The global tyre industry has evolved on all fronts.  Tyre manufacturers faced a constant trade-off between meeting productivity goals and increased requirements from the customers and new regulations. Hauvala and his colleagues realised that tyre manufacturers could no longer do everything by themselves in the changing market environment: to design tyres, tyre factories and manufacturing processes in a way that would support the new demands for efficiency. Instead, they should be able to concentrate on their core business. “We had a great vision with true market potential, plus an attractive option to reform the tyre industry,” said Hauvala.

‘We’, that is a key founding team of twelve tyre technology professionals. Hauvala uses the plural form throughout the interview, pinpointing the obvious fact that you cannot change the industry alone. “It is all about ‘collaboration’,” Hauvala stresses.

In 2011, the tyre industry, well known for its strict conventions, was however not ready and waiting for a changemaker. It took long before tyre manufacturers accepted the new service concept and realized its potential business value. “It was the depth of our expertise that convinced the first customers. The fact that we knew the tyre industry from inside out and could provide the whole package under one roof,” Hauvala says

Today, Black Donuts is an established and recognised technology house providing innovative solutions for tyre manufacturers. The concept of turnkey solutions has remained as the company’s key strategic principle. Elaborating the solultion provided by Black Donuts, Hauvala, said, “We are a full-service technology house providing the entyre solutions for designing, building, and running a smart and sustainable tyre plant with maximized productivity and best-in-class products.”

The company’s customer portfolio includes 20 out of the top 25 tyre manufacturers, which a glaring sign of competence and an option to reform the industry. “You need references to be convincing. And you need a network of partners sharing your vision of a brighter future for making it happen,” Hauvala says.

Changes And Challenges In Tyre Production

In last ten years, according to Hauvala, tyre manufacturing has witnessed the diverse challenges, including complex product mixes, shorter product runs, and the pressure for faster deliveries – a myriad of different demands affecting day-to-day factory operation. “ Things are changing at an accelerating pace, and there are no signs of slowing down. From the tyre manufacturers’ perspective, the operational environment has become complicated,” thinks the Black Donuts CEO.

Focusing on core competencies is a clear industry trend. Other operations outside manufacturing high-end products are increasingly being outsourced – aligned with Black Donuts’ original business idea.

Nevertheless, all players regardless of their area of specialization benefit from partnering with a company that understands the entire sector. In the era of ever-tightening cost and efficiency targets, choosing a partner to lead and actualize major investment projects, such as setting up a new factory, has become a mainstream option. “Tyre manufacturers desire a proven and effortless end-to-end service, provided by professionals, whose core competence is to plan and manage investment projects,” he says.

Assuming total responsibility for the production design, ramp-up, and material handling, Black Donuts controls that every detail in the production aligns with the customer’s goals. A shortened payback time creates concrete extra value for the customer. Hauvala says, “Our finetuned processes and advanced technology tools enable a smooth ramp-up. The reduced time-to-market generates faster and greater ROI.”

The rise of automation is another key trend in the tyre manufacturing. Black Donuts helps tyre manufacturers improve productivity and take the required technology leaps towards smart factory efficiency. The company has developed its own MES concept that gives multiple benefits for tyre manufacturers, such as improved insight and the potential for full traceability of tyres in production. The new plant concept also enables a remarkable decrease in stock levels and factory manning. “ In our latest factory design plans, the required manning is only half of the level in the first plans ten years ago,” tells Hauvala.

Also, the end-customer demands are higher now than a decade ago, forcing tyre manufacturers to rethink their business models to live up to the growing expectations.  In the concept of Black Donuts, the manufacturing process is optimized, flexible and efficient despite the increased number of simultaneous products and sizes in production. “With us, the manufacturing process gets new flexibility that enables shorter delivery times,” Hauvala promises.

The Rise Of New Brands

During the past decade, the tyre industry has witnessed a geographic change. The number of brands in the market is growing, just like in any other industry offering low-involvement consumer products. Established international brands get new challengers from local manufacturers offering good quality for moderate prices. “ The interest in tyre production raises its head particularly in the countries of fast economic growth with own raw material sources,” says Hauvala.

Black Donuts has developed a tailored turnkey service for the industry newcomers. It covers the entire solution from A to Z for designing, building and running a tyre plant. “We step in on day one and work hands-on with the customer throughout the process from feasibility study to the market entry. Or beyond, keeping the production and products always in the frontline of tyre technology,” explains Hauvala.

Today, Black Donuts is a genuinely international company with customers on almost every continent except Australia, where there is no domestic tyre manufacturing. “ We don’t have any borders in our minds, but the whole world is our market area. We are fully open to all directions,” says Hauvala.

Quality Leap In Tyre Development

According to Hauvala, a quality leap is the single biggest change in tyre development, driven by a continuing high-performance trend and technological advances. “ The quality of tyres is remarkably higher today,” adds Hauvala.

Black Donuts’ customers get access to the latest technology, the smartest innovations, and the most advanced materials. All the best-in-class product qualities, such as superior performance, lowest rolling resistance and a quiet ride, are at hand. Within the past ten years, the debate about tyre qualities has increasingly shifted to the total environmental impact of the tyre. Parallel to tightening regulations on emissions and rolling resistance, tyre manufacturers are being pushed to enhance the use of biomaterials in tyre compounds and to minimize waste.

“The tyre industry has made remarkable progress in reducing waste, yet compared to many other industries, the use of biomaterials is still in its infancy,” Hauvala admits. He anticipates new regulations to emerge concerning the recyclability of tyres.

In-Built Sustainability

Improvements in tyre manufacturing and development have accelerated over the last decade, spurred by the sharpened focus on environmental issues. The demands for sustainability now concern the entire industry from products to production.

At Black Donuts, sustainability is a strategic driver. The company not only contributes to sustainability in its own operations but also supports its customers and partners in the move. “The ideas of circular economy are inherent in our business philosophy. All our solutions focus on manufacturing excellence and resource efficiency, optimizing biomaterial use, minimizing emissions and maximizing recyclability,” says Hauvala.

Enjoying a comprehensive view of the tyre industry, Black Donuts has a great opportunity to improve overall branch sustainability. The company runs several major investment projects that aim at making the tyre industry greener – one tyre at a time, like Hauvala says.  “All our most important development projects support a more sustainable tyre industry.”

Recently, the company developed a new stud concept that remarkably reduces the negative side effects of safe winter driving. The new, patented technology tackles the environmental challenges of studs, such as road wear, pollution, and noise. Revealing a bit of the company’s future aspirations, Hauvala reports that Black Donuts is also developing a high-end winter tyre for electric cars, doing research in biomaterials, and investigating the usability of recovered carbon black received from an integrated pyrolysis solution. “We are getting closer to zero-emission factories, although it will require dedication, engagement, and collaboration,” Hauvala concludes.

Future-Proofing The Industry

Today, Black Donuts employs over 60 professionals with skills that cover all areas of tyre manufacture and tyre technology. During the 10-year journey, the company has grown, reinforced its skills and recruited new talents from areas outside its original core competences. Hauvala praises the employees for making it possible to celebrate such a significant milestone. “Our team is exceptional. We have great people from diverse backgrounds, working together for a common goal and inspiring each other to make a difference,” says Hauvala proudly.

Although the company has rapidly grown, it has managed to preserve the flexible and agile corporate culture from the early days. In a recent employee survey, team spirit was named as the strongest motivator. “Team spirit is our internal source of power and a strong pillar supporting the whole business.”

According to Hauvala, every team member at Black Donuts shares the same value-adding commitment and passion to help customers and to make the tyre industry an exemplary branch that considers the generations to come. He encourages all players in the industry to prepare for the future, starting today. “ We know the best practices, future challenges, and opportunities in the tyre industry. For us, it is quite simple to evaluate if a tyre business is future-proof or not. Is yours?” (TT)

Apollo Tyres Ltd has secured a one-season shirt-sleeve sponsorship agreement with AS Monaco, one of French football's most successful clubs, to increase awareness for its premium Vredestein brand.

This partnership will leverage Ligue 1's ranking as the fifth most watched football league in the world to raise awareness of Vredestein's award-winning products among a large audience in France and abroad. On November 22, AS Monaco's home league game against Brest will have the new sleeve branding for the first time. The Vredestein brand will be heavily promoted at Stade Louis-II for the 2024–2025 season, including on player sleeves and LED screens around the field. Exclusive social media initiatives will further help make the brand prominent, reaching a large and interested audience.

Yves Pouliquen, Vice President – Commercial, Europe, Apollo Tyres, said, “This partnership is an exciting opportunity to strengthen Vredestein’s presence in one of our key markets. AS Monaco’s rich history and commitment to excellence mirror our focus on performance and innovation. We look forward to building a successful relationship with the club and celebrating its achievements this season.”

Thibaut Chatelard, Marketing and Revenue Director, AS Monaco, said: “We are delighted to welcome Apollo Tyres and its Vredestein brand to the family of AS Monaco partners. This collaboration makes sense in view of the values we share, such as the constant pursuit of performance and excellence. There’s no doubt that this new support will be precious for the rest of our season, which promises to be thrilling.”

Nexen Tire, a leading global tyre manufacturer, has launched the Nexen N´Blue S tyre, adding to its range of summer tyres and providing drivers with advanced safety, energy efficiency and superior driving stability in wet and dry conditions.

Developed using highly dispersed silica and equipped with an optimised structural design, the Nexen N´Blue S tyre provides reduced road noise and improved driving stability. The tyre features an innovative tread compound, formulated with hydrophilic fillers and microstructure-controlled polymers, and provides lower rolling resistance and exceptional dry and wet grip. The tyre also excelled in test results by demonstrating an 11 percent improvement in wet braking distance compared to its predecessor.

Apart from providing excellent performance, the Nexen  N´Blue S also scores high on the sustainability index. The tyre provides an eco-friendly solution for environmentally conscious drivers by minimising fuel consumption and CO2 emissions. The Nexen N´Blue S summer tyre is available in 58 sizes, which makes it compatible with different types of vehicles.

Kumho Tire Vietnam Co., Ltd. is all set to expand its investment project in Binh Duong province of Vietnam, with the phase 3 of expansion commencing in early 2025. This was discussed at a recent meeting between Vo Van Minh, Deputy Secretary of the Provincial Party Committee and Chairman of the Provincial People's Committee (PPC), and Kim Hyun Ho, General Director of Kumho Tire Vietnam Co., Ltd.

The meeting was held on 13 November at the Administrative Centre of Binh Duong province, as per an official statement. Apart from the company’s investment till date and the planned investment for phase 3, the two also discussed about the challenges and obstacles regarding procedures and processes to have more land funds to expand the manufacturing plant, along with taking measures to tackle the obstacles. Kim Hyun Ho also conveyed to the PPC Chairman that Kumho Tire Vietnam Co., Ltd. belongs to South Korea's Kumho Tire Group and is currently ranked 10th in the car tyre manufacturing industry.

The company had invested in a tyre manufacturing plant in My Phuoc 3 Industrial Park in 2007 with a total initial investment of USD 308 million, which was supplemented by another USD 300 million in 2021. This extended the factory scale to six hectares and increased the production capacity to 12.5 million tyres annually. With the expansion in early 2025, the company will raise its total investment to USD 908 million and increase the factory's production capacity to 17 million tyres annually. The expanded capacity is expected to be operational by early 2026.

Yokohama-ATG, a leading manufacturer of all-terrain and off-the-road tyres, has expanded its Galaxy MFS 101 SDS range of forklift tyres with the launch of white, non-marking tyres.

The Galaxy MFS 101 SDS range consists of puncture-proof SDS tyres with extended wear limits designed for high-intensity working shifts and long durability. These are premium, solid rubber tyres developed for tough demands, a long service life and high driving comfort. The addition of white, non-marking tyres is specifically aimed at clean working environments.

Marked by a 3-stage construction process, the forklift tyres feature reduced heat build-up, effective shock absorption and minimised vibrations. The pattern design guarantees a smooth ride and good steerability thanks to its continuous centre lug and circumferential grooves. Furthermore, the flat walls and wide flat profile offer excellent stability when using a forklift for vertical stacking. The tyres are also equipped with anti-slip steel beads for improved rim fitment

In a case study on a CAT 2.5-tonne forklift that was used for handling heavy pallets on asphalt, the Galaxy MFS 101 SDS outshone the competitors with impressive performance. The tyre delivered an approximate 900 working hours before replacement against competitors’ 500 working hours.