and you can get on-demand access.”

“As for a semi-manual warehouse, there are fork trucks, people moving things around and putting them in different storage locations,” Heelis further clarified. “This process is much more manual, involves a lot more interaction and is time consuming. Therefore, you have much less control over the process.”

Automation – a need not to be confused as a luxury
The automotive industry has been one of the earliest industries to adopt automation. So it’s high time that tyres, an integral component of any vehicle, did so too. It’s clear that automation, today, is not a luxury but a need. No company can afford to not have it. No tyre company must be limited to older technologies, and they must invest in automation for the long term. This would not just help tyre manufacturers meet their customers’ demands without any delay, but also help modernise the industry with the world’s rapidly changing technologies.

The Goodyear Tire & Rubber Company and TNO have successfully demonstrated that the integration of tyre intelligence technology into the automatic emergency braking (AEB) system of a vehicle has the potential to mitigate crashes even in challenging road conditions.

According to recent wet road testing, an improved AEB system with Goodyear SightLine technology may help reduce collisions at up to 80 kmph (50 mph) by applying brakes early. All things considered, the combination of AEB and SightLine insights on tyre and road condition data contributes to reliable performance in a variety of situations. This follows Goodyear and TNO's successful CES 2024 demonstration of tyre intelligence integration with antilock braking systems (ABS).

The automotive industry has placed a lot of emphasis on the AEB system, which applies the brakes automatically when a collision is about to occur in order to assist prevent or lessen the severity of crashes. The AEB system can work more efficiently in a variety of driving conditions, including low-friction surfaces like wet roads or ice, by integrating Goodyear SightLine, the company's suite of tyre intelligence solutions. Currently, existing systems are usually tuned for high-friction surfaces like dry asphalt. Tyre intelligence may give the AEB more detailed information about the real tyre and road conditions through the contact patch with the road, allowing for more intelligent and accurate decision-making.

Chris Helsel, Senior Vice President and Chief Technology Officer, Goodyear, said, "Safety is a cornerstone of Goodyear's commitment to innovation. By providing critical inputs about tyre and road conditions into AEB systems, we are helping OEMs and their customers take a leap forward in safety, well ahead of the National Highway Traffic Safety Administration's (NHTSA) 2029 mandate for AEB systems in passenger vehicles. Beyond this mandate, AEB systems will play a critical role in automated driving, helping to provide a comprehensive safety solution at all times."

Martijn Stamm, Marketing Director, Unit Mobility & Built Environment, TNO, said, "TNO is dedicated to enhancing the safety, efficiency and sustainability of vehicles. Our collaboration with Goodyear aims to predict the braking distance of a vehicle in more conditions, like dry and wet asphalt, and trigger the AEB timely to reduce accidents and ultimately safe lives. This knowledge is a key enabler for a safe introduction of higher levels of automation."

Italy-headquartered Rodolfo Comerio, a leading supplier of advanced systems for calendering lines, has come out with a new innovative solution, which it believes will further make plants more sustainable.

The company’s new calendering lines provides rigorous control, which enables thickness uniformity. Its production versatility processes a wide range of technical materials with different chemical and physical properties. This reduces production times and maximises productivity all the while cutting down on wastage.

Rodolfo Comerio stated that energy efficiency in buildings starts with roof insulation, which is also an effective way to cut down on thermal dispersion and enhance indoor comfort.

The company claims that materials manufactured with its calendering lines are higher efficient, have better durability even in extreme weather conditions and are much more sustainable.

Comerio Ercole, the Italian machinery manufacturer, is poised to enhance industrial performance with its advanced calendering solutions, which enable greater flexibility, precision and efficiency in production processes.

The company’s innovative Shuttle CE windup unit is designed for fully automated roller changes without halting operations, offering substantial cost savings and improved productivity.

The Shuttle CE unit features two identical stands on a shifting platform. While one stand operates under the cross-cutter unit, the other remains offline for roller replacement. This dual-stand configuration, combined with offline loading and unloading via dedicated cranes or integrated systems, eliminates manual intervention and enhances process optimisation.

Further demonstrating its technological leadership, Comerio Ercole recently commissioned a cutting-edge MINIDUPLEX rubber sheeting calendering plant. The plant’s HYDROPLUS configuration achieves ultra-thin rubberised sheets as fine as 0.075 mm, marking a significant breakthrough in precision calendering. The company continues to invest in R&D to refine its solutions and maintain competitive leadership.

Sumitomo Rubber Industries has decided to deploy Rockwell Automation's manufacturing execution system (MES) platform at its largest domestic factory in Shirakawa City, Fukushima Prefecture, Japan.

The factory will begin operations using the new platform in the second half of 2025.

This move comes as part of the company’s efforts to promote the use of digital technology in tyre production, aiming to enhance and streamline factory operations globally.

Kenji Saito, Executive Officer, General Manager of Manufacturing HQ, Tyre Business HQ Sumitomo Rubber Industries, said, “We believe that leveraging Rockwell Automation’s expertise and flexibility, and our strong partnership with PTC to the maximum will enable us to standardise manufacturing management and enhance operational efficiency globally, driving our growth. To implement DX management as set out in our management vision, we intend to deploy the MES system beginning with the domestic factory and other manufacturing sites thereafter. We will continue to collaborate with Rockwell Automation, a global leader in manufacturing, and embrace new challenges with a forward-looking approach, making full use of AI.”

James Glasson, Vice President, Global Industry Auto, Tire and Advanced Mobility, Rockwell Automation, said, “This initiative will enhance operating efficiency, minimise manufacturing risks, reduce implementation costs and significantly accelerate speed to market.”

In recent years, the manufacturing industry has faced numerous challenges, including rapid changes in the business environment and labour shortages due to Japan’s declining working-age population. To address these challenges, Sumitomo Rubber Industries has been working with PTC since 2019 to adopt PTC’s IoT platform and develop applications to integrate data across production lines and manufacturing sites.

This system has been rolled out at nine of the company’s 11 tyre manufacturing sites, including all four factories in Japan.

The deployment of the Rockwell Automation MES platform will accelerate data organisation and enable the accumulation and sharing of valuable data such as quality and production forecasts across the company. By linking the collected and managed data with the enterprise resource planning (ERP) system, corporate management can gain a comprehensive view of manufacturing operations worldwide.

The Shirakawa Factory will begin operating the MES platform in the second half of 2025. After verifying its effectiveness by the end of 2026, Sumitomo Rubber Industries aims to standardise and roll out the platform to its factories in Japan and overseas.