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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Continental has signed on as a global partner of the International Biathlon Union (IBU), with the agreement set to run from the 2026/27 season through 2029/30. The deal, negotiated by the IBU’s exclusive global marketing partner Infront, covers the LaVita IBU World Cup, the IBU World Championships and the Loop One Festival.

Biathlon’s close ties to winter make it a fitting fit for the tyre maker, which frames the sport as a natural setting for a partnership rooted in a positive view of the cold season. Athletes contend with shifting snow, weather and course conditions, blending endurance with shooting precision, a combination that mirrors Continental’s emphasis on preparation and confidence.

The tie-up places Continental inside one of EMEA’s strongest winter sports properties. The IBU calendar features 54 LaVita World Cup races and 12 World Championship races, many staged in key European winter markets, with Germany, France and Sweden among the largest EMEA television audiences for the sport. Beyond reach, European biathlon fans show a strong affinity for individual mobility, as 88 percent own at least one car, 80 percent drive at least semi-regularly and 59 percent drive regularly.

For the IBU, the cooperation adds an internationally established mobility brand to a partner platform that accompanies athletes and fans across the season, opening chances to develop fan experiences and market activities around major competitions. The deal extends Continental’s longstanding sports engagement in EMEA, giving it a season-long platform that links biathlon’s emotional pull with winter mobility relevance, on the idea that proper preparation turns winter conditions into possibilities rather than limits.

Alexandra Gaillard, Head of Marketing, Continental, said, “Our partnership with the International Biathlon Union brings together two organisations that share a common belief: challenging and unpredictable conditions do not have to limit what is possible. They can create opportunities for those who are prepared. Whether on the biathlon course or on winter roads, determination and the right equipment make all the difference when conditions change. Together with the IBU, we want to inspire people to rediscover winter and embrace the possibilities it offers, helping them navigate changing conditions safely and confidently.”

Ferdinand Hoyos, Head of Business Area EMEA, Continental, said, “Biathlon is a natural fit for Continental: success in the sport depends on the perfect combination of performance, precision and control in winter conditions, just as it does for our winter tire portfolio. For decades, biathlon has been one of the most popular and successful winter sports on the Olympic stage, and throughout those decades, Continental has remained a trusted leader in winter tyre technology. This shared commitment to excellence, performance and reliability makes for a great partnership and provides a strong platform to engage with fans, customers and retail partners across EMEA.”

Felix Bitterling, Commercial & Marketing Director, IBU, said, “With Continental, we are welcoming a strong and renowned brand to the biathlon family. The company’s commitment to quality, innovation and performance resonates perfectly with the values of our sport and federation. Biathlon provides an excellent platform for global visibility while creating meaningful engagement opportunities with our passionate fan base.”

Marco Sautner, Managing Director, Infront Germany, said, "Continental has seen firsthand the value that winter sports can create for leading brands. Biathlon's passionate fan base, strong presence in key European markets and range of activation opportunities provide an excellent platform to build on that success. It is hugely satisfying to bring together two organisations that stand to benefit from a long-term collaboration."

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Sun Auto Tire & Service has entered a strategic partnership with Interstate Batteries, designating the company as the primary battery provider for the Sun Auto Network. The announcement marks a significant development for one of United States’ largest independent automotive service providers.

Operating over 600 locations across 27 states, the Sun Auto Network encompasses more than 70 local and regional automotive service brands. This partnership represents another step in Sun Auto's ongoing efforts to strengthen operations and enhance customer experience through leading category partners.

Interstate Batteries, a battery specialist with national scale and strong consumer awareness, brings dedicated category expertise, marketing resources and nationwide support to the network. The company's products are now available at Sun Auto locations nationwide, combining Sun Auto's growing service footprint with Interstate's specialised expertise and distribution capabilities to create greater consistency in product availability, promotions and warranty support.

With over 70 years of industry presence, Interstate Batteries is recognised as one of North America's most trusted consumer battery brands. Sun Auto locations will support Interstate's warranty coverage, offering customers convenient access to warranty service across the network. The partnership advances Sun Auto's broader strategy of leveraging national network strength to improve products, resources and support for its local brands.

Tony Puckett, Chief Executive Officer, Sun Auto Network, said, "As we grow the Sun Auto Network, we're continually looking for ways to use our scale to make our local brands stronger and deliver more value to our customers. That means aligning with partners who bring deep expertise in their category and can support us consistently across the country. Interstate Batteries brings a trusted brand, specialised battery expertise and nationwide capabilities that make them a strong fit for our network and the customers we serve."

Lain Hancock, President and Chief Executive Officer, Interstate Batteries, said, "Interstate Batteries is proud to partner with Sun Auto Network and serve one of the nation's largest automotive service networks. Sun Auto's scale, customer-first approach and commitment to excellence make them an ideal partner. This agreement creates an exciting opportunity to support more than 600 locations operating under trusted local brands while ensuring drivers have access to dependable battery solutions wherever they travel."

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Lassa Tyres has launched its new Snoways 5 and Competus Winter 3 winter tyres to address shifting demands across passenger car and SUV markets. Both products carry the company's EV Ready designation, confirming their compatibility with electric, hybrid and conventional vehicles. The Snoways 5 has additionally secured the TÜV Performance Mark, recognising its strength in key winter and wet handling criteria.

Designed for improved control on snowy and wet surfaces with enduring performance, the Snoways 5 surpasses its predecessor in snow, wet and wear results, as verified by independent TÜV testing. It also improves its rolling resistance label by one grade, cutting energy loss for more efficient driving. TÜV SÜD testing found measurable gains over the competitor average in snow acceleration, snow braking, lateral snow grip, aquaplaning, wet braking and lateral wet grip, alongside lower rolling resistance. Notable improvements include roughly 4 percent better aquaplaning and 3 percent gains in both snow acceleration and lateral snow grip.

The Competus Winter 3 brings this winter design to SUVs, tailoring the Snoways 5 pattern and technologies for larger, heavier vehicles. It offers assured braking and controlled handling on snow and wet roads, with next-generation winter technology delivering stronger snow and wet performance plus greater fuel efficiency. Its EV-Ready construction suits electric and hybrid SUVs while keeping drivers confident throughout winter.

Lassa has expanded its winter range in response to growing demand for larger rim sizes. Snoways 5 comes in 46 sizes spanning 15 to 21 inches, while Competus Winter 3 offers 42 sizes from 16 to 21 inches. This brings European passenger car and SUV winter fitment coverage to 84 percent, with 18-inch and larger fitments reaching 75 percent. Both tyres will launch across Lassa markets for the 2026 winter season.

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New research findings from a doctoral dissertation by Dr.-Ing. Sebastian Bogdahn examine how end-of-life tyres can yield high-quality recovered carbon black (rCB) through pyrolysis while delivering substantial environmental benefits. The work, titled ‘Production and Environmental Assessment of High-Quality Carbonaceous Materials from End-of-Life Tyre Pyrolysis’, was presented in condensed form at an AZuR Chemical Recycling Project Group meeting in Dillingen/Saar on 1 October 2026.

The dissertation tackles how end-of-life tyres can be recovered and recycled to maximise their value. Pyrolysis is identified as a complementary technology that helps close recycling gaps in the circular economy and offers an alternative to fossil-based carbon black, a material that plays a crucial role in determining tyre properties.

In the pyrolysis process, rubber granules from processed tyres undergo thermal decomposition without oxygen, producing three main streams: solid rCB, tyre pyrolysis oil and pyrolysis gas. Previous evaluations of such technologies often separated technical and environmental perspectives, relied on secondary data and lacked standardised methodologies, making findings difficult to compare.

Image credit: Dr.-Ing. Sebastian Bogdahn

Bogdahn overcomes these limitations by integrating a technology-specific process model with a detailed life cycle assessment model. This combination enables a scientifically robust environmental evaluation of pyrolysis and its secondary raw materials using reliable primary data. A central component is a process model that mathematically describes material conversion by combining reaction kinetics, reactor behaviour and mass and energy balances.

Starting with laboratory-scale experiments, the model was scaled up and validated using a pilot-scale rotary kiln at the Institute of TH Köln. Comprehensive laboratory analyses of feedstocks and products supported development and validation. Optimal conditions for the investigated system were found at 650 degrees Celsius with a residence time of about one hour, achieving complete material conversion and high-quality recovered carbon black. Product distribution was roughly 40 percent rCB, 37 percent TPO and 23 percent pyrolysis gas by weight.

Image credit: Dr.-Ing. Sebastian Bogdahn

Using validated primary data, Bogdahn conducted a comprehensive environmental assessment and developed a methodological matrix covering relevant standards and guidelines to address inconsistent approaches. In the rotary kiln baseline scenario, one metric tonne of recovered carbon black results in a global warming potential over 100 years of about 918 kilogrammes of carbon dioxide equivalents, compared with the International Carbon Black Association’s global industry average of 3,910 kilogrammes for conventional fossil-based carbon black, a reduction of approximately 77 percent. Even after a quality adjustment for lower carbon content, the reduction remains about 70 percent. The study followed ISO 14067 and underwent independent external critical review under ISO 14071, also covering TPO and sustainable carbon black.

Further improvements remain possible. Emissions mainly stem from electricity consumption and gas combustion, with rCB processing accounting for about 44 percent, pyrolysis gas cleaning and combustion about 36 percent and tyre shredding about 19 percent. Sensitivity analysis confirms that renewable electricity offers substantial additional greenhouse gas reductions, reinforcing that a circular economy achieves genuine sustainability only when powered by renewable energy. Enhancing material quality through demineralisation and activation could enable higher substitution rates for fossil-based carbon black.

Image credit: Dr.-Ing. Sebastian Bogdahn

A central conclusion extends beyond pyrolysis itself. Raw materials, tyre manufacturing, the use phase and recovery pathways form an interconnected system spanning the entire tyre life cycle, closely linked to the carbon black, chemical, steel and energy sectors. Achieving circularity requires collaboration across systems and industries, along with greater methodological harmonisation and stronger integration of industrial value chains. The AZuR network’s work reflects this need, recognising that extended tyre use, repair, regrooving, retreading, mechanical recycling and appropriate chemical recycling must all function as interconnected elements of the value chain.

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