The global demand for efficiency and precision in tyre manufacturing has reached unprecedented levels, and VIPO a.s., a pioneer in advanced bead winding technology, has delivered a game-changing solution: the LIHEXAL 8 – octuple head single wire bead winding machine (production of 8 beads per cycle). Designed specifically for the production of PCR (Personal Car Radial) tyres, this latest innovation epitomises cutting-edge research and development, coupled with decades of expertise in rubber and wire applications.

A LEAP FORWARD IN BEAD MANUFACTURING

The LIHEXAL 8 sets a new benchmark for bead winding machines, enabling the simultaneous production of up to eight beads per cycle. This state-of-the-art machine accommodates bead diameters ranging from 13” to 24.5” and cross-sections in both hexagonal and rectangular profiles.

The latest model of VIPO’s bead winding machine significantly reduces production time while maintaining consistent quality. The result is an increased beads output, minimised downtime and improved profitability for tyre manufacturers around the globe.

INNOVATION AT EVERY STEP

The LIHEXAL 8 redefines bead production with cutting-edge sensing and automation technologies. It offers real-time monitoring of material levels and predictive maintenance, ensuring seamless operations. Precision is at its core, measuring key variables like wire temperature, rubberisation and other parameters to guarantee beads of impeccable quality. Its advanced festooner system with independent pulleys allows precise control of wire tension and pressure, adapting effortlessly to unique production needs. Meanwhile, the upgraded bead winding station delivers unparalleled accuracy and speed, producing one bead every two seconds with flawless consistency.

VIPO’s innovations go beyond speed – they deliver reliability. With every cycle, manufacturers achieve premium-quality beads, securing their competitive advantage in the tyre industry.

GROUNDBREAKING WRAPPING TECHNOLOGY

One of the most notable features of the LIHEXAL 8 is its integrated bead wrapping system. In collaboration with the world’s best wrapping tapes suppliers, VIPO has developed a high-performance wrapping solution that applies tape to bead ends simultaneously without affecting the machine’s cycle time. With a machine autonomy and real-time verification of tape application, this system guarantees optimal quality and consistency.

A LEGACY OF EXCELLENCE

Rooted in the legacy of Tomáš Bata’s historic town, VIPO a.s. has been at the forefront of rubber and wire technology for over 50 years. Combining generational expertise with cutting-edge innovation, VIPO proudly serves the world’s leading tyre manufacturers – partners who trust its solutions to deliver excellence. This enduring trust drives VIPO to continuously push the boundaries of innovation, with gratitude to its customers as the foundation of its success.

EXCEPTIONAL SERVICE, UNMATCHED RELIABILITY

From installation and training to continuous support and machine optimisation, VIPO ensures that clients harness the full potential of the LIHEXAL 8. This exceptional level of service, combined with the machine’s unparalleled performance, makes it a cornerstone for modern, efficient and premium tyre manufacturing. Moreover, the LIHEXAL 8’s unmatched reliability and advanced automation significantly reduce human intervention, paving the way for streamlined operations and optimised production workflows.

WHY EVERY TYRE MANUFACTURER NEEDS THE LIHEXAL 8

The LIHEXAL 8 isn’t just a machine – it’s a revolution in tyre manufacturing. With precision, flexibility and speed, it meets the demand for high-quality beads while driving down costs and enhancing efficiency. Designed to adapt to each customer’s unique needs, it’s the ultimate solution for modern production challenges.

More than a supplier, VIPO is the trusted partner and committed to its clients’ success. The LIHEXAL 8, as well as the other VIPO equipment and services isn’t just about transforming production – it’s about empowering your business to lead in a competitive market.

GRP Limited has commenced commercial crumb rubber production at its new manufacturing unit in Solapur, Maharashtra.

The company invested approximately INR 250 million in the new facility, with funding sourced from borrowings ( INR 180 million ) and internal accruals ( INR 70 million ). The new unit has an annual production capacity of 31,875 metric tonnes of crumb rubber.

According to the filing to the BSE, the new manufacturing facility is strategically positioned to meet growing demand across various sectors, including reclaim rubber, tyre pyrolysis, tyre manufacturing, road surfacing and rubber goods production.

Located in the MIDC Industrial Area in Chincholi, Solapur, the unit began commercial production on  24 March  2025. The facility represents a significant expansion for GRP Limited, with the company noting that it is a new manufacturing location with no existing production capacity.

Covestro, one of the world’s leading manufacturers of high-quality polymer materials and their components, has announced that it will open an automated laboratory for optimising coating and adhesive formulations to provide better support to its customers.

Formulations for coatings and adhesives including Covestro binders and crosslinkers will be tested in the new facility. Properties like hardness, adhesion, opacity, gloss or durability are guaranteed by their astute selection. The qualities of the finished product are determined by the mix of these formulas, which usually include seven to 15 components. Standard formulas are typically employed due to the large number of conceivable combinations that arise. The computer-aided design of test series and automation have also made it possible for the new laboratory to conduct longer test series.

The new facility can operate 24/7 with a goal to conduct tens of thousands of tests annually. In terms of quantity, diversity, accuracy and testing speed, this establishes a new benchmark. A significant quantity of structured data is produced by the automated laboratory. As a result, the body of information regarding formulation options and contributing factors will expand quickly. To further enhance formulations, the gathered data is assessed using specialised machine learning algorithms in conjunction with measurement data from previous experiments. In order to create a self-learning system, artificial intelligence is also employed to forecast future experiments based on property goals and concurrently validate them in the automated laboratory.

Apart from creating 1K and 2K systems based on water and solvent, the automated laboratory also conducts a variety of material tests on the applied films, formulations and raw materials. To replicate product use under application settings, application can even be conducted in a lab setting with varying climates. The quick transfer of created samples to more specialised testing labs is another benefit of Covestro's ongoing laboratory digitisation. This facilitates the addition of market-specific test findings to the datasets and speeds up the identification of pertinent relationships.

Thomas Büsgen, head of the laboratory, said, "With our automated laboratory, we can work together with our customers on the future of coatings and adhesives. Because it operates almost completely autonomously and learns from our existing knowledge and data lake as well as newly generated data, it makes the process of optimising and developing formulations many times more efficient and precise. This allows us to optimise existing formulations faster or even develop completely new formulations for and together with our customers. We can say: we are reaching a new level of modern research.”

Martin Merkens, Head of Sales & Market Development EMLA in Covestro's Coatings and Adhesives business entity, said, "Our new automated laboratory gives us more possibilities for testing formulations. It relieves our specialised laboratories of their standard tasks and can analyse samples more systematically. This allows us to focus our expertise and experience even more on customer-specific topics or try approaches we couldn't have implemented otherwise. This will particularly help us in the area of circular economy: Alternative raw materials, for example bio-based or recycled materials, can be tested faster and evaluated for their properties in the final product.”

Covestro has successfully completed the modernisation of its TDI (Toluene Diisocyanate) plant in Dormagen, Germany. The facility was formally commissioned by Covestro as it unveiled its new goal of boosting production energy efficiency during an event attended by over 60 visitors from the commercial, political and personnel sectors, including Oliver Krischer, North Rhine-Westphalia Environmental Minister.

By using 80 percent less energy than traditional methods, the modernised plant reduces CO2 emissions by 22,000 tonnes annually. This is made possible by a new reactor that is over 20 metres high and weighs more than 150 tonnes. It produces steam using the reaction energy that is created. Covestro began the modernisation process in the summer of 2023. Over 3.5 kilometres of new pipes, over 14 kilometres of cables and hundreds of new pieces of equipment, valves and monitoring devices were placed throughout the facility. Through its federal subsidy programme for energy and resource efficiency, the Federal Ministry for Economic Affairs and Climate Action (BMWK) has provided assistance for this modernisation.

The company targets a 20 percent reduction in CO2 emissions from energy use per tonne of product by 2030 compared to 2020, underlining energy efficiency as a key component in reaching operational climate neutrality by 2035. With a 300,000-tonne-per-year capacity, the Dormagen TDI facility stands as a shining example of how to successfully convert current manufacturing facilities to be more energy-efficient.

Dr Philip Bahke, Head of the North Rhine-Westphalia Site Network, said, "The successful completion of this project shows that climate protection and competitiveness can go hand in hand. The modernised plant sets new standards in energy efficiency and underlines our path toward climate-neutral production. In light of persistently high energy costs, the project significantly strengthens the competitiveness of TDI production in Europe. My special thanks go to the entire project team, who professionally implemented this complex modernisation during ongoing operations."

Dr Christine Mendoza-Frohn, Head of Sales Performance Materials for the EMEA and LATAM regions, said, "In Dormagen, we operate Europe's largest TDI production plant. With the successful modernisation, we can now offer our customers TDI with an even better carbon footprint. This supports our customers in achieving their own sustainability goals and strengthens our position as a reliable partner for climate-neutral and circular solutions."

The Infiniteria joint venture between Scandinavian Enviro Systems (Enviro), Antin Infrastructure Partners' NextGen Fund and Michelin has made progress on its end-of-life tyre (ELT) pyrolysis factory in Uddevalla, Sweden, according to Enviro's most recent update. The joint venture, which was established in March 2023, intends to build ELT recycling facilities with a combined processing capacity of one million tonnes around Europe by 2030.

The most recent report from Enviro, which is also in charge of project management and coordination, states that the buildings and civil construction are going well and that the production equipment is prepared for installation. The commercial-scale plant's development got underway in February, with an emphasis on pipe rack installation and outside construction. It is anticipated that crane installation would start around the beginning of March or early April in order to raise production equipment, including the reactor.

The plant can recycle 34.5 kilotonnes of waste tyres annually, which is equivalent to 40 percent of Sweden's annual ELT arisings. According to Enviro, it has already inked legally binding contracts worth EUR 170 million for the delivery of recovered carbon black and oil from the facility.