Like many other sectors, India’s tyre industry is undergoing a massive digital transformation. Companies like CEAT have been at the forefront of this shift, adopting state-of-the-art technology.

The company was recently included in the World Economic Forum’s Global Lighthouse Network due to its impactful digital transformation using Fourth Industrial Revolution (4IR) technology.

The leading tyre manufacturer has also planned to extend its technological advancements to its Nagpur plant. “CEAT’s vision for a smart factory dates back to 2015, when it commissioned its Nagpur plant. The groundwork, however, was laid earlier at Halol, where barcode tagging was introduced for traceability and error-proofing. While Nagpur became the first facility to implement a manufacturing execution system (MES), deeper analytics and machine learning capabilities were not yet in focus between 2015 and 2020,” revealed Jayasankar Kuruppal, Sr Vice President –Manufacturing, during an exclusive interview with Tyre Trends.

As Halol expanded and exports to Europe surged by the early 2020s, CEAT had to rethink its manufacturing strategy, shifting from a high-volume, low-variant model to a high-variant, low-volume approach. Once limited to 60-70 stock-keeping units (SKUs), the company's passenger car segment expanded nearly fivefold to meet European demand, requiring a complete overhaul of production workflows. 

At the same time, the adoption of silica-based compounds, which is critical for wet grip and rolling resistance, posed new challenges. These materials inherently increased cycle times, impacting capacity utilisation. While Halol was not initially designed for high-silica production, the company’s Chennai plant incorporated necessary corrections. However, tighter OEM specifications and European market requirements led to higher scrap and yield losses. 

Recognising the limitations of conventional manufacturing, CEAT turned to 4IR technology to optimise its processes. The 4IR technology refers to the advanced digital and automation-driven technologies transforming industries today. It builds on the Third Industrial Revolution by integrating AI, IoT, big data and robotics to enhance efficiency and decision-making.

“The digital transformation began at the Halol plant, expanded to Chennai and is now planned for Nagpur. Between 2020 and 2022, CEAT developed and deployed over 80 digital use cases, earning its first Lighthouse Factory designation. This data-driven manufacturing approach is now being systematically rolled out across its entire production network,” added Kuruppal.

Intelligent factories

4IR plays a crucial role in tyre manufacturing and recycling by enhancing predictive maintenance through IoT sensors, increasing energy efficiency via AI, production optimisations and advancing smart tyres with real-time monitoring.

On the other hand, an intelligent or smart factory in tyre manufacturing is defined by two core pillars, namely automation and digital intelligence. Traditionally, the tyre industry has been labour-intensive, but the shift towards smart factories is transforming operations through seamless machine-to-machine communication, real-time data sharing and AI-driven decision-making. 

The first layer of an intelligent factory is pure automation. This includes automated machines for tyre handling, programmable logic controllers for managing machine operations and automated warehousing systems to ensure smooth flow.

“For a plant to be truly smart, data must move seamlessly across all these systems, creating a connected ecosystem. This integration extends to ERP systems and advanced AI/ML-powered analytics, optimising throughput and efficiency,” said Kuruppal.   

The next stage is where operations run end-to-end with minimal human intervention. CEAT has already implemented elements of this, particularly through curing-to-dispatch automation, where tyres move untouched from uniformity testing to segregation, grading, storage, retrieval and final dispatch. It also has AI-driven IoT integrations that enhance energy efficiency, yield optimisation and first-time-right accuracy across all processes.

“The fusion of AI, IoT and automation is enabling tyre manufacturers to move from traditional manual-heavy processes to a digitally orchestrated, high-efficiency production model,” quipped Kuruppal.

CEAT’s production capacity spans multiple plants, each specialising in different tyre categories. The Chennai and Halol plants both produce 20,000 passenger car tyres daily. The Nagpur plant, India’s largest two-wheeler tyre manufacturing facility under one roof, with a capacity of close to 78,000 two-wheeler tyres daily.

Digital implementation

Curing operations in CEAT’s passenger car and truck tyre segments are almost entirely automated. While the curing medium remains unchanged, continuing with a combination of steam and nitrogen across Halol, Chennai and other facilities, the company is also exploring radical new processes, though still in the proof-of-concept stage. 

One key digital use case implemented in Chennai focused on reducing steam consumption through real-time process monitoring. Traditionally, mould heating followed fixed time cycles (e.g. 120 or 150 minutes). CEAT optimised heating based on actual temperature data, cutting steam consumption by almost 30 percent by integrating sensors and applying a machine-learning model.

The manufacturer has invested approximately INR 450-500 million in capital expenditure across its three factories to implement automation and digital transformation initiatives. On the operational expenditure side, CEAT spends INR 60-70 million annually on software licenses, infrastructure upgrades, sensors and scanners to sustain these smart factory systems.

Adopting smart manufacturing technologies has led to significant cost reductions for CEAT. Factory conversion costs at Chennai and Halol have decreased by 20-30 percent, driven by lower energy consumption, improved yield, higher manpower productivity and throughput enhancements.

Lead times from order placement to tyre dispatch have been cut by 50-55 percent, significantly improving supply chain efficiency. Additionally, material wastage has been reduced with process scrap, both component-level and finished product waste, dropping by 25-30 percent, resulting in substantial raw material savings.

Alluding to how difficult was it to implement such extensive digital changes, the executive explained, “From an infrastructure standpoint, Chennai had a clear advantage over Halol since the latter was commissioned in 2010 and 2015, when network and digital infrastructure were not as advanced. Unlike Chennai, Halol still does not have a fully integrated MES, making digital transformation more complex.”

“However, the approach to smart manufacturing differed at both plants. At Halol, the primary focus was on efficiency improvements. In contrast, Chennai underwent a more comprehensive transformation, covering the entire manufacturing chain from design and production to dispatch and supply chain optimisation. The goal at Chennai was to reduce overall turnaround time, significantly cutting the cycle from customer order receipt to final dispatch,” he added.

While Chennai benefited from a stronger digital foundation, CEAT did not merely replicate Halol’s use cases but developed new ones tailored to Chennai’s specific needs, further driving end-to-end operational efficiency.

Commenting on the challenges surrounding this paradigm shift, the executive noted, “Integrating legacy systems with Industry 4.0 technologies posed a significant challenge as ensuring compatibility between older manufacturing infrastructure and new automation, IoT and AI-driven solutions required meticulous planning and phased implementation.”

“Another critical hurdle was maintaining data quality and governance, necessitating robust validation processes, data lineage tracking and an accountability framework to enhance data integrity and reliability,” he added.

Answering whether such transformation is possible on OTR production lines, he said, “Unlike passenger or two-wheeler tyres, OTR tyres have a longer cycle time and high levels of customisation, making digital automation less complex but highly specific. While digital transformation is feasible, CEAT plans to prioritise full automation at Nagpur in the next 18–24 months, before shifting focus to digitalisation in OTR production.”

Workforce re-alignment

CEAT is reshaping its workforce strategy to align with its digital transformation, ensuring that shop floor employees are equipped and actively involved in adopting new technologies. 

It has digitised over 100 operator touchpoints to secure operator buy-in. The programme simplifies shop floor tasks through digital tools, MES integration and real-time dashboards, allowing operators to make decisions independently and reducing reliance on supervisors. Every operator has undergone basic digital awareness training to facilitate this transition. 

A key move was the introduction of business translators, who are frontline supervisors with strong technical acumen. They bridge shop floor pain points with digital solutions. Working alongside data engineers and scientists, these individuals co-develop AI-driven use cases, such as reducing setup time in mixing processes to improve efficiency. 

The company also strengthened its talent pipeline, hiring computer science graduates, a rarity in the tyre sector just a few years ago.  It has pioneered hiring female operators in the tyre industry, beginning in Halol in 2009.

“Today, 24–30 percent of shop floor employees in Chennai and Nagpur are women. While digitalisation isn’t the primary driver of this shift, automation has made traditionally labour-intensive jobs more accessible. The company also enforces pro-women policies, including home pick-ups and drop-offs, designated rest areas, female security and an internal support forum (V Power) to address workplace concerns,” informed Kuruppal.   

When asked whether digitisation will lead to a cut in vacancies, Kuruppal stated, “Contrary to fears that digitalisation reduces shop floor jobs, we find ourselves grappling with the bigger challenge of talent attraction. Post-pandemic, fewer young workers are willing to pursue manufacturing roles, with many opting for finance, retail and IT-driven careers instead. This trend is evident across major tyre-producing states like Tamil Nadu, Maharashtra and Gujarat.” 

“While automation and AI reduce physical strain and deskill certain operations, a fully manless tyre plant remains economically impractical in the near term. However, with rising labour costs and shrinking workforce interest, a fully automated future – perhaps within 15–20 years – isn’t off the table,” he added.

Sustainability through digitisation

CEAT is driving sustainability through digital transformation, reducing energy and water consumption while lowering its carbon footprint. Energy efficiency measures have led to a 15 percent reduction in power consumption at Halol and 25 percent at Chennai.

Renewable energy accounts for 40 percent of the company’s power mix, cutting Scope 1 and Scope 2 carbon emissions by nearly 30 percent. Water usage has been reduced by 30-35 percent over the past three years through steam optimisation, with future plans to eliminate steam in curing.

In green material adoption, integrating silica-based compounds in tyre manufacturing has required process adjustments as it increases cycle time. CEAT collaborates with equipment manufacturers to enhance efficiency. It has upgraded mixers to improve silica processing and support its shift towards sustainable materials.

Commenting on future plans to implement digital solutions, Kuruppal said, “We plan to integrate virtual and mixed reality into the manufacturing processes to enhance equipment maintenance and reduce mean time to service. We are also exploring AI-driven process optimisation, as these models will auto-correct processes in real-time, enhancing product consistency and accelerating decision-making. These technologies will also help identify and eliminate bottlenecks in manufacturing and planning, ensuring a more agile and efficient production flow.”

“The company is looking into GenAI to address complex operational challenges. AI-driven predictive maintenance will improve equipment reliability by forecasting potential failures before they occur. Additionally, GenAI will optimise supply chain and production planning, ensuring better resource allocation and efficiency,” he added.  

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Maxxis Rubber India has been presented with an Appreciation Award from the Ahmedabad Rural Police in recognition of its support during VIP movements. The accolade was conferred by Superintendent of Police Om Prakash Jat, acknowledged for his role in fostering community safety and collaboration through his leadership.

Guided by its core principles of respect, care and appreciation, the company emphasises its commitment to quality, service and trust alongside cooperation with authorities. Expressing gratitude to the police department for acknowledging its efforts, Maxxis stated that the honour reinforces its dedication to integrity and public safety partnerships, motivating the organisation to continue contributing with the same unwavering commitment and a focus on building stronger, more resilient communities every single day forward together.

“At Maxxis, our core values – respect, care and appreciation – drive us beyond business. Whether ensuring 100 percent quality, service, trust in our products or standing alongside authorities for public safety, we believe strong partnerships build stronger communities. We sincerely thank the Police Department-Ahmedabad Rural Police for acknowledging our ‘unwavering support’ and ‘invaluable cooperation’. This honour motivates us to continue contributing with the same commitment and integrity,” the company acknowledged in a social media post.

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The organisers of the International Rubber Conference 2026 have opened exhibitor applications for the accompanying Rubber & Elastomer Technical Exhibition, with discounted early-bird rates available until 30 April 2026.

The conference will take place from 2 to 6 November at the Aichi International Exhibition Center (Aichi Sky Expo), bringing together global scientists, engineers and industry stakeholders working across rubber and elastomer technologies.

Exhibitors submitting applications by the April deadline will benefit from reduced participation fees. The final deadline for regular applications is 15 July 2026.

Held alongside the conference from 3 to 6 November, the exhibition is expected to attract more than 4,500 visitors and is regarded as one of the leading international platforms for showcasing advances in rubber science, materials engineering and industrial applications.

IRC 2026 marks the sixth edition hosted in Japan, following previous conferences in Tokyo, Kyoto, Kobe, Yokohama and Kitakyushu. Under the theme “Future Rubber Technology toward Sustainability”, the event aims to address evolving industry demands, particularly as Asia accounts for a growing share of global rubber production and consumption.

Organisers said the event will provide a platform not only for established players but also for emerging engineers and researchers to engage with international experts, fostering collaboration and technological advancement across the sector.

Applications and further details are available via the official conference website.

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Tegeta Green Planet, in partnership with the Wasteless specific waste management association, hosted the Georgia Rubberized Asphalt Summit (GRAS) 2026 in Tbilisi. This international conference was designed as a platform for exchanging global knowledge on sustainable road infrastructure and rubber-modified asphalt technologies, bringing together industry leaders and international experts to examine both the challenges and opportunities within the sector. A dedicated panel discussion formed a central part of the event, fostering in-depth dialogue among participants.

Despite being widely adopted in United States, Portugal, Spain and across Europe for over six decades, rubber-modified asphalt remains unused in Georgia. This technology offers significant advantages over conventional pavement, including a service life of 8 to 10 years, superior resistance to water damage, reduced noise pollution and a substantial decrease in environmental harm caused by automotive waste. The summit’s organisers aim to address this gap by promoting responsible waste management and raising public awareness about the dangers of unprocessed refuse.

More than a forum for knowledge exchange, the summit served as a call to action, underscoring Georgia’s potential to become a regional frontrunner in sustainable infrastructure. Tegeta Green Planet, a subsidiary of Tegeta Holding established in 2022, was among the first companies in the country authorised by the Ministry of Environment and Agriculture to recycle used tyres, oils and batteries under extended producer responsibility principles. The organisation operates by collecting specified waste types, managing their transport and recycling and ultimately processing these materials in line with circular economy models, thereby supporting the nation’s shift towards innovative green initiatives.

Ekaterina Kavtaradze, CEO, Tegeta Holding, said, “For Tegeta Holding, sustainable development is one of the most important principles of our operations, which is reflected in concrete solutions. I am delighted that Georgia has had the opportunity to host such a large-scale event. GRAS 2026 demonstrates that the circular economy can become a real economic priority in Georgia as well, bringing significant benefits to the country, as waste is transformed into a resource, creating economic advantages and reducing the negative impact on the environment.”

Shalva Akhvlediani, Director, Tegeta Green Planet, said, “Georgia is at a stage where infrastructure decisions can shape the economic and environmental outcomes of the next generation. This summit provides us with a unique opportunity to learn from the world’s leading countries and implement these lessons at the local level. Overall, the circular economy is the way forward: it allows us to transform waste, such as used tyres, into a useful resource, ensuring economic stability, environmental protection and sustainable development.”

Giorgi Guliashvili, Chairman, Wasteless, “Our goal is to implement a fully circular model in Georgia – from waste collection to recycling and the effective use of recycled materials. Starting this autumn, Georgia will launch its first high-tech tyre recycling plant, which will process used tyres collected throughout the country. Using recycled rubber in asphalt is a clear answer to the question of how the resulting raw materials are utilised. As a result of the plant’s launch, we estimate that we will produce up to 12–15 thousand tonnes of rubber crumb per year, which will allow us to use this material locally to build more durable and environmentally friendly roads. This will bring significant benefits to both the environment and the economy.”

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Sailun recently welcomed trade and media representatives from across the Nordic region to the Sailun Polar Drive 2026 event, where the focus was on hands-on testing of the new Alpine Evo2, Arctic 2 and studded Ice Blazer Spike winter tyres. Held under severe winter conditions, the gathering was designed to let participants experience the full capabilities of this new range through direct driving experiences rather than passive demonstrations.

Situated in Munio, Finland, 200 kilometres north of the Arctic Circle, the location offered consistently harsh weather that served as the ultimate proving ground. Around 120 guests, including journalists, original equipment representatives and retail partners from the Baltics and Nordic countries, put the tyres to the test across a variety of challenging surfaces. From loose snow and slush to polished ice and wet pavement, the Alpine Evo2, Arctic 2 and Ice Blazer Spike each had the opportunity to showcase their specialised winter performance.

The event took advantage of temperatures fluctuating between -20 and +5 degrees Celsius, creating the mix of snow, ice and wet roads typical of Nordic winters. Testing took place on a frozen river track straddling the Finnish-Swedish border, featuring dedicated sections for handling, acceleration, braking and drifting. The remote Munio area, known for its pristine natural environment, also reflected Sailun’s commitment to sustainability, which includes reducing energy use and emissions during manufacturing and developing fuel-efficient tyres. A fleet of Audi A3, Audi A6 e-tron and Audi Q6 e-tron vehicles allowed participants to assess not only performance but also comfort, low noise and energy efficiency.

Beyond the driving sessions, the programme included an in-depth workshop covering tyre technology, the new winter product lineup and Sailun’s broader brand direction. Attendees also had ample opportunity to engage directly with members of Sailun’s management team throughout the event.

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