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.

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Tyres Europe and the Association of Synthetic Amorphous Silica Producers (ASASP) have released a joint position paper on synthetic amorphous silica (SAS) in tyre manufacturing. The document highlights SAS as a critical component that improves wet grip, reduces rolling resistance and supports durability, thereby enhancing vehicle safety, fuel efficiency, electric vehicle range and lowering use-phase emissions.

A proposed harmonised classification for SAS is under consideration. Though not an outright ban, the industry warns it would likely compel manufacturers to phase out SAS during design rather than manage exposure, effectively bypassing practical risk controls.

Tyres Europe and ASASP urge regulators to base any action on robust evaluation of SAS properties, exposure conditions, established industrial uses and broader socio-economic impacts on European value chains. Policy measures must reflect these factors to avoid unintended disruptions.

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Tegeta Green Planet participated in the recent Social Design Days conference, a three-day event hosted by the Design Institute that centred on circular design and sustainable innovation. The gathering brought together diverse professionals to explore the intersection of creative disciplines and environmental responsibility.

During the proceedings, Tegeta Green Planet Director Shalva Akhvlediani engaged in a panel discussion that examined Georgia’s trajectory in building a circular economy. The conversation addressed the nation’s current obstacles and prospective avenues for growth, with a particular focus on systemic shifts in resource management and regulatory frameworks.

Akhvlediani pointed to measurable advancements in Georgia’s waste management infrastructure, the adoption of Extended Producer Responsibility standards and a growing national recycling ethos. These developments, he observed, are creating a robust base for more judicious resource utilisation and fostering habits of conscientious consumption. The panel further acknowledged that resourcefulness is deeply rooted in Georgian heritage, where mending, reusing and bequeathing goods were traditional practices, though modern consumerism has eroded these customs, necessitating a blend of age-old wisdom with contemporary circular strategies.

A critical takeaway from the discussion was the assertion that technological fixes and legislation alone are insufficient. Genuine progress, Akhvlediani argued, hinges on synergistic cooperation between designers, architects, researchers and creatives to engineer products and systems that prioritise longevity and recyclability from inception. Social Design Days proved instrumental in facilitating cross-sectoral dialogue, promoting circular principles and inspiring actionable solutions for national sustainability. Tegeta Green Planet reaffirmed its dedication to advancing these environmental objectives and supporting collaborative platforms that drive meaningful change.

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Continental is set to construct its first company-owned wind farm adjacent to its tyre production facility in Korbach, within the municipality of Twistetal, Hesse. The initiative will supply electricity directly to the plant, situated roughly eight kilometres away, thereby diversifying the manufacturer's energy portfolio. This strategic move aims to accelerate renewable power adoption, enhance cost competitiveness and diminish reliance on volatile energy markets.

The project features three turbines that, alongside existing solar systems, are projected to satisfy approximately two-thirds of the Korbach plant's electricity requirements. With an annual generating capacity of around 55 gigawatt-hours, the turbines could supply roughly 15,000 average households. Continental has allocated a mid-double-digit million-euro investment, having secured all necessary permits. Groundbreaking is anticipated in 2026, with commissioning expected about 18 months later.

Tyre production consumes significant power for operations like mixing raw rubber and extruding components. The Twistetal wind farm will enable the Korbach plant to meet a larger proportion of demand with locally sourced renewable energy fed directly into manufacturing. This addition complements existing infrastructure while maintaining reliable operations during fluctuating wind or solar conditions. The Korbach facility, employing approximately 2,400 people, produces tyres for passenger cars, motorcycles, bicycles and industrial uses.

Photovoltaic systems at Continental’s Korbach tyre plant.

The selected Nordex N175/6.X turbines have a hub height of 179 metres and a rotor diameter of 175 metres, reaching a total height of 267 metres, making them among the most powerful onshore turbines available.

The Korbach project represents a key step in Continental's broader strategy to expand proprietary energy generation, with similar initiatives considered globally. The goal is a flexible, economically viable energy supply while increasing renewable power proportion, ideally produced near each manufacturing site.

Continental is evaluating feasibility at worldwide plants, considering local conditions, regulations, storage, integration with existing sources and financial viability. Since 2020, the firm has covered global purchased electricity demand with renewables and reduced tyre production greenhouse gas emissions by approximately 180,000 metric tonnes over four years. By early 2026, coal and heavy fuel oil were eliminated at all production sites, replaced by electricity from renewables, biomass, biogas, LPG and natural gas for steam and heating.

Dr Bernhard Trilken, Head of Manufacturing & Logistics in Continental’s Tires group sector, said, “Having our own wind turbines near the plant will give us more predictable energy costs and reduce our exposure to volatile energy markets – key factors for competitive tyre production in Germany. This is fully aligned with our global strategy to expand our own renewable energy generation and will serve as a blueprint for other sites worldwide.”

Klaus Ohlwein, head of the Continental tyre plant in Korbach, said, “The wind farm will bring major benefits to our location. It will help us cover a significant share of our electricity needs in Korbach with our own renewable sources at competitive and more predictable costs. The electricity generated will be used directly in tyre production, including in mixers and extruders. The project is an important step in our sustainability activities at the site and demonstrates how industrial competitiveness and sustainable energy use can be effectively combined in Germany.”

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Pirelli is set to play a central role as the FIM Superbike World Championship concludes the first half of its season this weekend at Donington Park for the UK Round. Marking the final event before the summer break, the Italian tyre manufacturer has equipped competitors with the softest rear compounds from its 2026 standard range. This selection represents a clear advancement in development from the previous year, when riders were limited exclusively to older specification tyres.

For the premier WorldSBK class, the rear tyre allocation is headlined by the SCQ extrasoft compound, intended primarily for qualifying and the Superpole Race. This option, the softest in Pirelli’s portfolio, has already garnered positive feedback from riders during the Emilia-Romagna Round for its exceptional single-lap pace and consistent performance over a sprint distance. Complementing the SCQ are the SCX supersoft and SC0 soft compounds, while front tyre duties are covered by the standard SC1 soft and SC2 medium solutions, with the softer front being the overwhelming preference of last year’s grid, including triple race winner Toprak Razgatlıoğlu.

The notoriously unpredictable British weather remains a critical variable, with cool morning temperatures and frequent rain showers posing significant challenges for teams. Pirelli’s range has historically demonstrated considerable adaptability across fluctuating track and air temperatures, maintaining reliable grip in both cooler and warmer conditions. To address potential precipitation, the allocation is supplemented by DIABLO Wet intermediate and full DIABLO Rain tyres for both front and rear positions, ensuring competitors have viable options regardless of the elements.

In the supporting categories, WorldSSP riders will retain the SCX and SC0 rear compounds alongside the SC1 and SC2 front options. Meanwhile, the WorldWCR field and the emerging talents of the Yamaha R3 World Cup will also be in action, with both series utilising the Pirelli DIABLO Superbike SC1 tyre on both axles throughout the weekend’s racing programme.

Giorgio Barbier, Pirelli Motorcycle Racing Director, said, “Donington Park is a very distinctive circuit and, in many respects, a unique venue on the FIM Superbike World Championship calendar. The opening part of the lap features a series of fast, flowing corners taken at high speed and rapid changes of direction that require riders to manage significant power while the bike is still heavily leaned over. This demands tyres capable of delivering outstanding grip, precision and stability while maintaining consistent performance over race distance.

"Compared with last year, when only standard range solutions were available and no development specifications were included, this season, while confirming the same compounds introduced in 2025, we will provide riders with the complete 2026 standard range. The SCQ extrasoft compound will be the softest option in the allocation and can be used not only in free practice and qualifying but also, potentially, in the Superpole Race. For the longer races, riders will be able to rely on the SCX supersoft and, should temperatures be lower, the SC0 soft compound – solutions that have already demonstrated throughout the season an excellent balance between outright performance and consistency, as reflected by the many new records that have been set.

"Finally, the weather, which has historically been unpredictable in the UK, will once again be a key factor. Rain and low temperatures, even in the middle of summer, can have a major influence on tyre management and race strategies. Having a complete and versatile range available will therefore be essential to provide the best possible support in any weather conditions.”

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