The praised solution has been in use at Eurl Saterex-Iris in Algeria since autumn 2019. Eurl Saterex-Iris is the third biggest tyre manufacturing plant in Africa, serving both local and export markets. The modern plant was mainly designed and constructed by Black Donuts Engineering and its international partner network. Black Donuts is also responsible for production management, which applies the core principles of Lean Management and focuses on reducing the interim stocks to the bare minimum according to the pull method. To enhance this, the company developed an RFID-based electronic eKanban solution together with Toptunniste.

 

“The eKanban project started from a need to improve production management. The first acute challenge we met was the lack of adequate and accurate information on the overall production status,” Solution Manager Aki Nurminen recalls.

 

Originally, there were nine Kanban boards located all over the two-floor factory. One had to check each board manually, so it took time and effort to capture a complete view of the production status.

Another deficit concerned the insufficient information provided on manufacturing schedules. The old Kanban boards did not give enough information on when certain materials were supposed to be in production.

The returned cards included no accurate time markings, so it was hard to stay updated, notice stock alerts and to respond on time.

Real-time production status

New technology was needed to solve the problem. It became clear that initiating remote monitoring would require electronic boards instead of the traditional ones. Black Donuts contacted another Finnish technology company, Toptunniste, to present the idea and search for a way to actualise it. The solution was simple: adding RFID features to an existing Kanban board would upgrade it to a more accurate, more informative, and easy-to-use eKanban board. Next, the old cards were replaced by RFID tagged cards, readable through RFID technology.

Now, all nine eKanban boards are online in Saterex’s internal data system and easily monitored from any computer. Consequently, an up-to-date overall view of the entire production is now always at hand.

The eKanban solution enables better and real-time tracking of overall production status and enhances the supervision of production processes.

It adds the time markings automatically to each card on return, keeps account, and establishes automatic triggers to replenish stock when predefined minimums are reached for each inventory item.

The system also calculates and presents the estimated time left before reaching the pre-defined minimum of each item in the downstream processes. This is the lens that helps us prioritize and schedule the production runs.

Optimised processes

The new eKanban boards were taken into use at Saterex tyre plant in fall 2019. For the users operating in the production lines, the new solution has not brought any changes in their daily routines, but the Kanban boards are used the same way as before. For the supervisors and factory management, the new system enables a remote and real-time view of the production status through a web interface.

The new solution helps in prioritizing the tasks and shortens the reaction time to different problems arising in production. eKanban is also a great planning tool, as it gives us a complete process overview, Aki explains.

The eKanban system gets all the production information it needs straight from the company’s MES, where the daily consumption levels of each process, as well as the minimum and maximum storage levels, are defined. Separate eKanban views, visualizing the interim storage levels, can be reviewed through MES which enables effective inventory management.

The eKanban solution is designed for tracking the production, not to automatically assign anything. It is always the team, the people, who make the decisions based on the information they receive. However, the solution helps to improve tracking and optimizing operations, Aki says.

Advanced work management

Moreover, the eKanban solution enhances work management.

Compared to manual Kanban systems, eKanban gives additional information on storage unit rotations, events and even stock rotation history. It is valuable information for both follow-ups and for managing transportation activities and best working methods. Earlier, the material transportation could idle, and the return of cards to the Kanban boards be irregular, which caused various scheduling challenges, stockouts and unexpected changes in demand.

It was nearly impossible to find the root cause for problems and consequently improve it. Thanks to the digitised solution, we can now track every event, which supports work development and feedback giving.

 

While the manual Kanban boards already gave a good boost for companies in optimizing production, the new eKanban solution brings monitoring, tracking and optimizing to a remarkably higher level.

eKanban is an excellent example of how we can improve proven old methods during digital transformation.

eKanban was designed to add a remarkable value to the supply chain support operations. This was accomplished by optimizing cost-effectiveness, efficiency, and the movement of materials. Currently, Aki’s team is already developing the next generation eKanban solution, one without any physical cards or printed labels and boards. This will serve the needs of the highest automation solutions, which require visual identification instead of manual labelling or printed cards.

The operators do not even need to touch the storage units anymore, but the Electronic Shelf Label (ESL) completes the visual identification. Electronic Shelf Label is automatically updated during the manufacturing processes and events referring to RFID identifications and data communication. This way, the labels are never missing, old or wrong, and they are readable in all occasions and all the time, Aki explains.

The Yokohama Rubber Co., Ltd. has initiated the full-scale deployment of a proprietary generative artificial intelligence system, which became operational in August 2026. This advanced platform employs Retrieval-Augmented Generation (RAG) technology to sift through the company’s extensive internal repository of technical documentation. The primary objective is to furnish development engineers with rapid and precise access to critical information, thereby streamlining decision-making processes in areas such as material innovation and tyre design.

This system represents a significant expansion of Yokohama Rubber’s existing HAICoLab AI framework, first established in October 2020. While the company had previously introduced AI tools for predicting rubber properties, generating novel compounds and assisting mould design, a persistent challenge remained in efficiently navigating the vast collection of regulatory texts, manuals, reports and case studies that constitute essential domain knowledge. The new generative AI system was developed specifically to address this gap, enabling swift retrieval of pertinent data aligned with specific development goals.

In practice, engineers pose questions tailored to their project’s specific context and the AI searches for the most relevant information from internal records to formulate its answers. To further refine accuracy, an integrated AI agent interprets the user’s intent and autonomously cycles through planning, information retrieval and evaluation steps. Moreover, the system provides direct links to the original source documents, allowing staff to confirm the validity of the AI-generated responses and incorporate them into their analytical and strategic work. This functionality effectively integrates accumulated technical knowledge into the HAICoLab-driven development environment.

Concurrent with these technological advancements, Yokohama Rubber is actively cultivating digital transformation personnel proficient in utilising the HAICoLab platform. The company remains committed to enhancing the system’s capabilities and leveraging its internal data and intellectual assets to foster the creation of innovative products, processes and services moving forward.

Linglong Tire has expanded its European summer tyre portfolio for light commercial vehicles with two new offerings under its subsidiary brands, Leao Tire and Crosswind Tire. Following the spring introduction of the Linglong Dura Master Van, the company has now launched the Crosswind Dura Peak Van and the Leao Nova-Force Van 2. This marks Crosswind's first entry into the summer van tyre segment, while the Nova-Force Van 2 succeeds its well-regarded predecessor.

Engineered specifically for vans, motorhomes and light trucks, both tyres emphasise durability, fuel efficiency and enhanced driving performance. Their new construction integrates optimised tread patterns and wider footprints to reduce wear and extend mileage. An innovative silica-based compound lowers rolling resistance for significant cost savings, a critical factor for commercial operators. The reinforced carcass supports heavy loads, while advanced sipe technology, combined with the tread compound, shortens wet braking distances and improves handling on both wet and dry surfaces.

Manufactured exclusively at Linglong's advanced facility in Zrenjanin, Serbia, each tyre line is available in 29 sizes ranging from 12 to 17 inches, with orders now being accepted. Development took place at the European Development Center in Hannover, with validation testing conducted at the Idiada circuit in Spain and the group's Sino Asia proving ground in China. These strategic choices underscore Linglong's commitment to European-quality engineering and rigorous performance standards for its commercial vehicle offerings.

Looking ahead, Linglong plans to complete the van tyre ranges for both Crosswind and Leao Tire with the introduction of new winter and all-season tread patterns scheduled for late 2026. This upcoming expansion will further solidify the group's comprehensive year-round coverage in the light commercial vehicle segment across its brand portfolio.

Wencheng Liu, Head of Product Management, Linglong Tire, said, "With the new Crosswind and Leao van tyres, we are expanding our range in the field of light commercial vehicles and offering a high-performance solution for both businesses and private households. Both tyres combine high mileage with safety and efficiency – crucial factors for cost-conscious families and entrepreneurs who use their vehicles on a daily basis."

India’s tyre exports rose 16 percent year on year to INR 77 billion in the first quarter of FY2026–27, despite geopolitical uncertainty, supply-chain disruptions and elevated input and logistics costs, according to the Automotive Tyre Manufacturers’ Association (ATMA), citing data from the Ministry of Commerce.

The April–June performance builds on a record export value of INR 273.12 billion in FY2025–26, indicating sustained external demand for Indian-manufactured tyres.

Passenger car radial (PCR) tyres led the growth, with export value increasing 21 percent during the quarter.

Arun Mammen, Chairman of ATMA, said: “The significant growth in tyre exports during the first quarter represents a strong start to the new financial year. It reflects the growing acceptance of Indian-manufactured tyres across discerning global markets and the sustained investments made by the industry in technology, capacity, product development and quality.”

Europe was a key growth driver, with exports to the region rising 25 percent to INR 30.03 billion in the quarter, accounting for nearly 40 percent of total tyre exports. The US remained the single largest export destination, contributing 16 percent of overall export value. Indian tyres are exported to more than 170 countries.

India’s global presence is also supported by tyres supplied as original equipment on vehicles manufactured domestically and exported worldwide.

ATMA said improved market access through trade agreements and supportive export policies could help the industry sustain momentum and strengthen India’s position as a global tyre manufacturing and export hub.

The Indian Rubber Materials Research Institute (IRMRI) recently announced the appointment of Professor (Dr) Abhijit Bandyopadhyay as its new Director. In a tete-a-tete with Tyre Trends, he delves into his top priorities and IRMRI’s roadmap under his leadership.

What will be your top priorities as the new director of IRMRI?

I have a list of four priorities. The first is to transform IRMRI from a testing and certification centre into an innovation hub that integrates research, technology development, scale-up engineering, innovation and commercialisation for the tyre and non-tyre rubber industries. The second priority is developing technologies for EV tyres. While automakers are using lightweight polymer composites and foams to offset battery weight, advancing EV tyre technology will remain a key focus.

Thirdly, to undertake autonomous research that benefits industry beyond traditional rubber compounds, covering plastics, rubber-plastic blends, advanced polymer systems and other emerging materials. Finally, internationalise IRMRI by establishing MoUs with global industries and academic institutions.

Sustainability and circularity are becoming central themes across industries. How do they fit into your vision for IRMRI?

Sustainability should not be viewed as a separate objective; it must be embedded in every project we undertake. Every technology we develop should inherently follow sustainable principles. The introduction of Extended Producer Responsibility (EPR) has fundamentally changed the tyre industry’s responsibilities by making manufacturers accountable for the waste generated by their products.

This naturally increases the importance of reclaimed rubber, rubber crumb, recycling technologies and broader circular economy practices. Today, applications for reclaimed materials remain limited and expanding their use will become an important research area.

How will you strengthen collaboration between IRMRI, academia and industry?

IRMRI has always supported industry through its testing services but its contribution to research and development can become much stronger. At present, academia and industry operate with very different priorities. IRMRI is uniquely positioned to bridge this gap because it already has advanced facilities in Chennai, Thane and the Eastern Centre, with new centres coming up in Tripura and Delhi.

Building on existing collaborations at the Thane Centre, IRMRI should expand partnerships with universities, IITs and industry beyond rubber technology into areas such as mechanical engineering, machine design, sustainable rubber processing, simulation, modelling, artificial intelligence and other multidisciplinary fields to strengthen both its research capabilities and national stature.

What are the biggest challenges facing India’s rubber and tyre industry today?

The industry’s biggest challenge is sustainability, particularly recycling, devulcanisation and compliance with EPR. While significant progress has been made in developing rubber and polymer products across numerous industries, recycling remains a major technological hurdle.

The same challenge extends beyond rubber to composite materials. Although material development has advanced considerably, achieving efficient, commercially viable recyclability remains one of the industry’s greatest unresolved problems.

What do you expect to be the biggest challenges in your new role at IRMRI?

I have worked closely with industry for the past 16 years and almost all of my current research projects are industry-sponsored. I understand industrial expectations, priorities and ways of working, so adapting to the industry itself will not be difficult.

The real challenge will be transforming IRMRI from a testing institute into a research and innovation institute. Achieving this will require a clear roadmap, well-designed policies and systematic implementation with some trial and error along the way.

How do you see AI and digital technologies accelerating rubber materials research?

AI, simulation, modelling and digital engineering will become integral parts of IRMRI’s future development strategy rather than standalone initiatives. Artificial intelligence is fundamentally a form of data science. It involves developing computational models and predictive systems that help researchers analyse data more intelligently and efficiently.

Computation, simulation and modelling are becoming increasingly important. The tyre industry already relies heavily on these tools because modern tyre development would be almost impossible without them. However, the non-tyre rubber industry has not yet adopted them to the same extent. Simulation and modelling also contribute engineering efficiency, reducing development costs, optimise manpower deployment and enable better product design before physical prototypes are built.

How can IRMRI strengthen its testing capabilities to meet future industry requirements?

IRMRI already has strong testing facilities for existing technologies, but the rapid growth of electric vehicles makes specialised EV tyre testing an important priority.

We also need to evaluate whether current testing protocols adequately assess EV-specific requirements such as acoustic performance, vibration characteristics and other parameters beyond rolling resistance. Where gaps exist, IRMRI will develop new testing methodologies and standards tailored to EV tyres.

What emerging technologies and materials should IRMRI focus on in the coming years?

Sustainability and next-generation materials must be major priorities. As bio-composites and natural-material-based rubber products gain importance, standardised testing methods for many rubber-polymer bio-composites are still lacking. Developing reliable performance evaluation standards for these materials while strengthening capabilities in recycling, devulcanisation and circular economy technologies will help Indian manufacturers meet global quality standards.

Material innovations, particularly in solution-grade Styrene-Butadiene Rubber (SBR), will also require advanced testing, reinforcing IRMRI’s vision of becoming an innovation-driven institute.

How can IRMRI help Indian manufacturers meet global quality standards?

Helping Indian manufacturers meet increasingly demanding global quality and performance standards begins with addressing the industry’s biggest technological challenges, which is recycling, devulcanisation and circular economy requirements. If IRMRI can develop technologies in these areas, it will benefit both the rubber and non-rubber industries.

As an NABL-accredited institution, IRMRI also has a unique advantage over most universities, whose testing and certifications, while technically credible, are generally not accepted for commercial compliance. Now that IRMRI has been recognised as an institute, it will strengthen its independent certification capabilities and establish itself as a nationally and internationally respected authority for testing and certification.

Does India need stronger collaborative testing programmes?

Yes. India needs a more structured ecosystem that brings together research institutes, OEMs, raw material suppliers, manufacturers, universities and IITs throughout testing and product development. IRMRI should become the platform that connects academia’s knowledge-driven research with industry’s application- and product-oriented approach, accelerating innovation.

Internationally, this model has proven successful through industry-sponsored academic programmes that create a continuous pipeline of research, skilled talent and commercial innovation. India has some examples of such collaborations, but they remain scattered and should be expanded significantly.

How do you plan to change the industry’s perception of IRMRI?

One of my biggest objectives is to fundamentally change how both the tyre and non-tyre industries perceive IRMRI. Today, the institute is primarily viewed as a testing laboratory. Testing will always remain an essential function, but I want IRMRI to be recognised as much more than that.

My vision is for IRMRI to become an innovation hub where research, technology development, product innovation, industrial problem-solving, scale-up engineering, commercialisation, multidisciplinary collaboration and advanced materials research all come together. Changing that perception will take time, but we will build that bridge eventually.

What opportunities do you see for retreading technology?

Retreading has enormous potential but also significant technical challenges because it involves bonding a new tread to an already vulcanised tyre. While unvulcanised rubber is naturally tacky, vulcanisation removes this property, making two vulcanised surfaces difficult to bond.

Strong adhesion requires roughening both surfaces for mechanical anchorage followed by specialised adhesives and carefully controlled processing. Since India’s retreading industry remains fragmented, advancing retreading technology will be a key focus, particularly for its sustainability and resource conservation benefits.

Looking ahead, what will define the success of IRMRI?

Success, in my view, will not be measured by the number of tests conducted or certifications issued but by whether IRMRI becomes an innovation-driven institute. That means undertaking autonomous research, developing industry-focused technologies, strengthening academia-industry collaboration and more.

Indian manufacturers compete globally. Ultimately, I want IRMRI to be recognised not just as a testing centre but as one of India’s leading innovation hubs for rubber, polymers, advanced materials and sustainable industrial technologies.