India’s tyre industry is accelerating at an unprecedented pace with a turnover of INR 900 billion and production exceeding 217 million units in FY23. Amid this dynamic growth, JK Tyre has emerged as a front-runner, combining manufacturing excellence with sustainability-focused practices. From advanced automation to energy-efficient operations and innovative product development, the company is re-defining tyre production standards. Its Chennai plant with premium and export-oriented capabilities exemplifies this transformation, positioning it at the forefront of next-generation tyres both domestically and globally.

A turnover of INR 900 billion and a production strength of 217.352 million units was the key figures of India’s tyre industry in FY23, according to statistics by the Automotive Tyre Manufacturers’ Association.

Unequivocally, the third-largest automobile market’s tyre sector is expanding by leaps and bounds. From passenger car to OTR tyres, Indian tyre makers are making a name for themselves not only in the homeland but internationally too.

With individual leaders in every segment of tyres, the industry as a whole is also changing its approach towards the different aspects of the supply chain.

One of the leaders, JK Tyre, is banking on its manufacturing excellence and sustainable methodology for paving the road for the next generation of tyres.

The statement is further reinforced during Tyre Trends’ tour of JK Tyre’s Chennai facility, which is spearheading this transformative movement. Commissioned in 2012 with investments exceeding INR 26 billion, the plant is one of the company’s most advanced facilities and is strategically located near Tamil Nadu’s automotive hub and major ports for exports.

It produces passenger car radial (PCR) and truck and bus radial (TBR) tyres including premium and export-oriented ranges. The plant has received International Sustainability and Carbon Certification Plus (ISCC Plus) certification for using bio-based, renewable and recycled raw materials and has been a consistent award-winner for energy and water efficiency, operating as a zero-liquid discharge facility while sourcing over half its power from renewables.

JK Tyre’s recent INR 14.3 billion expansion plans will increase TBR capacity by 800,000 tyres and PCR capacity by two million tyres annually, enabling JK Tyre to roll out next-generation sustainable products like the UX Royale Green.

“We save around 56 percent of our energy through renewable sources and significantly reduce coal consumption. On sustainability, we have several products that can be commercialised through back-end raw material suppliers, although global adoption is still evolving due to cost and scale feasibility. Every energy efficiency initiative involves upfront investment with payback realised over time. Our company vision emphasises green and sustainable mobility, evident even in the plant environment as our facilities are designed with greenery and environmental considerations in mind,” said Managing Director Anshuman Singhania.

Automation is another defining feature of the plants. Very few people are directly involved in machinery operation as most processes have been automated to minimise or eliminate manual intervention. In tyre building, for example, green tyres move seamlessly via conveyor systems through painting units, curing and finally to inspection, mostly without human handling.

Across facilities, processes are fundamentally auto-controlled. Manpower is primarily assigned to oversight roles such as conducting checks or managing specific material movements that cannot be automated.

Otherwise, each stage is tracked through sensors, cameras and online data capture. The high level of automation is evident throughout operations from AGVs transporting tyres to robotic handling systems.

TECHNOLOGICAL PROWESS

A tyre’s birth involves many stages starting from the raw materials that go into a gigantic mixture. According to the company’s Technical Director V K Misra, a PCR tyre needs 8-10 raw materials, while a TBR tyre needs 16.

Once the raw materials are intricately mixed, the mixer sends it to an extruder machine to shape raw rubber compounds into continuous strips or profiles that form different tyre components.

The third step involves the extruder passing on the strips to an auto booking machine, which automatically measures, stacks and aligns these sheets for easy handling. The following step uses a leaf truck machine that carries and transports the stacked sheets or semi-finished materials to the calender machine.

The calender then coats the rubber sheets and sends them to the steel wire room, where the tyre gets its much-favoured durability. The next steps involve assembly, testing and the final roll out.

Across the entire manufacturing unit, a key metric is traceability ranging from individual components to final rollout and even through the operational life of the tyre – every stage leaves a footprint.

The company primarily uses German and Chinese machinery at its Chennai facility and is exploring the integration of Radio Frequency Identification (RFID) chips in tyres for enhanced traceability, while currently, tyre life is monitored through embedded sensors.

The plant takes around 15 minutes to produce a PCR tyre and 50-55 minutes for a TBR tyre.

“We collaborate closely with equipment suppliers to implement automation, robotics and conveyor systems. Some proprietary solutions are exclusive to our plants, though specific details remain confidential. Many robotics systems were developed in-house, integrating artificial intelligence and machine learning to optimise productivity, quality and minimise wastage,” explained Singhania.

He added, “We benchmark ourselves against global standards across productivity, scrap, energy efficiency and water conservation. In water management, we are global leaders. For instance, innovations implemented at our first plant in Kanpur have set industry standards for water conservation.”

Furthermore, the company’s in-house research indicates that nearly 70 percent of low-inflation tyres, especially on highways and city roads, contribute to accidents or injuries. To mitigate this risk, it is deploying tyre pressure monitoring systems and advanced sensor technologies that alert consumers via smartphones.

Efforts are also underway to integrate these alerts directly into OEM dashboards across trucks, buses, passenger cars, two- wheelers and three-wheelers and even farm or off-the-road (OTR) applications.

“The next generation of tyres will incorporate embedded sensors directly within the tyre, eliminating the need for external kits. This approach not only improves consumer safety but also generates valuable research and development insights in a large and diverse market like India. Adoption has been particularly strong among younger consumers,” contended a confident Singhania.

SUSTAINABILITY

JK Tyre developed the UX Royale Green with 80 percent sustainable, recycled and renewable materials. The tyre was produced at its Chennai facility. The development of this line was a result of over a decade of research at JK Tyre’s Global Tech Centre.

The tyre incorporates bio-attributed polymers, recycled rubber powder, recovered carbon black, renewable oils, sustainable steel wire and recycled polyester. Despite its sustainable composition, the UX Royale Green delivers performance comparable to standard tyres and has a lower carbon footprint.

Moreover, the ISCC Plus certificate serves as a testament towards the company’s relentless efforts towards sustainability. “When we talk about sustainability, it encompasses the circular economy by using recycled materials where feasible, incorporating natural raw materials and minimising fossil-based chemicals. For example, recycled polyester, steel and natural rubber may be used without compromising performance,” averred Singhania.

He added, “We are committed to sustainability and green practices. While investments are necessary, balancing productivity, quality and cost control ensures profitability in cost-sensitive markets like India. Measures such as process optimisation, quality control and energy efficiency help us reconcile green mandates with financial goals.”

Commenting on the same lines, Misra stated, “Extensive testing ensures that recycled or sustainable materials do not reduce tyre performance metrics and mileage, ride comfort and handling remain consistent. The use of recycled rubber from cured tyres is minimal and does not impact the product beyond a small percentage. End-of-life tyre recycling is a separate initiative and does not feed directly into new tyre production at significant levels.”

MARKET OUTLOOK

Singhania affirmed that the company is anticipating 8–9 percent growth in the tyre industry this year. While commercial vehicle tyre demand remains subdued, passenger vehicles are stable and two-wheelers are expected to perform well post-monsoon.

“This growth is supported not only by GST sentiment but also by overall economic activity, government infrastructure pushes and strong rural demand. We are targeting white spaces in India, especially in towns with populations under 100,000, where demand for tyres is rising and our presence is limited,” noted Singhania.

The tyre maker is also confident of a significant growth opportunity in the off-road segment with GST reducing the rate to five percent for farm tyres. “We have re-positioned our product line and introduced a premium offering with enhanced performance. Activities were initiated well before the season began and our OEM footprint has already shown positive signs. With improving monsoon conditions, rising rural demand and GST benefits, the outlook for this segment looks very bright,” explained Chief Financial Officer Sanjeev Aggarwal.

He added, “The commercial vehicle industry, where we are primarily present, stands to benefit the most from GST. Increased consumption of goods and white goods will raise total freight availability. Alongside reduced interest rates, capacity utilisation in CVs is expected to increase, further supporting demand for new tyres.”

Radialisation in the TBR segment has reached around 68–70 percent of the market. JK Tyre continues to lead this segment, supplying directly to 85–90 percent of fleet operators and maintaining a strong market presence.

Innovative products such as the XF tyre provide fuel-saving benefits, a critical factor for transporters focused on cost per kilometre. These tyres are supplied entirely to OEMs while also being available in the replacement market.

The company serves approximately 1,800 fleets directly or through dealer networks. Its tiered fleet management programmes include a per-kilometre model, where transporters pay only for the distance covered with tyre performance guaranteed for that usage. This hands-off, mobility-based solution is unique in the industry, creating a clear differentiation from competitors, including international players.

Moreover, the company has strategically diversified its exports across multiple international markets to mitigate risk. Its key export products include TBR tyres, covering heavy trucks from SDM to HD, passenger vehicle radial tyres, truck bias and radial tyres, light commercial vehicle tyres in both radial and bias formats, farm tyres in limited quantities, industrial tyres and tyres for two-wheeler and three-wheelers.

Truck bias tyres are primarily exported to Brazil, parts of Latin America and select African countries, while PCR tyres are directed mainly to the European Union and the UK, particularly for heavy trucks.

OUTPACING HURDLES

About half of the company’s rubber requirements are met through imports. However, it doesn’t see tyre imports currently a threat to domestic manufacturing, and the market remains balanced.

Imports, particularly from China and Southeast Asia, including Vietnam, are carefully managed through a license-based restricted system. For very small tyre sizes, limited imports, typically around 100 units annually for applications such as passenger cars, are allowed in close coordination with government authorities and ATMA, ensuring domestic production is not adversely impacted. Broader policy continues to encourage capacity creation within India to meet local demand, noted Singhania.

On the exports front, approximately 12–15 percent of JK Tyre’s total revenue comes from international markets, with around three percent previously destined for the US. Some of this volume has been redirected to other countries with key markets including Southeast Asia and the Middle East.

Europe is identified as a growth opportunity with significant product launches planned for the start of the next financial year. Latin America and Brazil are also showing promising demand following previous disruptions. Overall, the company anticipates mid-to-high single-digit growth in exports.

Another major industry challenge is sourcing skilled talent. Commenting on this, Singhania mentioned that JK Tyre addresses this through comprehensive internal training programmes, upskilling initiatives and structured human resource interventions ensuring a consistent pipeline of capable personnel.

The Chennai plant contributes approximately 26 percent of the company’s total revenue and plays a critical role in its portfolio. Continuous upgrades and investment in advanced equipment is on the books to allow the plant to continue producing high-quality TBR and PCR) tyres.

JK Tyre’s approach underscores the convergence of technology, sustainability and market foresight. By integrating automation, embedded sensor technologies and energy-efficient processes, the company ensures quality, safety and environmental responsibility.

Its diversified product portfolio, ranging from passenger car radials to truck and bus tyres, coupled with a robust aftermarket and export strategy, strengthens its competitive edge.

Strategic investments in talent, research and development and sustainable materials position JK Tyre to meet evolving industry demands while addressing global challenges.

As domestic growth aligns with international opportunities, the company is set to become a pioneer in an innovation-driven future.

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Nexen Tire America recognises that with energy and fuel costs continuing to challenge drivers, many are seeking ways to maximise efficiency beyond simply altering their driving routines. While adjusting habits like reducing speed is common, the company points to several overlooked factors that can significantly affect a vehicle’s energy consumption and overall cost per mile.

A critical yet often underestimated element is the role of tyres. Rolling resistance, which is the energy needed to keep tyres moving, directly impacts fuel economy and electric vehicle range. Choosing tyres specifically engineered to minimise this resistance, such as Nexen’s N’Priz S Grand Touring All-Season, can yield noticeable improvements. However, even the best tyres require consistent care; underinflation and misalignment create excess drag that forces the vehicle to work harder, quietly eroding efficiency over time.

External vehicle modifications also play a significant part. Accessories like roof racks and cargo carriers disrupt aerodynamic flow, and even open windows at highway speeds can create more drag than using air conditioning. Driving habits themselves deserve a strategic rethink as well. Opting for a slightly longer route with fewer stops can prove more efficient than a short, start-and-stop journey. Smoother acceleration, gradual braking and coasting to a stop help conserve momentum, which is especially beneficial for regenerative braking systems in electric vehicles.

For electric vehicle owners, additional steps can further extend range. Preconditioning the cabin while the car remains plugged in reduces the strain that climate control places on the battery during travel. Combined with a conscious effort to ease off the accelerator early to maximise energy recovery through regenerative braking, these practices allow drivers to go further on every charge, complementing the efficiency gains from proper tyre selection and mindful driving.

Aaron Neumann, Head of the Nexen Tire America Tech Center, said, “There are several opportunities to improve efficiency that aren’t immediately visible to drivers. From tyre design and maintenance to subtle driving habits, these factors work together to influence how much energy a vehicle uses. By paying attention to the details, drivers can take meaningful steps toward reducing costs and getting more out of every mile.”

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Hankook Tire has claimed the top position in the latest Auto Bild manufacturer ranking, securing a dominant presence across key tyre categories. The brand’s ascent was driven by a double test win for its newly launched Ventus evo, which propelled Hankook to share first place in the summer tyre segment. In the all-season category, the company delivered a consistently strong performance, earning third place overall thanks to the Kinergy model series, which accumulated four top placements across various evaluations.

The Ventus evo made an impressive entry into the current tyre season by clinching victory in two separate Auto Bild summer tyre tests, a feat that positioned Hankook as the only manufacturer alongside one other to achieve a double win in the summer tyre manufacturer standings. This debut underscored the tyre’s seamless fit within the premium segment, with the results highlighting its capabilities across critical criteria such as wet braking and dry handling.

In the all-season arena, the Kinergy series demonstrated remarkable consistency across four distinct tests, securing Hankook’s third-place finish in the manufacturer ranking. The model line proved its reliability by delivering strong results across all relevant performance areas, including winter characteristics, further cementing Hankook’s reputation as a dependable leader in that segment.

The Auto Bild manufacturer ranking aggregates results from all tyre tests conducted during the season, assigning points based on a structured system. A test win earns six points, followed by five for an exemplary rating, three for good, two for satisfactory and one for recommended with reservations. Additional bonuses apply, with one extra point for Eco Champion recognition and two for a Green Tyre designation. Across the 2025/2026 season, a total of 67 summer tyres and 61 all-season tyres were evaluated under this framework.

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Brisbane-based NTD has strengthened its leadership position in Australia and New Zealand by finalising four exclusive multi-year supply agreements with major global tyre manufacturers. These deals solidify the company’s standing within a regional wholesale and retail sector valued at over USD 11 billion, ensuring long-term collaboration with key suppliers across a diverse array of tyre segments. The agreements with Radar Tyres, Giti/GT Radial, Cooper Tires and Mickey Thompson Tires cover passenger vehicles, SUVs, 4-wheel drives, electric vehicles, light trucks, commercial fleets and specialised applications in agriculture and mining, reinforcing NTD’s ability to serve a broad customer base.

According to NTD’s Chief Executive Officer and Managing Director, Warwick Hay, these partnerships are fundamental to the company’s growth strategy. By securing exclusivity over an extended period, the group can pursue deeper collaboration with manufacturers in areas such as product development, supply planning, and brand building. This structure not only supports commercial flexibility but also enhances supply chain reliability, ultimately ensuring that NTD’s extensive dealer network and customers benefit from consistent product availability.

Two of the newly formalised agreements involve American brands Cooper Tires and Mickey Thompson Tires, both owned by Goodyear. NTD first introduced Cooper Tires to Australia in 1989, and the brand has since become well established in the SUV and light truck segments. Meanwhile, Mickey Thompson Tires maintains a strong focus on high-performance and off-road applications, building on a legacy of innovation in tread design and safety. Representatives from Goodyear and Mickey Thompson noted that NTD’s expertise and commitment have been instrumental in driving brand growth, with the renewed agreements set to build on that momentum.

The remaining two agreements are with Singapore-based entities: Radar Tyres, owned by Omni United, and GT Radial, part of the Giti Group. Radar Tyres has gained recognition in Australia for its value-focused passenger and all-terrain offerings, alongside its distinction as the world’s first carbon-neutral tyre brand. Giti Tire supplies premium products across multiple vehicle categories and has made significant inroads into the electric vehicle segment, supplying original equipment manufacturers such as BYD, GWM and Tesla. Executives from both companies highlighted the combination of global manufacturing capability with NTD’s national distribution network as a key factor in ensuring reliable supply and strong dealer support across Australia and New Zealand.

As the largest independent tyre and wheel importer and distributor in the region, NTD serves more than 4,000 business customers through an extensive network of distribution centres and retail outlets. The company also manufactures retread tyres and provides performance management systems for commercial fleet operators. Hay noted that in a context of global uncertainty, these agreements formalise longstanding supplier relationships while reinforcing continuity of supply. He added that maintaining a broad and dependable product range is essential, particularly as demand grows for eco-friendly, smart and electric vehicle tyres across the diverse sectors the company serves.

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Falken has once again demonstrated its strength in the summer tyre segment, with the ZIEX ZE320 securing an impressive second-place finish in Autoflotte’s latest test. Scoring a total of 791 points, the tyre competed in the popular 235/55 R18 size against a strong field of rivals, reinforcing its status as a top-tier choice for discerning drivers.

Safety on wet roads proved to be a defining strength. The ZIEX ZE320 set the benchmark in longitudinal aquaplaning with the highest recorded speed, while its performance in lateral aquaplaning and critical cornering remained composed and predictable. A wet braking distance of 36.1 metres earned a solid good rating, placing it among the frontrunners. The tyre’s wet handling further impressed with precise steering response and stable road manners, instilling confidence in challenging conditions.

On dry surfaces, the Falken tyre delivered an equally compelling account of itself. It was praised for being highly agile through corners, offering precise lane stability and clear feedback that earned a rating of almost very good. The standout achievement came in dry braking, where a stopping distance of just 33.6 metres from 100 kmph was the best in the entire test, surpassing even established premium names. This result underscores the tyre’s formidable safety credentials during summer driving.

Beyond pure performance, the ZIEX ZE320 excels in efficiency and comfort. Rolling resistance was recorded at a competitive 6.7 kg/t, keeping it close to premium rivals, while interior noise levels ranked among the quietest in the group. Ride comfort emerged as a particular highlight, earning the top very good rating and leading the category. By blending exceptional aquaplaning resistance, class-leading braking, refined comfort and precise handling, Falken has delivered a well-rounded package that is especially compelling for SUV drivers who prioritise safety and reliability, all supported by a five-year guarantee.

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