The new headquarters of the Group, which has a history of 165 years of steady growth, serves the business units HF TireTech Group and HF ToolTech Group.

The designing of the new office is tuned to the needs of the Group’s forward march. Direct access from the office facilities to the assembly hall and machine testing area brings all fields of work close together and ensures optimised communication. The established and well proven production unit in Belišće, Croatia remains. Continuous investments in logistics, painting, warehousing and machining under highest economic aspects guarantee state of the art manufacturing.

Back on track

The COVID 19 pandemic and the global lockdown that came with it saw HF being tested hard for its resilience and the capability to help its partners put their production process back on track through its engineering and other services.

“For HF, partnership means to support its valued customers with benefits that will help to keep their production back on track,” says HF TireTech Group Managing Director Dr. Joern Seevers.

HF´s benefits & services for the tyre production are many:

• Technical support for restarting the HF Curing Presses

• Inspection and readjustment of mechanical settings

• Inspection of safety-related components

• Performance check and functional analysis of hydraulic/pneumatic systems

• Software check-up and functionality test

• Close coordination and supply of spare parts

• Individual training for technicians and service people for a smooth and efficient production ramp-up; trainings can take place on customers site or in Hamburg at the Group’s testing press. Virtual support is also available

Dr. Seevers said: “Together with our customers we analyse production processes, optimise, adjust to changed situations, look behind the production and develop new strategies to achieve more flexibility, increase quality, reduce costs and raw material - get into action with a higher level in automation and smart retrofitting and be ready for sustainable tyre production.”

Tandem Mixer technology:

HF takes it to the next level

HF Mixing Group is supplying Tandem Mixers for more than 15 years and has kicked off a revolution in mixing since then. The concept appears to be simple, but all those years of experience have shown that the highest degree of machine engineering has to be combined with extensive process know how to make a Tandem Mixer successful. And a mixing line is only successful if the calculated output and productivity is achieved – combined with a reliability which enables stable production for years.

As matter of fact to develop the process to mix on a Tandem Mixer takes some time and efforts – not to forget the technological know-how of the mixing process itself. HF offers the possibility to accompany this development by offering extensive trials and engineering studies – to shorten the time from ordering a machine up to the point of running in full production.

The goal of a Tandem Mixer is to reduce the specific cost of mixing a compound – on many occasions, HF has proven that overall cost reductions of 15% can be achieved compared to standard lines with a single mixer. This, in between other, is achieved by reducing the mixing steps for a PCR compound from 2,5 to 1,5 steps.

But productivity is not the only driving factor to invest in a Tandem Line – the quality of the compound overall and specifically constant and repeatable mixing of modern compounds is to be ensured. To optimise dispersion, distribution, temperature control and process stability makes a significant difference in today’s production of more complex compound recipes. The intermeshing mixers produced by HF and used in a Tandem Line guarantee to meet these requirements more than any other mixers on the market.

Experiences have shown that no compromise on quality can be made – and HF is supporting this approach with delivering a control system for Tandem Lines which enables their customers to not only run the machine efficiently but also uses online condition monitoring to always reflect on a reliable compound quality which is repeatable.

HF emphasises on result driven production concepts for its customers – further innovations in terms of integrating industry 4.0 solutions to the mixing process are on its way and the focus is clear: Intelligent machines will integrate new digital solutions into the mixing process and will ensure to meet the expectations of the future.

Brownfield projects

The COVID pandemic put a stronger focus on replacing existing machines instead of adding new capacities to a production plant. Also, productivity as well as sustainability aspects are driving many tyre companies to have a closer look to the installed base.

But inspecting a mixing line which has run for more than 15 years (or sometimes even 25 years) brings to light what challenges may come up if this line will be replaced by a new one. Output values need to be increased, a new mixer technology should improve the quality of compounds, modern automation solutions should support the daily production procedures and increase process stability – many more requirements should be met. One of the largest challenges is limited space when looking at an upgrade of machinery.

Not only the pure space but also intralogistics within a mixing line can create headache – from upstream equipment feeding a mixer all the way to downstream machinery processing the batch further – many modern solutions can be used today but looking at the available space installing them is the challenge.

With a clear focus on such brownfield projects, HF has managed several conversions from old to new with unmatched success. A key in such projects is the planning and pre-engineering process. Starting with an inspection of not only the mixer but all surrounding factors in the building – considering also the material flow – and then continuing with a 3D- scan of the existing equipment including pipe and cabling routing the basis for planning can be laid. Supported by this 3D-scan HF engineers plan and design with 3D models the complete mixing mill room.

By keeping the existing machinery as the base layer and inserting new equipment in an over-lay collisions of steel constructions, limitations in space and optimised pipe and cable routing can be identified. Furthermore, an improved process flow chart is the basis of planning material flow, work processes and even manpower to operate the new mixing line. Finally, new controls and automation solutions – on the basis of industry 4.0 – will improve operating and monitoring the equipment.

One of the largest benefits using HF’s Pre-Engineering is shortening the planning and execution time – and last but not least the reduction of financial funds is possible by starting up the new line much quicker compared to the conversion of lines in earlier years.

Safety first

Supporting all major tyre manufacturers with mixing technology HF constantly strives for improving operational procedures in the mixing mill room. When it came apparent that the variety of compounds increased more and more – driven by many more types and technologies in tyres today – the changeover times from one recipe to the other was put in the focus of operational optimisation. Not only flexible automation solutions are required but also quick availability of the mechanical equipment after the last batch of the current recipe was dispatched. In between other HF identified the cleaning of the mixing chamber as a critical action during changeover in two aspects: First it needs to be safe for the maintenance personal to enter the mixing chamber and secondly time can be saved if the access to the chamber can be optimized.

In order to meet both requirements HF’s engineers designed a maintenance box, the so-called mBox©, which is mechanically integrated directly underneath the mixer – combining the mixer with the chute of a dump extruder for example.

In the moment the mixing line is switched to cleaning mode and all movements of parts are blocked a moveable platform – the floor of the maintenance box – is inserted horizontally underneath the mixer. A door of the box can be opened, and maintenance personnel can enter the box safe and secure, standing underneath the mixer with easy access to the mixing chamber.

Besides the safe working environment customers from HF have noticed saving time and having the opportunity of even inspecting the mixing chamber easier and more frequent during a changeover.

Especially in new installations of a mixing line the mBox© can be integrated in the design of the line easily and right from the start – benefitting the safety and operation of the line daily.

HF Screw Presses

The production of screw presses is one of HF`s core competences for decades. The screw press has gained recognition during its affiliation with KRUPP. Thus, the presses operate all over the world and more than 2.500 presses are installed in various industries for example the edible oil industry, biomass technology and rendering. And, most interesting for the tyre industry, the presses accomplish benchmarking results in the dewatering of natural and synthetic caoutchouc. As a more efficient and space saving solution instead of band dryer systems or similar the screw press has its strong eligibility in dewatering process.

HF Curemaster

HF brought the first hydraulic column type curing press to the tyre industry in 1997. Since then, it continued to develop this product to meet the demanding requirements of its customers.

The HF Curemaster was launched two years ago and since then the patented truck tyre curing press has been successfully installed in multiple locations and in efficient operation. The press provides a flexible and compact footprint, making it possible to replace older presses with potentially more presses per existing trench.

The HF Curemaster also focuses on optimising energy efficiency to ensure the lowest total cost of ownership in the curing plant. The HF Curemaster´s hood design incorporates insulation inside the hood to provides the best insulation effect. In addition, the HF Curemaster provides an extremely fast cycle time to minimise the overall amount of heat loss during the open and close sequence of the press.

HF PCR Design

Delivering for a new greenfield plant is relatively straightforward. However, HF understands the important need of the replacement market as well. It is important to be flexible to meet all the varying trench layouts (pit, shelf, pitless, and so on). Equally important is the need to be able to replace existing 42” – 45” old mechanical presses with 48” – 52” modern presses in order to meet the growing demand for larger tyre sizes.

All replacement projects are analysed carefully together with customers. Attention is paid closely to all details related to operation, maintenance access, mould & bladder change requirements as well as all local safety regulations. HF´s long experience with curing presses provides a large variety of modular options to be used for finding the optimised fit for each specific request.

HF Stack Passenger Car Inflator (PCI)

The requirement for post cured tyres continues to grow in the market and HF has designed a simple and compact solution that can be incorporated in all HF presses as well as behind most all existing older presses.

The patented HF Stack PCI design allows for the PCI to be integrated into even the tightest footprints. This solution eliminates any movement or rotations of the PCI body itself and greatly reduces the amount of moving mechanical components and maintenance.

HF Digitalisation

HF recognises the important trend of digitalisation for the tyre manufacturers and has developed reliable, customised software solutions for machine data communication between machine control and customer IT systems. The main steps were to focus on MES, SCADA and Recipe Management interfaces.

HF Smart Curing enables customers to get started quickly and effectively with a future-oriented digitisation solution. The main advantage in this case is that software for machine data acquisition is supplied directly by the supplier and not by IT service providers.

OPC server technology and efficient network solutions are tailored to the machine enable secure data acquisition. This software can provide feedback in regard to condition monitoring, diagnostic function, machine services, energy monitoring and remote service.

The benefit of connecting your equipment with digitalised solutions clearly accelerates a target-oriented development and improves the Total Cost of Ownership of the equipment.

Apollo Tyres Ltd has launched the new Apollo Aspire 5 summer tyre designed for performance sedans and SUVs, including electric vehicles. The next-generation model succeeds the Aspire 4G+ and is offered in 24 sizes to fit rims from 17 to 21 inches. Engineered to provide a premium driving experience at a competitive price, the tyre incorporates several key technological advances.

At its core is Apollo’s Dynamic Contour Technology, which utilises an advanced tread design and specialised compound. This includes integrated ‘diamond ridges’ that absorb road shocks to improve comfort and control. Building upon its predecessor, an evolved Synchronised Tread Pitch system effectively reduces vibrations and road noise, with some sizes achieving a top-tier noise rating.

Performance and durability are enhanced through a structure that ensures even pressure distribution during demanding manoeuvres, promoting stable handling and uniform wear. A novel low-hysteresis carbon black compound reduces heat generation and rolling resistance, contributing to both extended tread life and better fuel efficiency, the latter reflected in a favourable rolling resistance rating for select variants. Furthermore, the tyre promises strong all-weather capability, with an excellent wet grip rating available on certain sizes for confident braking.

The Aspire 5’s development was validated through rigorous global testing. The results indicate that its overall refinement and comfort meet or surpass the standards set by leading premium European tyre brands.

Daniele Lorenzetti, Chief Technology Officer, Apollo Tyres Ltd, said, “With the Aspire 5, our R&D teams focused on enhancing refinement and comfort without compromising dynamic performance. Every element of the tyre has been developed to meet the expectations of premium and executive car owners seeking both comfort and control, resulting in a tyre that combines quietness and composure with responsive handling and efficiency.”

Madison, UK’s leading distributor of bicycle parts and accessories, has solidified its relationship with global tyre manufacturer Maxxis through a new exclusive agreement. Effective from the start of 2026, Madison has become the sole distributor of Maxxis bicycle tyres across the United Kingdom and Ireland. This move expands upon a partnership that began in 2017 and signifies a deepened, long-term commitment to growing the brand’s footprint in the region.

The decision to grant exclusivity underscores a mutual belief in the potential for further market development. Maxxis, an established leader in the premium tyre sector, will benefit from Madison’s extensive experience in cultivating cycling brands within the UK market. The distributor plans to implement a cohesive strategy for retail partners, focusing on consistent pricing, coordinated marketing and strengthened in-store support.

To bolster the brand’s visibility, Madison will channel additional investment into targeted marketing campaigns, retail activations and ambassador programmes. These efforts will be supported by the company’s in-house marketing resources, which encompass digital commerce, content production, public relations and social media management. Retailers can also expect tailored support through merchandising solutions and point-of-sale materials designed to enhance consumer engagement.

Operational stability and product availability for retailers of all sizes are set to be prioritised, leveraging Madison’s established logistics network. The existing roster of UK athletes and teams representing Maxxis will continue as a core component of the broader promotional strategy, supported by dedicated content creation.

Dom Langan, CEO, Madison, said, “We are delighted to strengthen our partnership with Maxxis. An exclusive approach allows us to work with clarity and purpose, offering consistent support for retailers and ensuring that Maxxis continues to thrive in the UK and Ireland. By aligning our strategy, resources and long-term ambitions, we are confident that we can drive meaningful, sustainable growth for the brand.”

Webfleet, Bridgestone’s advanced fleet management solution, has partnered with Bia Power and ChargeBroker to form a comprehensive solution for electric vehicle fleet management. This integrated system is designed to work with a company's current setup, avoiding the need for new infrastructure.

The service begins with Webfleet providing operational data to Bia Power, which uses it to create optimal charging schedules. ChargeBroker then brings together various charging networks into one simplified platform. This end-to-end process makes managing large electric vehicle fleets far more efficient by seamlessly connecting vehicle operations with depot energy management.

It specifically solves the challenges of coordinating different vendor systems, offering a faster and more cost-effective path to fleet electrification. The services are now available globally for Webfleet users.

Apollo Tyres has achieved a significant international distinction in workplace safety, with its Chennai and Limda (Gujarat) plants each receiving the prestigious Sword of Honour from the British Safety Council. This accolade represents one of the highest global recognitions for excellence in health and safety management. The honour was formally presented to Chief Quality and Safety Officer Yoichi Sato, alongside Chennai Unit Head C Thomasmathew and Limda Unit Head Piush Bansal.

This award follows both facilities having previously secured top-tier five-star ratings in the British Safety Council’s rigorous Occupational Health and Safety Audit. The Sword of Honour is specifically reserved for organisations that exhibit an outstanding and sustained dedication to upholding the utmost standards in employee health, safety and wellbeing. Notably, the Chennai plant received additional commendation for its achievements in Innovation and Development.

These awards highlight Apollo Tyres' proactive and systematic approach to fostering a pervasive safety-first culture across its operations. The company's efforts extend beyond mere regulatory compliance, reflecting a deep-rooted commitment to cultivating secure, healthy and sustainable working environments for all employees, contractors and stakeholders. By consistently demonstrating world-class safety management and a drive for continuous improvement, this milestone reinforces Apollo Tyres' standing as a responsible industry leader aligned with global best practices.

Yoichi Sato, Chief Quality and Safety Officer, Apollo Tyres Ltd,, said, “Receiving the Sword of Honour for both our plants is a matter of great pride for everyone at Apollo Tyres. This recognition reinforces our belief that operational excellence begins with putting people first. We remain committed to continually strengthening our health and safety practices across all our operations, guided by our ‘Safety First’ philosophy.”

Peter McGettrick, Chairman, British Safety Council, said, “On behalf of the board of trustees and staff of the British Safety Council, I would like to congratulate Apollo Tyres on achieving the highest standards of its health, safety and wellbeing management. Achieving recognition of this sort takes absolute dedication and the utmost professionalism. We are proud to support you in your achievements and delighted we can contribute to your ongoing success.”

Mike Robinson, Chief Executive, British Safety Council, said, “I would like to congratulate Apollo Tyres and its staff on this award, in tribute to their commitment to keeping their workplace safe and healthy and contributing to safeguarding the environment. All of the Sword, Globe and Shield award-winning organisations share a commitment and willingness to achieve the uppermost standards of health and safety. We thank Apollo Tyyres  for contributing to achieving our vision that no one should be injured or made ill through their work.”