Apollo Tyres recently opened its first two-wheeler tyre manufacturing unit in India to cater to growing demand for the premium two-wheeler bikes. In an interview, Neeraj Kanwar, Vice Chairman & MD, Apollo Tyres, spoke on the new plant and growth in the premium bike segment and the company’s readiness for the premium two-wheeler tyre market..

With the opening of its two-wheeler manufacturing facility, Apollo Tyres aims at having a “strong foothold” in the premium segment of two-wheeler tyres, which is the comparatively high-value and highly profitable segment, India.

With having a vision of to be a premier tyre company with a diversified and multinational presence, Apollo Tyres manufactures and supplies a wide range of tyres for trucks and buses, light trucks, passenger vehicles, off-highway vehicles and two-wheelers.

“We are known for offering technologically advanced products to our consumers in all the categories. Getting into the premium biking segment was a natural progression for us,” said Neeraj Kanwar, Vice Chairman & MD, Apollo Tyres. 

With the new facility, Apollo Tyres now plans to have a strong foothold in premium motorcycle tyre market in India. Despite being a late entrant, Apollo Tyre has already grabbed a 7% market share in the replacement market in the two-wheeler tyre space due to a best-in-class and high-technology product portfolio.

The new two-wheeler tyre manufacturing unit is located within Apollo Tyres’ Limda plant in Vadodara, Gujarat, which has an initial capacity to produce 30,000 motorcycle radials and 60,000 cross-ply motorcycle tyres per month.  With a modular layout of the facility, the capacity can be replicated easily, as the demand increases.

“We now have a global portfolio of high-end bias and steel radial tyres for two-wheelers, which will be produced at our highly advanced and futuristic facility in Vadodara, Gujarat,” added Kanwar.

Apollo Tyres, in 2016, entered the two-wheeler tyre business by launching India’s first zero-degree steel radial tyres, a global gold standard for motorcycle tyres, and now commands a double-digit market share in this segment. “Being a late entrant into the two-wheeler tyre space, we wanted to create an impact in the market. In under four years, we have built an entire range for Indian and European market, grown at a CAGR of 35%, catered to market with a new last-mile distributor model and built a grounds-up connect with the biking community through our multiple brand initiatives,” said Kanwar.

Apollo Tyres is looking at selling our two-wheeler tyres from the Vadodara facility to all market segments, including exports. “In fact, we already have shipped the first consignment from this facility for the European market,” added Kanwar.

Premium bike segment

The premium bike segment, which constitutes nearly 20% of the motorcycle market in India, is the fastest growing one. According to a TechSci research report, the Indian premium motorcycles market is projected to reach $ 161 million by 2023, on account of rising Y Generation population and per capita income, and availability of a wide array of premium motorcycle models and easy financing options. The report also added that increasing number of CKD and SKD units, the launch of newer and advanced premium motorcycle brands and models, rising popularity of superbike clubs and communities, and increasing biking culture are among the key factors expected to drive the country’s premium motorcycles market in the coming years.

“India also is the largest market for two-wheelers, and it still has headroom for further growth. In the current pandemic era as well, there is the demand coming in as people are moving away from shared and public transport and gradually moving to own a personal vehicle, including a two-wheeler, further driving the demand for tyres in this category,” said Kanwar.

Though many tyre companies are betting high on the premium tyre segment, commuting bikes will continue to dominate the market. According to Kanwar, the economy segment bikes still drive volumes for Apollo Tyres’ two-wheeler tyre business. Instead of looking at this segment as a commodity business, the company caters to the segment with multiple product offerings according to various markets in India. “We have seen emerging trends in this segment like the rapid rise of delivery and courier services and have built specialised offerings for this space as well,” said Kanwar.

Along with having a leading position in India, Apollo Tyres is also expanding its business in the challenging and advanced automotive markets in Europe and the Americas. Apart from having five manufacturing plants- Chennai, Perambra, Limda, Kalamassery and most recently, Chittoor- in India, the company has established two manufacturing plants outside of India – The Netherlands and Hungary.

Having global R&D centres in India and Europe give distinctive advantages to Apollo Tyres to caters to all segments. Both R&D teams use their collaborative experience to come up with technologically advanced products for the premium bikes. “Entering the two-wheeler segment in 2016, we used the global knowhow, to come out with zero-degree steel-belted radials in 2018, a global gold standard for motorcycle tyres,” said Kanwar.

 Apollo Tyres has used the concept of ‘design to delivery’ while setting up this two-wheeler tyre facility in Vadodara, Gujarat. Most of the equipment used are special purpose machines, which have been conceptualised in-house and converted to reality.

However, the competition in the two-wheeler tyre segment in India is very high, and few companies have dominated the segment. The segment is expected to be more crowded with new entrants. Apollo Tyres has set its focus on the premium segment of two-wheelers, which is 20% of the entire two-wheelers while supplying to the mass market segment. “We are looking at servicing this segment with our zero-degree steel belted radials and high-end bias tyres. Our strategy is to build the brand and create a pull for our products across categories. We have been actively engaging with several biking communities and enthusiastic and passionate riders,” explained Kanwar.

In FY 2020, in the two-wheeler segment, the company launched 17 new SKUs for the higher premium bikes and scooters and extended its steel radial portfolio with the launch of two new SKUs – Alpha S1 140/60 R17 and 130/70 R17. For its two-wheeler business, the company executed the Alpha sustenance campaign earlier in 2020 to make it one of the most viewed brands by the end of the campaign.

Talking on the recent imposition in Chinese tyres, Kanwar said, “We are definitely better placed than before.”

 

When the World Economic Forum inducted CEAT’s Chennai facility into its Global Lighthouse Network in January 2025, it made the Indian tyre-maker the first tyre brand in the world to hold two such honours – Chennai following in the footsteps of the company’s Halol plant. Add to that CEAT’s Deming Grand Prize, awarded by the Union of Japanese Scientists and Engineers for sustained excellence in Total Quality Management, and the company finds itself in rarefied company: one of only a handful of manufacturers worldwide, and the only tyre brand to hold both distinctions.

Behind these accolades sits a quieter, harder story – one of culture change, shop-floor scepticism and years of disciplined, incremental investment in artificial intelligence, the Industrial Internet of Things and automation. In an interview with Tyre Trends, Jayasankar Kuruppal, Senior Vice President, Manufacturing at CEAT, spoke on what these recognitions actually mean on the factory floor, and where the company believes manufacturing is headed next.

AWARDS AS A BY-PRODUCT, NOT THE GOAL

CEAT’s Chennai plant has posted striking numbers since its digital transformation began: a 54 percent improvement in dispatch turnaround, a 25 percent uplift in labour productivity, an 18 percent reduction in cycle times, a 31 percent improvement in operating cost and a 47 percent cut in Scope 1 and 2 emissions. Yet Kuruppal is quick to reframe the narrative around these achievements.

“The awards are lagging indicators, not the goal. What actually matters is what they force us to build: a common language for problem-solving across every plant, real-time visibility into quality and efficiencies and a workforce that trusts data over gut-feel,” Kuruppal said.

“That discipline shows up directly in the numbers – tighter process capability, better efficiencies and faster changeovers leading to shorter lead times. There is a commercial dividend too: global OEMs increasingly audit manufacturing maturity, and being part of the WEF Global Lighthouse Network gives us instant credibility in those conversations,” he added.

WHAT’S REALLY DRIVING THE INVESTMENT

CEAT has been pouring capital into AI, IIoT and automation across its plants. Is this cost pressure, premiumisation or a simple need to stay globally competitive? Kuruppal’s answer suggests it is all three, each playing a distinct role.

Kuruppal explained, “Quality, cost and efficiency is what gets the funding approved. Premiumisation is what’s shaping which lines we automate or upgrade first – you cannot hold the tolerances a premium radial demands with manual, operator-dependent processes.” According to him, global competitiveness, meanwhile, sets the ambition. “We’re not benchmarking ourselves against the best tyre plant in India anymore – we’re benchmarking against the best factories in any industry,” he added.

Asked to rank the three forces, he summarised neatly: competitiveness sets the ambition, premiumisation sets the sequencing and cost discipline keeps the whole effort honest.

REPLICATING HALOL AT CHENNAI: CULTURE OVER CODE

Chennai’s transformation built directly on lessons learned at Halol, the world’s first tyre facility inducted into the Lighthouse Network. And when asked what proved hardest to replicate, the technology, the culture or getting the underlying processes right, Kuruppal said, “Technology was actually the easiest part to copy. A use case that works at Halol can be re-deployed at Chennai in weeks.”

But the real difficulty, as per Kuruppal, was culture, people and change management. At Halol, habits such as daily data reviews, operator ownership of quality metrics and a managerial focus on coaching rather than firefighting were built steadily over several years. Chennai, by contrast, has had to replicate that trajectory on a compressed timeline, with a workforce encountering these practices for the first time.

“We had to resist the temptation to just parachute in dashboards and call it digital. We spent real time getting the underlying process standardisation right first, because AI on top of an unstable process just gives you a faster route to the wrong answer,” Kuruppal said.

Jayasankar Kuruppal, Senior Vice President, Manufacturing, CEAT

WHERE THE RETURNS SHOW UP – AND WHERE THEY HAVEN’T YET

The productivity and dispatch gains at Chennai, he explained, hit the balance sheet in different ways. The productivity improvement lowers conversion cost per tyre and improves absorption of fixed costs as volumes grow. The dispatch improvement is more of a customer-experience story: less finished-goods inventory sitting idle, and OEMs and dealers receiving faster, more predictable delivery windows – ‘which matters a lot when you’re chasing premium and export business’.

Not every initiative has paid off yet, however. Kuruppal was candid about the areas still short of return, singling out ‘some of the more exploratory AI use cases – like computer-vision pilots – which need more data cycles before the accuracy justifies scaling them further’.

QUALITY, MAINTENANCE, OUTPUT: AI TOUCHES ALL THREE

Rather than picking a single area where artificial intelligence delivers most value, Kuruppal argued that its power lies in the way it now touches quality, maintenance and output simultaneously – and that these reinforce one another. “Better quality data feeds better predictive-maintenance models, which reduces unplanned downtime, which directly lifts output,” he said. The most immediate impact shows up in more consistent product quality, higher yields and earlier detection of equipment issues. He pushed back, though, on the idea that AI at CEAT is a single flagship project: “On our floor, it’s dozens of narrow, specific use cases, each solving one operator’s or one supervisor’s actual problem.”

JUSTIFYING THE SPEND IN A MARGIN-TIGHT BUSINESS

Tyre manufacturing is not a business with room for indulgent technology spending, and Kuruppal was clear that CEAT does not fund innovation for its own sake. “Every use case has to show a clear line to quality, efficiency, cost or capacity enhancement before it gets budget,” he said. The company deliberately starts small – piloting on a single line, proving value with real production data, and scaling only what works – a discipline that means ‘the savings from scaled use cases fund the next round of pilots’. He offered a broader rationale too: in a commodity-adjacent business where raw material costs sit largely outside a manufacturer’s control, manufacturing capability itself becomes the differentiator. “If we can’t always control input costs, we can control how efficiently and consistently we convert them into tyres,” he added.

CHENNAI PLANT WIDENS ITS PREMIUM PUSH

CEAT on Oct. 1 announced an expansion of manufacturing capabilities at its Chennai plant across passenger car and SUV, commercial vehicle and two-wheeler tyres. The company said the move targets premium customers in India, Europe and North America.

What’s new

Cars and SUVs: The plant now makes the SportDrive SUV ZR22. CEAT said this makes it the first Indian tyre company to manufacture 22-inch tyres in India. It also makes the 4SeasonDrive+ all-season tyre and the CrossDrive RT rugged-terrain tyre, built for the U.S. market.

Trucks and buses: The plant can now produce seven advanced truck and bus radial sizes, including wide-base tyres that can replace dual-tyre setups, and low-profile sizes. CEAT is also scaling light truck steel radials in 15-, 16- and 17.5-inch sizes.

Two-wheelers: The SportRad Racing Slick range targets track use, and SportRad ST is a sport-touring range for motorcycles above 650cc.

“This investment strengthens our ability to compete in premium segments with products developed and manufactured in India,” CEAT managing director and CEO Arnab Banerjee said.

The 163-acre plant in Sriperumbudur, Kanchipuram, runs on connected machinery and real-time analytics. It also has a 9 MW rooftop solar installation and operates as a zero-liquid-discharge facility.

FROM PILOT TO SCALE: AN OPERATING-MODEL PROBLEM

With a large share of CEAT’s lines now running as ‘smart lines’, when asked what changes when a company moves from isolated pilots to scaling technology across multiple plants, the CEAT executive explained, “The problem changes completely. A pilot is a technology and data-science problem – get the model working, prove the use case. Scaling is an operating-model problem – standard work, training, change management, IT infrastructure that can handle load across sites and governance so every plant isn’t reinventing its own version of the same solution.”

CEAT has built what he calls a central playbook – reusable architecture, common data standards and the ability to roll a proven use case out to a new plant in weeks rather than months. “Just as importantly, ownership shifts: at pilot stage, a project team owns the initiative; at scale, it must become the plant’s own way of working, run by operations rather than a digital team sitting alongside it,” he added.

BRINGING 80 PERCENT OF THE WORKFORCE ALONG

CEAT reports that more than 80 percent of its workforce is now digitally enabled – a transformation Kuruppal admits did not come without resistance. “Yes, and I’d be understating it if I said otherwise,” he said. Crucially, he insists the resistance was never really about technology itself but about ease of operation. What worked, he explained, was making tools visibly useful to the person using them first – an operator seeing a dashboard that helps them hit their own target before it ever becomes a management reporting tool. CEAT invested heavily in shop-floor-specific training rather than generic digital-literacy courses and made a point of promoting from within, demonstrating that digital skills opened up better roles rather than closing off old ones. The company has also created new shop-floor roles beyond data scientists and engineers – ‘Business Translators’ and ‘Champions’ who act as torchbearers driving scaled implementation and wider blue-collar involvement.

CONSISTENCY, NOT JUST DEFECT COUNTS

Asked whether tighter process control has genuinely reduced defects, Kuruppal reframed the question around consistency. “Tighter process control means less batch-to-batch variation, which matters enormously in tyre manufacturing because so much of performance and durability comes down to material consistency through mixing, extrusion and curing,” he said. Real-time monitoring now catches drift early, rather than at final inspection – both a quality win and a material-efficiency win, in the form of less scrap and rework. The habit that has changed most, he said, is that quality data now drives daily decisions on the shop floor, rather than featuring only in a monthly review.

MANUFACTURING FOR A PREMIUM, ELECTRIC FUTURE

CEAT’s push into premium tyres calls for a step-change in manufacturing discipline. “Premium tyres are far less forgiving of variation, so the shift starts with tightening process capability across every stage – not just final inspection. That means more precise equipment, better process capability and closed-loop control,” said Kuruppal. In this context, flexibility takes on a different meaning: a wider SKU mix, smaller batch sizes and faster changeovers are pushing the company towards more modular manufacturing, alongside a workforce increasingly weighted towards process engineering expertise.

Electric vehicles introduce an additional layer of complexity. EV tyres must carry greater weight, handle instant torque and operate more quietly, tightening specifications around structural strength, noise and rolling resistance beyond those of conventional tyres. On the shop floor, that translates into new compound formulations requiring precise mixing, reinforced construction demanding tighter control of building machines and significantly lower tolerance for micro-variation.

CEAT’s existing leadership in the e-two-wheeler tyre segment, Kuruppal noted, is already feeding lessons – particularly on noise and efficiency – into how the company prepares lines for growing e-four-wheeler volumes in India.

SUSTAINABILITY AND RESILIENCE, BUILT IN

Sustainability, once a separate reporting exercise, is now ‘a line item in almost every manufacturing decision’, with energy and emissions sitting alongside cost and quality when evaluating new processes or equipment – Chennai’s 47 percent emissions reduction being the clearest proof point. Resilience, too, has become as much a data problem as a sourcing one. “Real-time visibility into inventory, machine health and production schedules means we can see a disruption coming and reschedule around it rather than reacting after a line has already stopped,” Kuruppal said, pointing also to greater flexibility in shifting product mix between lines and earlier warning signals from digitised supplier and logistics data.

SPEED AS A COMPETITIVE WEAPON

Manufacturing speed and flexibility, Kuruppal argues, have become one of CEAT’s most important competitive dimensions, as OEMs compress their own development cycles and expect tyre partners to match their pace – faster prototyping, faster line trials, faster ramp-up to volume. Chennai’s faster dispatch turnaround is part of the same story. “It’s not just about making tyres faster; it’s about the whole chain from order to delivery being more predictable and quicker,” he said.

GROUND STILL TO COVER

For all its Lighthouse credentials, Kuruppal was refreshingly honest about the distance still to travel. “Being part of that network is genuinely humbling. You see factories in electronics and consumer goods running end-to-end AI-driven planning and quality systems at a level of maturity we’re still building towards – particularly in advanced analytics for demand-and-production planning and in scaling generative-AI use cases beyond pilots,” he said. CEAT’s strength, he believes, lies in shop-floor execution and quality; the next frontier is connecting that data seamlessly across the full value chain, from raw-material sourcing to the end customer.

MANUFACTURING AS A GROWTH DRIVER

Perhaps the most striking shift Kuruppal describes is a change in how manufacturing itself is perceived within the business. “Traditionally, manufacturing was viewed in this industry as a cost centre that executes what sales and product teams decide,” he said.

“Today, our manufacturing capability is directly opening up premium and export opportunities, because global customers evaluate factory maturity as part of their sourcing decision. It works in the other direction too, shaping which premium and EV products the company can confidently commit to launching. Manufacturing has moved from being an execution function to being a genuine input into growth strategy,” he added.

WHAT COMES NEXT

Looking ahead, Kuruppal frames the next horizon as connecting what CEAT has built plant-by-plant into a single, integrated digital thread – spanning raw-material and demand planning, production and distribution – so decisions are optimised end-to-end rather than site-by-site. Generative AI, he said, is increasingly being explored for process and equipment troubleshooting and knowledge capture, making the expertise of CEAT’s best engineers accessible across every plant. Sustainability, meanwhile, will be designed into new lines from the outset rather than retrofitted. “The common thread is moving from isolated smart use cases to a genuinely integrated smart manufacturing system,” he explained.

THE ONE NUMBER THAT MATTERS

Answering the question on if he could track just one metric across every CEAT plant, what would it be, he admitted, “If I’m honest, no single number tells the whole story, but if forced to pick one, it would be Overall Equipment Effectiveness – OEE.”

“As a composite of availability, performance and quality, a healthy and rising OEE generally signals that machines are running, running at the right speed and producing good tyres – which is really the definition of a plant working as it should,” he said. It has its limits – OEE alone won’t reveal a lapse in safety culture or the pace of digital adoption – which is why, in the end, Kuruppal names two figures he watches above all: OEE and safety indicators.

Tana Oy has appointed Panu Ärölä as its new Territory Business Manager, a role he will assume on 2 November. In this capacity, he will focus on strengthening customer and distributor relationships across designated markets while contributing to the company’s ongoing expansion within the waste management and recycling sector.

Ärölä returns to Tana after previously serving as Sales Manager, where he developed expertise in distributor network growth. His background includes extensive international experience in sales, marketing, business development and strategic leadership. Most recently, he held the position of Head of Sales and Marketing at Jet-Tekno Oy, overseeing customer relationship development and business growth initiatives.

Gerd Schreier, VP – Sales, Marketing & Channel Development, said, “We are delighted to welcome Panu back to Tana. His industry knowledge, customer focus and experience in international sales make him a valuable addition to our team. We look forward to working with him as we continue to develop our business and create value for our customers and partners.”

Stephan Sielaff took over as chief executive of the Schill+Seilacher Group on 1^st October , as the chemicals group seeks to strengthen links between its businesses and focus more closely on customer needs.

Sielaff brings about 30 years of experience in developing international businesses and organisations. His previous roles include positions at Unilever, Symrise, Archroma, Lenzing AG and SSI SCHÄFER Plastics.

His priorities at Schill+Seilacher include getting closer to customers, encouraging greater knowledge-sharing across the group and making better use of capabilities across its businesses and locations.

“A good product alone is no longer enough. What matters is the value we create for our customers,” says Stephan Sielaff.

The group said it would seek to share knowledge, pursue opportunities jointly and strengthen connections between its locations and business areas.

Sielaff's appointment is intended to support a more integrated approach across the group as it develops its businesses in the years ahead.

Toyo Tire Corporation of Japan (Toyo Tire) has announced executive appointments at Toyo Tire Holdings of Americas Inc. (TTHA) and Nitto Tire U.S.A. Inc. (NTU), effective 1 October 2026. Keiko Brockel has become President and Chief Executive Officer at TTHA, while Angelo Naval has beeen promoted to President and Chief Executive Officer at NTU.

Brockel, the first woman and first American to hold the TTHA role, will oversee daily North American business operations. She joined NTU in 2008 and previously served as its President and Chief Executive Officer and President and Chief Operations Officer. Over 18 years at NTU, she has held various executive leadership positions, providing strategic oversight in sales, finance, supply chain and operations, contributing significantly to the company's growth and evolution.

Angelo Naval

Naval, formerly Vice President of Sales and Business Strategy at NTU, will now oversee its business operations. He joined NTU in 2000 and also served as Vice President of Product and Business Strategy. During his 24 years with the company, he has been instrumental in shaping the business, gaining deep understanding and a unique perspective on the Nitto brand, its customers and the markets it serves.

Takashi Shimizu, President & CEO, Toyo Tire Corporation, said, “On behalf of Toyo Tire, I would like to congratulate both Keiko Brockel and Angelo Naval on their well-earned new appointments and thank them for their invaluable contributions to the growth and success of Nitto Tire in the American market.”