BKT has announced that with its enhancement at Bhuj, it is aiming for an annual tyre production of 600,000 metric tonnes (MT). The company also envisages the achievement of two billion dollars in turnover in three years.

Bhuj from 201 to 2023
When the first tyre rolled off the Bhuj production line in 2012, the plant was located on an area of 123 hectares. Then it was a $500 million investment. Before starting the works, the desert landscape was completely arid. There was neither water nor electricity. But after the laying of many kilometres of drinking water pipes and power lines, the site grew with 126 hectares in 2016, 131 in 2019, 137 in 2021 and 258 in 2022. By the end of 2023, the forecast is to reach a total surface area of 323 hectares, of which 283 have already been acquired.

Better production and safety
BKT claims that Bhuj today sees more efficient machinery installed, with features that make it possible to work faster and more precisely. This increases the quantity of production and the quality of the finished product. This means, for example, that the amount of product discarded is reduced, increasing the sustainability of the manufacturing process and consequently reducing production costs. Occupational risks are also reduced and worker comfort improved.

Self-produced carbon black
A further strategic choice by BKT to enhance the Bhuj site was to invest in its own carbon black plant. The plant came into operation in 2017, when the first 65,000 MT/PA of hard grade carbon black was produced, the type of carbon black used specifically in tyre tread.  The following year, production increased from 65,000 to 110,000 MT and saw the addition of production of soft grade carbon black. This carbon black is used in the casing compound to improve its strength and durability, generating less heat. In 2021, total production of the two types of carbon black reached 138,000 MT per annum, while last year it rose to 165,600 MT per annum.

The goal for 2023 is 198,600 MT. In addition to this, the R&D department plans to add a third type of carbon black, the ‘specialty carbon black’. It is a type of carbon black with unique properties compared to that used in rubber compounds, such as high resistance to colouring, a high level of purity, a low ash level and very low level of PAHs, which make it suitable for use in specific applications, such as paints, plastics and inks.

Increasing production capacity
The expansion of the plant means an increase in production capacity. The operational logistics have also improved significantly. This has allowed the introduction of new specialist workers, as well as providing greater flexibility in production and storage flows. Speaking of work, the construction of new facilities also marked an improvement in employees' safety conditions, an aspect which BKT takes very seriously. The community that operates on the Bhuj site today is very large. At the end of December 2022, the number of people working there was 4,776.

The wellbeing of the BKT family
BKT dedicates a significant investment to the wellbeing of its community every year, through the expansion of the area housing the families of employees (now almost 1,000 people live there), in the care of their health and in the education of their children.

A good use of resources
Bhuj is also a model for the good use of resources. In 2013, the internal power plant was created to have a reliable and controlled source of electricity. Today, both solar panels and the cogeneration plant make it possible to self-produce energy. In 2022, the cogeneration plant was expanded from 20 MW to 40 MW. Projects are still underway to increase the power of self-produced renewable resources.

Water is also at the heart of BKT's path towards sustainability. Since 2019, the Zero Liquid Discharge (ZLD) principle has been adopted. This means that no liquid waste is released outside the plant. All water used in the plant is treated, purified and reused. The objective of the ZLD principle is to conserve water resources, reduce the environmental impact of wastewater discharge and improve the overall efficiency and sustainability of the plant.

Carbon black production made more sustainable
The tyre manufacturer has also taken an approach to carbon black production to make the whole process more sustainable. The company has substituted bulk bag containers with mobile silos. This means that the tyre production plant receives the carbon plant with the aid of mobile silos transported pneumatically to the storage. This will make BKT save on packaging, i.e., 100,000 bulk bags in the next few years. The whole transportation system is also designed to reduce energy usage, consumption and quality. Every transfer system is controlled by weight and the energy used. The future goal is challenging – reducing energy consumption up to 70 percent. This translates in saving more than two million kilograms CO₂ emissions per year, which are comparable to 5,000 apartments of 100 square metres each.

At the same time, the gas used to manufacture carbon black is now ending up in a co-generation plant, able to reuse 75,000 cubic metres of gas per year. This means saving 215,000 MT of coal per year. 

Research opens up the future
BKT's R&D division was what allowed the Bhuj site to grow. Established in 2017, this hub develops both products and processes, to ensure the company can maintain its international leadership. Led by a specialist team of researchers and analysts, it remains an important and up-to-date research centre in the tyre sector.

Coming to testing, a special test track was inaugurated in 2017. With six different tracks, this circuit includes tracks for tyre performance tests in dry and wet conditions, an asphalt track and a sloping concrete track. Thanks to a wide variety of tests, many important characteristics such as traction, handling, comfort, soil compaction and more can be measured here because of high precision devices and instruments.

A concrete vision
Rajiv Poddar, Joint Managing Director at BKT, says, "People have asked me if all this was really necessary, so much in such a short time. The goals we set ourselves when we decided to open the Bhuj site were proportional to the financial solidity of the time, but above all, to a vision which is as great as it is concrete.”

He added, “Analysing the market and anticipating it with passion and foresight is what we have done all these years. Growth has always been in step with demand, not without – let me say it – courage and creativity, but never without our objectives and investments having solid foundations. Global tyre demand is growing and we see no signs of it slowing down over the next five years. This is a demand which started to rise during the 2020 pandemic, and which today is above pre-Covid levels. Will it be difficult? Will it be a challenge? Our vision is simple, which is why it is very concrete. The journey we started out on at Bhuj in 2012 was never a return journey, but one to prepare ourselves to discover the future."

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Following the 2025 General Assembly, Law Hieling has been elected to the Global Platform for Sustainable Natural Rubber (GPSNR) Executive Committee to represent the Manufacturer category. His 27-year international career at Michelin, encompassing roles in finance, commercial sales, distribution and his current leadership in natural rubber purchasing, provides a profound, ground-level understanding of the global tyre industry.

This extensive background has given him a clear appreciation for the intricate balance between commercial needs and ecological responsibility. He is committed to leveraging this perspective to help drive the collaborative, transparent and equitable solutions that are essential for a genuinely sustainable natural rubber value chain, benefiting both people and the planet.

Hieling said, “I look forward to contributing to the work of the Executive Committee in advancing responsible practices across the natural rubber sector.”

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As the world grapples with the environmental challenges of discarded tyres, IIT Bombay researchers are developing sustainable solutions by repurposing waste rubber into innovative construction materials. Nilesh Wadhwa reports on how their work not only aims to mitigate landfill waste but also offers unique thermal, electrical and structural benefits for future infrastructure.

With over a billion tyres discarded globally each year, the world faces an escalating crisis in managing tyre waste. Beyond the mounds of rubber in landfills, the environmental and health hazards from tyre degradation, microplastics and toxic emissions are profound. However, a team of researchers at the Indian Institute of Technology (IIT) Bombay is charting a sustainable path forward. By transforming waste tyres into innovative construction materials – Rubcrete, which is a form of concrete mixed with shredded waste tyres. This is said to not only provide strength to the material but also make it more environmentally friendly. The idea is to turn an environmental problem into a valuable resource for civil engineering.

In an interaction with Tyre Trends, Prithvendra Singh, a principal researcher at IIT Bombay, explained the motivations behind this ground-breaking research. “The main aim of this research was to address the dual challenge of excessive end-of-life tyre (ELT) accumulation and the unsustainable depletion of natural aggregates due to ever-rising demand in infrastructural development,” he stated.

By converting waste rubber into engineered rubber aggregates (RA) and rubber-plastic blends (RPB), the team seeks to not only reduce landfill dependency but also enhance the sustainability of construction materials.

This pioneering approach is timely. The sheer scale of tyre waste, with millions of tonnes generated annually, has far-reaching consequences. Tyres are durable, non-biodegradable and pose serious fire hazards.

“One of the most overlooked issues is the generation of microplastics and toxic volatile compounds through tyre wear and tear, degradation, weathering or fires. Landfilled rubber fires can take months to extinguish and result in the emission of carcinogenic gases. These pose risks to human health and ecosystems, and their long-term contamination potential – especially via water, soil and air – is often overlooked in conventional waste management frameworks,” emphasised Singh.

FROM LAB TO FIELD

The IIT Bombay team’s research has revealed promising properties in both RA and RPB, which could revolutionise the use of secondary materials in civil engineering.

Singh elaborated on the mechanical characteristics, “RA and RPB exhibit significantly lower stiffness and higher deformability than natural aggregates, which makes them suitable for specific geoenvironmental applications but limits their use under high structural loads.”

While these properties may exclude them from load-bearing infrastructure, they open up opportunities in other areas. “Despite their lower mechanical strength, both materials demonstrate promising insulation characteristics and environmental safety under controlled conditions,” Singh added.

Thermal and electrical insulation capabilities are where these materials truly shine. “Both RA and RPB have superior thermal resistivity compared to standard sand, confirming their suitability for thermal insulation. Electrically, dry RPB shows the lowest conductivity, making it highly suitable for electrical insulation applications. Both materials also act as excellent dielectric materials over a broad frequency range,” Singh explained.

These characteristics make them ideal for construction projects where insulation and resistance to extreme temperatures or electrical fields are critical, such as in utility corridors or specialised building applications.

However, the journey from laboratory research to real-world applications is not without its challenges. “The lower stiffness of RA leads to higher vertical deformation under applied loads, making them less suitable for high-load applications such as base layers of highways,” Singh pointed out.

“However, they are ideal for lightweight fill applications like embankments or drainage layers, where flexibility and energy absorption are more beneficial than stiffness,” he added.

This insight highlights the potential for using RA and RPB in applications where traditional materials fall short, such as in earthquake-prone regions or on unstable soils where flexibility can mitigate damage. The process of creating RA and RPB depends heavily on the methods used to shred and process waste tyres.

SHREDDING METHODS: BALANCING COSTS AND PERFORMANCE

Singh outlined the pros and cons of various shredding technologies. “Ambient shredding is cost-effective but produces rough-surfaced particles, which exhibit better interaction in cement and polymer composites,” he noted. “Cryogenic shredding yields smoother particles with a broader size distribution but poorer bonding characteristics, and the created particles are generally suitable for turf or sports surfaces. Water-jet grinding offers finer control over particle size but comes at high energy and equipment costs.”

Each method results in materials with distinct properties, influencing their performance in construction applications.

Real-world validation is a crucial step in advancing this technology. To this end, IIT Bombay has partnered with GRP India, a leader in rubber recycling.

“We are currently collaborating with GRP to venture into production and field applications of these sustainable aggregates,” Singh revealed. “This partnership provides a foundation for scaling up through industrial-grade shredding, blending and real-world performance validation.”

These collaborations not only bring academic research closer to commercial implementation but also offer a model for future partnerships between academia and industry.

Of course, environmental safety remains a central concern in adopting new construction materials, especially those derived from waste. Leaching of metals and organic contaminants can pose long-term risks if not properly managed.

Singh’s team addressed these concerns through rigorous testing. “ICP-AES analysis showed that heavy metals like Pb and Zn are present in low concentrations, well within permissible limits,” he reported. “Previous studies corroborate that such materials typically stay within permissible toxicity limits under standard conditions. However, long-term leaching behaviour under varied field conditions remains necessary to confirm safety under varying environmental exposures.” This underscores the need for comprehensive testing and monitoring to ensure environmental safety.

THE ROAD AHEAD

Looking forward, IIT Bombay’s research agenda is ambitious. Singh described plans for further experimentation to expand the applications of RA and RPB. “We are currently planning long-term loading-unloading experiments and elevated temperature testing to establish the thermo-mechanical response of RA and RPB under realistic field stresses,” he said. “These experiments aim to address limitations in durability data and expand application potential. Also, future experiments will simulate realistic landfill environments, including interactions with leachate, microbes, humidity and temperature, to understand long-term behaviour.” Such studies will be essential for certifying these materials for broader use in civil engineering.

Could tyre-derived materials eventually replace traditional aggregates in certain applications? Singh is optimistic. “Yes, particularly in non-structural or semi-structural applications such as leachate drainage layers, landfill covers, thermal insulation barriers and lightweight embankments. The lightweight, high porosity and insulation capabilities of the RA and RPB present unique advantages that traditional aggregates cannot provide,” he said.

This vision aligns with global efforts to promote circular economies and reduce reliance on finite natural resources.

Responding to his expectations from the industry, Singh stated that stakeholders need to support the integration of sustainable materials into mainstream construction.

“The message I would like to convey to the academicians, tyre industry stakeholders and policymakers is to embrace innovation through cross-sectoral collaboration. Sustainable solutions like RA and RPB not only offer environmental remediation but also open new markets for green construction materials. With the right policy incentives, certification frameworks and industry support, we can mainstream these materials and accelerate the transition towards a circular, resilient economy,” he said.

IIT Bombay’s work exemplifies how innovative research, when coupled with industry collaboration and policy support, can turn a pressing environmental problem into a sustainable solution. By reimagining waste as a resource, Singh and his team aim to not only address the tyre waste crisis but also lay the groundwork for more resilient and eco-friendly infrastructure in the future.

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Pirelli has confirmed that all five of its new slick tyre compounds will be used during the first three races of the 2026 Formula One season, beginning with Australia, China and Japan.

The Italian tyre supplier said the compound selections for the opening races mirror the approach taken in 2025, with nominations spanning from the hardest to the softest compounds to suit varying circuit demands.

For the season-opening Australian Grand Prix in Melbourne, scheduled for March 6–8, teams will have access to the C3, C4 and C5 compounds. The same combination in 2024 led to a two-stop race strategy using all three tyres. Earlier this year, however, variable weather conditions limited the use of slicks, with intermediate tyres required for much of the race.

At the Chinese Grand Prix in Shanghai, from March 13–16, Pirelli has selected the mid-range compounds: C2, C3 and C4. The 5.451-kilometre circuit, which was fully resurfaced this year, places average lateral and longitudinal loads on the tyres, with greater wear on the left-hand side of the car. Shanghai will again host the first sprint weekend of the season.

Suzuka, which hosts the Japanese Grand Prix from March 27–29, will require the hardest allocation, with C1, C2 and C3 nominated. The circuit is regarded as one of the most demanding on tyres. In 2025, low track temperatures and reduced graining allowed drivers to complete the race with a single pit stop, whereas higher thermal degradation in 2024 required at least two stops.

Drivers will arrive in Melbourne after an extended pre-season testing programme. The first test will take place behind closed doors in Barcelona from January 26–30, marking the first on-track running of the new tyres on 2026-specification cars. Each team will select three days of running during the five-day test. Two further tests will be held in Bahrain, from February 11–13 and February 18–20.

Pirelli said the use of all five slick compounds across the opening races will allow it to assess performance gaps between the tyres under competitive conditions, as well as their resistance to graining and overheating. The data will be used to inform compound selections for the European rounds later in the season.

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Shandong Dawn Polymer Material Co., Ltd has agreed to acquire an 80 per cent stake in Ningbo SK Synthetic Rubber Co., Ltd for RMB515.97m, as the Chinese polymer materials group seeks to extend its elastomer value chain and strengthen its EPDM rubber capabilities.

Dawn Polymer’s board approved the transaction on 10 December 2025. The company will use internal funds to purchase the stake from SK Geo Centric Investment Hong Kong Limited. Upon completion, Ningbo SK Synthetic Rubber will become a controlled subsidiary and be included in Dawn Polymer’s consolidated financial statements.

The acquisition is subject to shareholder approval but does not constitute a related-party transaction or a major asset restructuring under Shenzhen Stock Exchange rules, the company said.

To support stable operations following completion, certain patents, proprietary technologies and trademarks related to Ningbo SK’s products are expected to be transferred to Dawn Polymer by affiliates of the seller, SK Geo Centric Co., Ltd and/or SK Innovation Co., Ltd. The intellectual property transfer, which has not yet been finalised, is capped at RMB 64.7 m based on an assessment as of 30 June 2025.

Founded in 2012, Ningbo SK Synthetic Rubber is based in the Ningbo Petrochemical Economic and Technological Development Zone. It focuses on the production and sale of EPDM rubber, along with related technical services.

As of 30 June 2025, the company reported total assets of RMB783.0m and net assets of RMB343.8m. Revenue for the first half of 2025 was RMB568.5m, according to audited financial statements.

An asset-based valuation placed the company’s net asset value at RMB647.3m, representing an increase of 88.27 per cent over book value, primarily due to the revaluation of fixed and intangible assets.

Dawn Polymer said the acquisition would enhance its integrated “polymerisation–modification–application” industrial chain. EPDM rubber is a key raw material for the company’s dynamic vulcanisation products, and in-house production is expected to reduce reliance on external suppliers and improve supply chain resilience.

The company cautioned that the transaction remains subject to regulatory approvals and integration risks following completion.

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