Harm Voortman, Chief Executive of VMI Group, explains how his company is mobilising its resources to cut energy use and reduce emissions, together with other forms of pollution in its strategic drive to make the business more sustainable and environmentally responsible. Having just been awarded the prestigious EcoVadis Gold Award in recognition of the progress made already, VMI is determined to keep enhancing its own performance while helping customers worldwide achieve better sustainability.

A STRATEGIC INDUSTRY

Tyres are essential for the modern economy. That’s a simple fact of life because much of the global economy depends on motor vehicles, and all those vehicles run on tyres. Two billion tyres are made every year across the world, and a high proportion of these are built on tyre building machines designed, built and supplied by VMI.

There is, however, another side to this story of economic and manufacturing efficiency. Those two billion new tyres every year also translate into something like six million tonnes of microplastics. These highly polluting particles end up in the environment – much of it in the oceans of the world. This means that one of the essential drivers for the global economy is also a major contributor to pollution and environmental damage.

The big question for all of us is how can we maintain the benefits of the tyre industry while also finding ways to reduce the harms it causes. In other words, how can we make it transformationally more sustainable?

OUR GREATEST CHALLENGE?

Sustainability is “not just a nice to have” it is an essential and non-negotiable requirement for every manufacturer and operator of automotive products.

Motor vehicles still largely use fossil fuels and require roads that must be built across the countryside, then constantly maintained and upgraded. Inevitably, this causes environmental damage.

Tyres are made from increasingly complex blends of materials, which are used to make the novel compounds required to meet the changing demands of the automotive industry. This requires a huge amount of energy and a continuous stream of raw materials.  

The move to electric vehicles (EVs), a key factor in making the industry more sustainable by reducing reliance on fossil fuels, also has one major disadvantage. EVs are often heavier than the conventional vehicles they replace. That leads to greater wear and tear on the road surface, generating a higher level of particulates that are harmful to the environment and to human health.

The need to make the entire industry less environmentally damaging, more efficient and sustainable is a challenge that every participant – car and truck manufacturers, energy companies and, above all, tyre builders – have no choice but to face. Here, as in so many other ways, VMI is leading the way.

COMMITMENT TO INNOVATION

VMI has become a strong and respected global player because it is an innovator. Many of the concepts that have transformed the tyre industry were developed by VMI, including ‘hands off, eyes off’ automation, advanced visions systems and now the use of AI to help eliminate errors and optimise production.

Yet perhaps the most important application for innovation today is in sustainability. Fresh ideas in this field lead to better environmental performance, assured regulatory compliance and to better commercial results as well. VMI believes that doing the right thing for the planet can also lead to the best outcome for shareholders.

The drive for enhanced sustainability has become a major focus for all VMI’s employees: one of its most striking features is how it involves everyone, at all levels and in all disciplines. This has become a personal goal, with every member of the wider VMI team committed to looking for new and better ways to reduce the environmental impact of their work.

At all times, the aim is to look for new methods that can deliver a real win-win to manufacturers and customers.

There is a continuing search for ways to use less energy in production, reduce waste and scrap, while eliminating errors – thereby cutting down on the amount of materials used. Reducing emissions and pollution also leads to business benefit, because less energy used means lower costs. Less scrap and waste leads to improved efficiency and, once again, cuts costs significantly.

Tyre manufacturers understand better than ever that commitment to sustainability is not just responsible, not just essential for regulatory compliance and being a good corporate citizen: it also ends up being good for shareholders through higher profits and better brand reputation.

KEY FOCUS AREAS FOR SUSTAINABILITY IMPROVEMENT

VMI’s policy focuses on four main areas of activity:

• Energy and emissions
• Efficient use of materials
• Eliminating errors and waste
• Whole lifecycle management

This strategic approach has delivered measurable benefits to VMI and also helps customers to improve their own performance. The positive impact on environmental performance is also now a matter of public record.

So how can other manufacturers learn from the approach taken by VMI? Let’s look at this in more detail.

ENERGY AND EMISSIONS

Improved energy efficiency does not usually make progress through a few big breakthroughs: instead, it’s the sum total of small improvements made to every stage of every process, and that involves the work of every employee in every department. From the design stage on, energy efficiency is a key factor in new concepts, but, at the same time, each team of engineers is accountable (and rewarded) for identifying ways in which their objectives can be reached more efficiently by using less energy.

This process starts very early. VMI sponsors educational programmes designed to build energy consciousness into future engineers from very early on and each team is empowered to scrutinise their processes critically to develop better methods. Above all, VMI and other responsible manufacturers use the regulatory system not as a painful duty to be obeyed but as a useful incentive for better performance.

Just as every employee has to be engaged in the drive for sustainability, VMI has taken the view that every supplier and partner also needs to be actively mobilised to enhance every aspect of sustainability performance. VMI’s vision is closely aligned with the EU’s adoption of the GHG Protocol’s Scope 1, 2 and 3 frameworks, which require manufacturers to account for their entire value chain emissions, not just those under their direct control.

Scope 1 covers direct emissions, Scope 2 includes indirect emissions from purchased energy and Scope 3 encompasses all other upstream and downstream indirect emissions, obliging manufacturers to take responsibility for the environmental impact of their entire value chain while driving sustainability across their supply chains.

By working actively with suppliers on every aspect of joint working, it is possible to enhance everything from component design, fabrication methods, transportation efficiency and even packaging to ensure progressive and measurable improvements. By making this not simply a ‘box ticking’ exercise but a mission that engages every participant, extraordinary improvements have been – and will continue to be – delivered.

EFFICIENT USE OF MATERIALS

One of the most important aspects of tyre design is the growing use of advanced new materials designed to reduce weight without any loss of tensile strength or safety performance, cut down on rolling resistance, reduce particulate emission and enable higher efficiency in operation. The rise of EV use is a key factor in driving this kind of research as EVs are often heavier, have different driving characteristics and are moving towards a self-driving future.

Every tyre manufacturer is now committing considerable resources into developing materials with precisely calibrated operating characteristics. They also need to deliver specialised tyres in smaller batches then before without waste, on time and efficiently enough to make a profit even from very short production runs.

VMI focuses on developing and testing new compounds in the lab without the need to rely only on trial and error. Lab testing is not a new technique – the VMI LAT100 tyre tread compound tester was first developed some decades ago – but use of advanced simulation software now means lab testing can be embedded within the tyre design and development process as never before. New compounds can be made, tested, evaluated, fine-tuned and tested all over again within (using a term borrowed from the software industry) a ‘DevOps’ approach to manufacture.

In this concept, there is no firm line between disciplines (design, build, test, core engineering…) because the entire end-to-end process is treated as an integrated whole. The tyre industry knows that new and higher performing, more sustainable compounds are a core requirement for staying competitive into the future. VMI’s integrated, lab-focused approach can fast-track new concepts and, used with new developments in continuous mixing and extrusion, this is a practical way to accelerate development without significant environmental impact.

ELIMINATING ERRORS AND WASTE

Tyre building, even with automated production systems, requires a complex blend of processes. In practice, it is as if a series of ‘just in time’ activities co-exist within a single factory with different machines, often supplied by different manufacturers, fabricating components, many of which are then moved to where the next process takes place.

There is huge scope for wastage in the average tyre factory as materials are loaded, unloaded, moved by truck or automated vehicle, put into storage until needed, then reloaded onto another machine, processed, stored again…

Innovators across the industry understand that the sheer complexity of this approach limits both the energy savings and emissions reduction that can be achieved – for the moment. Yet new technologies are being used today to make significant progress possible. Again, VMI has been a major innovator in this field as well.

OPEN SIDE BAR

There are many ways in which taking an integrated view of tyre building processes can bring greater efficiency with better sustainability performance to the whole process. VMI has taken aspects of its UNIXX single cell technology to deliver standalone solutions that can be used with a conventional TBM to streamline conventional methods, leading to greater efficiency, reduced footprint, drastically lower energy use and better sustainability performance.

The UNIXX Beltmaker, for example, cuts out the need for a separate calendering line with the massive energy use and huge space required. By using UNIXX Beltmaker, and considering use of continuous extrusion Strip Winding, it is possible not just to eliminate process stages but accelerate production and build smaller batches without damaging profitability. All this can be achieved with lower energy use, reduced emissions and much lower wastage.

CLOSE SIDE BAR

VMI introduced vision systems to measure the placement of materials as they enter a MAXX automated Tyre Building Machine (TBM). Now these increasingly advanced vision systems are being matched with emerging AI to improve other aspects of performance. This enables automated placing, use of pattern recognition and machine learning (ML) to deliver accurate cuts and AI algorithms to ensure higher efficiency in materials usage, leading to a major reduction in all aspects of wastage due to errors.

VMI, like other businesses in the wider industry, is investing heavily in specialised software development and management, with AI now forming a major part of its solutions.

Beyond the hype caused by GenAI, we can see that the combination of sensors, pattern recognition, ML and data analytics is a proven AI combination that delivers higher sustainability through reduced waste, scrap, rework and energy investment. The intelligence of each system is now greater than ever and the sustainability benefits are increasing in step.

WHOLE LIFECYCLE MANAGEMENT

VMI moved from building standalone machines some years ago and now specialises in Production Platforms, which are designed to be updated regularly over an extended lifecycle. VMI tyre building machines are designed to operate at maximum efficiency over a very long lifecycle (between 10 and 20 years is normal), and the Platform approach adds value by making it easier to keep machines operating at best practice level. They are designed to make it easy for higher performance components, assemblies and upgrades to be retrofitted over the lifetime of the product.

The goal now is to make sure that the TBM at the heart of any production facility lasts for longer, continues to meet sustainability goals, remains highly efficient and is always at best practice level. Yet, that is not the whole story. VMI is also aware that end-of-life is part of the process as well and that all systems must be designed for safe recycling (including extended life for specific components) and environmentally responsible disposal.

End-of-life management has to be designed into a product from the very start. This is now a basic requirement for all VMI machines.

WHAT ABOUT THE FUTURE?

The tyre industry is essential for almost all aspects of economic life. The world economy runs on the road, and every vehicle runs on tyres. This simple truth means that every method we can find to improve performance in terms of efficiency and sustainability is a benefit to the world.

This is why the VMI approach matters. It was VMI that enabled the whole industry, not just the ‘Tier Ones’, to use the most advanced, automated systems in their daily activities. Others have followed – yet VMI’s pioneering work in creating and making available automated production systems, even to relatively small companies, has been transformational.

Today, MAXX for passenger tyres and MILEXX for trucks are in use worldwide and have made it possible for companies originating in China and India, for example, to challenge the biggest companies in the world, while many other countries have become major production hubs for the industry. VMI has had a permanent presence in China for almost 30 years and has important centres in India, Brazil, Thailand, US, Poland, Germany, Malaysia and, from the end of this year, in Mexico as well.

There is a clear roadmap to the future for the industry wherein we will see an increasing use of specialised software, including AI, to reduce human touch points still further, cut out errors and optimise quality. Further use of automation will reduce the need to move materials by hand and further cut wastage through optimised handling. We are already using hybrid systems, with UNIXX Beltmaker and Strip Winder, combined with MAXX TBMs to enable profitable, quality-assured building of small tyre batches.

The next step will be the use of single cell machines, in which ‘batches of one’ are the norm, with every stage of production taking place as part of the same process, cutting waste as close to zero as possible while driving down energy use and emissions still further.

The tyre industry remains at the heart of the world economy, but its very importance makes it essential for all of us who are shaping the future of this business to keep sustainability front and centre of our minds. VMI is proud of the way we combine innovation and care to deliver outstanding results for our customers, but there is still a lot of work to do, and we are already focused on the next steps.

Now and into the future: Sustainability is at the heart of our strategy.

Apollo Tyres Ltd is broadening its cycling portfolio with a new all-season, high-performance option: the Vredestein Superpasso Pro 4S. Engineered for competitive cyclists, this tyre is designed to provide reliable speed and handling throughout the year, regardless of weather or road conditions. It will be available across Europe from 1 March 2026 in four different width sizes to accommodate various road bikes.

Developed at the company's European Global R&D Centre, the tyre builds upon the existing Superpasso Pro platform. It aims to merge the low rolling resistance and responsiveness of a summer performance tyre with the enhanced grip, durability and puncture resistance necessary for consistent year-round use. A key innovation is the proprietary ‘TriComp’ technology, which utilises multiple rubber compounds. A harder, reinforced centre section promotes efficiency and longevity, while softer shoulder compounds deliver superior traction and stability when cornering, even on wet or uneven surfaces.

Further contributing to its all-season capability is an optimised tread pattern. This design efficiently channels water away and maximizses the tyre's contact patch with the road, ensuring predictable handling. Underneath this tread, a 120 TPI casing and a reinforced breaker layer work in tandem to bolster puncture protection and overall resilience. Additionally, the model incorporates ‘Active Control Technology’, featuring a unique bridged centre structure. This construction method reduces overall weight and enhances the direct feedback transmitted to the rider, resulting in a more agile and connected riding experience.

Nic Knippers, Divisional Head – Vredestein Two Wheel Tyres, Apollo Tyres Ltd, said, “Following the success of the new-generation Superpasso Pro, we saw a clear opportunity to create an all-season variant that would allow competitive and enthusiast riders stay on the bike longer, regardless of the weather. The Superpasso Pro 4S achieves exactly that, faithfully transmitting rider power and steering inputs to all surfaces, year-round.”

Polymer Alumni Welfare Association (PAWA), in association with Indian Rubber Institute (IRI) and Dr D Banerjee Centre of Excellence (DBCOE), Mysuru and with the support of Department of Polymer Technology at Karnataka (Govt) Polytechnic, Mangaluru, is jointly conducting the third edition of DPT-Con 2026, a national-level conference scheduled to be held on 23rd & 24th January 2026 at KPT College campus, Mangaluru.

Carrying the theme “Sustainable Polymer for a Smarter Future,” DPT-Con 2026 aims to bring together industry professionals, alumni, academicians, and students on a common platform to advance learning and collaboration for infrastructure development in polymer science and technology.

“Karnataka (Govt.) Polytechnic, a 78-year-old institution approved by AICTE, as India’s first Autonomous status Polytechnic, has been home to the Department of Polymer Technology since 1975. Over the past five decades, the department has produced more than 1,000 polymer technologists who today serve across the Tyre, Rubber, Plastics, TPE and composite industries in India and abroad. Many of these alumni now hold senior technical and leadership roles, forming a strong industry–academia bridge,” says S Vasudev Rao, convener, DPT-Con 2026. 

PAWA, established in 2017 by senior alumni of the department, has played a pivotal role in strengthening this ecosystem. The association focuses on enhancing student competencies through industry engagement, infrastructure upgrades and knowledge-sharing initiatives. Earlier editions of DPT Con, held in 2018 and 2023, directly contributed to the upgradation of the rubber processing laboratory and the establishment of a modern plastic processing laboratory at the institute.

Building on this legacy, DPT-Con 2026 has set ambitious objectives. The conference seeks to fundraising to establish a cutting-edge incubation centre for composites, to provide scholarships to meritorious & deserving students, and support the maintenance and modernisation of existing rubber, plastic, TPE and composite laboratories. Enhanced student exposure through advanced equipment and real-time industrial interaction is a key focus area, alongside fostering long-term collaboration between industry, alumni and academia. The two-day programme will feature technical paper presentations, expert lectures, networking sessions and cultural programmes. A structured sponsorship framework—ranging from main and platinum sponsors to gold, kit and lunch sponsors—has been designed to encourage active industry participation, with opportunities for technical presentations and brand visibility during the event.

Organisers have set a fund-raising target of INR 2 million to support the planned initiatives and have invited industry leaders, alumni and well-wishers to contribute through sponsorships, kind support or direct participation. According to the organising committee, contributions to DPT-Con 2026 will have a direct and lasting impact on student skill development and the creation of infrastructure aligned with contemporary industry standards.

"With sustainability, innovation and collaboration at its core, DPT-Con 2026 is positioned not merely as a conference, but as a collective effort to shape the next generation of polymer technologists and strengthen India’s polymer ecosystem for the future," adds S Vasudev Rao. 

In addition to Polymer Alumni dedicated team Indian Rubber Institute- DBCOE team joined hands to fulfill this noble cause.

Pirelli’s 2025 was defined by exceptional innovation and acclaim across its product lines and pioneering technologies, earning numerous independent awards and test victories. The company’s flagship families – P Zero, Cinturato and Scorpion – collectively secured 27 podium finishes in 34 comparative evaluations, with 15 of those positions being first place. New global market launches were particularly successful; both the fifth-generation P Zero and the new Cinturato summer tyre each claimed two major victories. The P Zero was celebrated as the top ultra-high performance summer tyre by industry experts, while the Cinturato demonstrated an outstanding blend of safety and efficiency. Winter performance was also highlighted by the P Zero Winter 2, which won its category in rigorous testing by a leading Swedish automotive magazine.

Specialised technologies integrated into these tyres further enhanced their appeal, offering motorists tangible benefits such as increased puncture resistance and reduced cabin noise. Meanwhile, the all-season segment saw remarkable dominance from Pirelli, especially in the European market. The Cinturato All Season SF3 proved extraordinarily versatile, earning 11 test victories and widespread praise for its balanced safety profile across diverse conditions. Its SUV-oriented counterpart, the Scorpion All Season SF3, quickly replicated this success following its launch. This collective achievement led Pirelli to be crowned the All Season Champion and Top Manufacturer of All Season Tyres by prestigious German institutions.

Complementing these product triumphs, Pirelli’s Cyber Tyre technology received significant international recognition, underscoring its role in advancing connected mobility. This integrated system uses in-tyre sensors and proprietary algorithms to communicate vital data with vehicle electronics in real time, enhancing safety and performance. Over the year, it was honoured four times across different continents, including a top innovation award in the United States, a safety prize in France, a pan-European safety accolade and a Company of the Year title from a noted market analysis firm. These awards collectively affirm how Pirelli’s digital advancements are fundamentally transforming traditional automotive components, positioning the company at the forefront of the industry’s connected future.

For over a decade, Continental has served as the exclusive tyre supplier to Cemex in the UK, providing comprehensive solutions for the building materials leader's entire fleet. This partnership, initiated in 2011, began when Cemex selected retreaded tyres from Continental’s Bandvulc brand and became an early adopter of the ContiConnect digital monitoring system. Cemex, founded in 1906 and a major supplier of concrete, asphalt and aggregates, operates an extensive UK network of quarries and plants serviced by a large fleet of cement vehicles, dump trucks, trailers and ships.

The demanding environments at Cemex sites, featuring sharp rocks and uneven terrain, previously made tyre-related vehicle breakdowns a significant operational hurdle. By equipping the fleet with Continental’s premium new and retreaded tyres, the company has substantially enhanced vehicle safety, reduced downtime and improved overall fleet efficiency. According to Carl Milton, Cement Logistics Manager – UK at Cemex, this open-book relationship has yielded continuous benefits, from lowering driving costs to increasing vehicle durability and performance.

A cornerstone of this collaboration is the ContiConnect tyre pressure monitoring system. Sensors in the tyres provide real-time data on inflation and temperature, transmitting this information to cab displays and a web-based platform for fleet management. Nigel Ponton, UK Fleet Engineering Manager at Cemex, notes that the system does more than monitor deflation; it analyses heat transfer to predict imminent brake or wheel bearing failures, enabling proactive maintenance. Email alerts from the platform allow both the transport team and tyre providers to address issues in advance, supported by additional checks from Yard Reader stations at Cemex plants.

The partnership has deepened through joint innovation and testing. Milton highlights that the two companies have worked closely to optimise tyre designs for Cemex’s unique operational environments, achieving the best possible fuel economy. Cemex is frequently invited to trial new tyre models, providing feedback that directly contributes to the refinement and development of Continental’s product range. Pina Wallace of Continental concludes that this cooperative relationship is a perfect example of mutual success, where tailored solutions meet specific customer demands while invaluable feedback enhances product offerings. This synergy underscores Continental’s customer-centric approach and the tangible, shared value born from a deeply collaborative alliance.