Nothing is stable. Technology is continuously evaluated. Materials science, electronics and software are the main three engines that reverse reactions or open new horizons.
Tyres are always known as black and round. However, the tyre engineers are aware of the weight achieved, the construction and the types of materials used in the tyres. What was the ancestor of the tyre, where is it going now?
The tyres were rated very quickly after vulcanisation 150 years ago. The first use of synthetic rubber and synthetic fibers, as well as the first radial tyre, go back around 70 years. Programming the control of the tyre building and curing machines with sensors and timer was a cornerstone. The new chemicals and advanced materials which suit well for process control, more homogeneous mixing, material integration and long-lasting rubber products.
Today's tyres last to the end of their useful life, which is primarily measured by the Remaining Tread Depth (RTD) which is greater than a limit value set by local legal approval. Twenty years ago, many defective tyres were found in scrapyards that were almost like new, but today the tyre will last almost lifetime.
Today, Mechanical rubber derivatives production machine parts are made to tighter tolerances. The integrity of the main body material is higher than in previous years. Alloys or composites are widely used compared to recent years. More controlled and homogeneous surface finishing is applied. Modern tyre production machines are equipped with robotics, full sensors and automation, stepper motors and greater controllability which are examples of the harmonization of creativity and innovation in the industry.
More than all that, today manufacturing machines are more purpose oriented, lighter, sensitive and modular.
The other very preliminary point of view is to analyse the needs of the main processes and what should be the strategy when you have an idea to buy new machines?
Every system needs new machines to install for a reason. It is used either to increase capacity or to renew a range of products, just to modernise or update technology. What should be the strategy when you have an idea to buy new machines? Either you are looking for a machine that matches your technology or you are taking the risk of a technology upgrade. The same category but a more efficient, more productive, safer and more controllable machine may be preferred or a completely new technology may be chosen.
If a very new technology is chosen, the time it takes to adapt can result in large production losses. It may take longer to adapt, etc. However, if you don't take such a risk, how will you manage the technology update in later years?
The other very preliminary point of view is to analyse the needs of the main processes. For example, if you are a tyre manufacturer, customers will only know your brand name. You are responsible for the end product. Third parties do not know where to start preparing tyres or what process to use to make them.
For example, you can have a textile calendar or you can get calendered textile and steel layers on the outside. When using a supplier, you don't need a factory calender machine. This also applies to the compounds used in the manufacture of the components. Today, a large volume of masterbatch is used in the rubber products industry. Organizing a good supply chain for manufacturing rubber compounds eliminates the need for mixers, a few mils, large silos, or process oil tanks.
A review of all processes and machine setup is necessary at regular intervals in order to remain competitive. Fewer production machines can increase productivity and controllability and intensify management. Less personal use, less energy and maintenance costs can be achieved. However, alternative suppliers need to be developed and diversified.
In the past, some particularly large tyre manufacturers had tyre cord treatment units in tyre factories. Some of them have steel wire production facilities for their own supply. Today we are witnessing a complete change of mind. The focus on the main process areas is mainly taken into account, which has completely changed the perspective in business. Today, most tyre manufacturers contract out the processing of 2nd class compounds. So, there is no refinery mill machines in tyre factories. The heating of the rubber in the preparation zones of the main components is carried out by cold feed extruders. Large capacity extruders are used under the drop door in mixing rooms. As a result, there are very few milling machine and milling operators in the tyre factory. Factory structures are smaller, parts production and machine maintenance are outsourced.
Full robot transfer units already exist, No man-tyre building and curing are achievable now. Profile extruders are already disabled, calendering might be totally needless by body ply webbing on tyre building drums.
Being open and innovative in the tyre and rubber industry is important. Support for technological innovation and productivity, as well as the vision to find more efficient devices, is required. New control systems with computers and automation are inevitable. Indeed, the company's employees must have a vision to choose the last and the best for the future. The most important thing is to find profitable solutions for the entire company.
As you follow the progress of the machine, keep in mind that new materials are coming. Any fashionable material will one day be a burden on the staff. Major hardware changes require new processes or machines. The ultimate case is the cancellation of part of the process, which means the cancellation of the production machines. Such a case can be irresistible at any time.
The increasingly demanding structure of the automotive industry and regulations will demand ever lighter, more environmentally friendly and more rolling-resistant tyres, which repeatedly calls for ambitious innovations. Innovative materials are inevitable to exceed expectations. Just as new materials come out of the R&D thicket box and enter the daily production inventory, the production area and machinery should be reorganised.
Full robot transfer units already exist in many phases instead of being transported. There are automatic scan and uniformity checks. No man tyre building and curing operations are achievable now. Profile extruders are already being phased out in some tyre factories. Body ply webbing could be more of a standard technology in tyre building. Calendering may be totally needless in tyre plants.
As far as automation and controllability technologies assess, there is still room for refinement or cancellation of production processes and machines in tyre factories.
Today, Mechanical rubber products production machine’ parts are made to tighter tolerances. The integrity of the main body material is higher than in previous years. (TT)
Pirelli's Sensor-Equipped Cyber Tyre To Feature In Future Aston Martin Models
- By TT News
- September 15, 2025
A new partnership between Pirelli and Aston Martin will integrate Pirelli's pioneering Cyber Tyre technology into the British ultra-luxury brand's future vehicles. This system represents a significant technological advancement as the first of its kind capable of gathering real-time data from sensors embedded directly within the tyre's tread. These sensors feed information to Pirelli's proprietary software and algorithms, which then communicate seamlessly with the vehicle's electronic architecture.
This integration, developed in cooperation with Bosch Engineering, allows the car's main dynamic control systems, including ESP, ABS and traction control, to receive and utilise a comprehensive set of precise tyre data that was previously unavailable. By processing this information, an electronic control unit can optimise the vehicle's dynamics, enhancing both performance and safety. The collaboration underscores a shared commitment to innovation in the ultra-luxury performance sector. The adoption of the Cyber Tyre system marks a notable step forward in Aston Martin's pursuit of class-leading capabilities, leveraging detailed, real-time insights to refine the driving experience.
Despite Improved Sentiment, German Rubber Industry Reports Deep Losses
- By TT News
- September 15, 2025
The latest data from the German rubber industry highlights severe challenges at the domestic location are compelling companies to fulfil local demand primarily through their foreign production facilities, according to the German Rubber Industry Association (wdk).
A recent business climate index indicates a slight improvement in industry sentiment for the second half of 2025. However, wdk President Michael Klein sharply contradicts this optimism, stating that the data reveals a far grimmer reality. He emphasises that critical performance indicators – including revenue, sales, employment and production – are all showing deeply negative results for the domestic market, underscoring a troubling exodus of manufacturing from its core German base.
Klein has acknowledged the federal government's pledge to launch an ‘autumn of reforms’ as a positive signal. Nevertheless, he insists these measures must urgently deliver tangible relief and cost reductions for industrial companies of all sizes. He argues that what is needed most is a decisive and rapid approach to the promised reduction in bureaucracy, stressing that only verifiable results, not further promises, will count towards improving the competitiveness of the German industrial location.
Sailun Group Breaks Ground On $1 Billion Tyre Plant In Egypt
- By TT News
- September 15, 2025
Chinese tyre manufacturer Sailun Group has begun construction on a new USD-1-billion tyre facility in Egypt. The plant is situated within the Sokhna integrated industrial zone, part of the Suez Canal Economic Zone (SCZONE). This investment, one of the largest Chinese industrial projects in Egypt, was officially launched at a ceremony attended by SCZONE General Authority Chairperson Walid Gamal El-Din.
The expansive 350,000-square-metre factory will be developed in three phases over a three-year period. The initial phase is scheduled to become operational in 2026, with a planned production capacity of three million passenger car tyres and 600,000 truck and bus tyres annually. This first stage is expected to generate 1,500 new jobs. Upon full completion, the facility's total output is projected to surpass ten million tyres each year.
As a global leader in tyre manufacturing with an extensive international sales network, Sailun Group will utilise this new factory as a strategic hub. The facility is designed to meet rising demand within the local Egyptian market while also creating substantial opportunities for export to regional and international markets.
Nynas Joins Collaborative Research On Tyre Wear Particles
- By TT News
- September 15, 2025
With the rise of electric vehicles reducing exhaust emissions, attention is shifting to non-exhaust emission like Tyre and Road Wear Particles (TRWP). These microscopic particles, generated from tyre and road surface friction, are a growing environmental concern and will be addressed in the upcoming Euro 7 emissions standard. To tackle this challenge, Nynas has joined a major research consortium coordinated by the Royal Institute of Technology (KTH), alongside Volvo Cars, Scania and the Karolinska Institute.
The project aims to close a significant scientific knowledge gap by thoroughly investigating the formation, characteristics and environmental impact of TRWP. Nynas contributes a unique dual perspective to this interdisciplinary effort, bringing deep expertise in both tyre rubber compounds and bitumen-based road materials. Pär Nyman, Technical Manager – Tyre & Chemical Industries, Nynas, represents the company in the project alongside the company’s Chief Scientist, Dr Xiaohu Lu, who brings extensive expertise in bitumen and asphalt to the collaboration. A key focus will be understanding how different materials contribute to wear mechanisms.
The research scope extends beyond particle analysis to include measuring the rolling resistance of various tyre and bitumen combinations, a parameter directly linked to vehicle energy efficiency and greenhouse gas emissions. By uniting industry and academia, this collaboration is poised to drive innovation and set new benchmarks in sustainable mobility research.
Pär Nyman, Technical Manager – Tyre & Chemical Industries, Nynas, said, “While Sweden lacks domestic tyre manufacturers, Nynas' research capabilities fill that gap by providing foundational insight into the chemistry and physics behind TRWP generation. Nynas' rubber and asphalt labs are at the heart of this contribution. One of the core insights driving this initiative is that wear particles cannot be fully understood by analysing tyres or roads in isolation. It's the interaction – the system – that matters. By studying both tyre composition and road structure, the project aims to develop a holistic view of TRWP formation, dispersion and toxicity. At Nynas, we are excited to contribute our unique knowledge of materials to help solve an important challenge for both the environment and human health. Through collaboration and scientific inquiry, we aim to pave the way for cleaner roads and cleaner air – one particle at a time.”
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