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."
PCBL Chemical Appoints Sanjay Ghawghawe As Chief Manufacturing Operations
- By TT News
- January 09, 2026
PCBL Chemical Limited said it has appointed Sanjay Prabhakar Ghawghawe as Chief Manufacturing Operations and Executive Director, with effect from 5 January 2026.
In its disclosure, PCBL said that Ghawghawe’s appointment is on a full-time basis and does not carry a fixed term.
Ghawghawe brings about 29 years of industry experience, including roles at Owens Brockway, Hindustan Unilever, Reliance Petro Marketing, Asian Paints and Avery Dennison (India). His most recent position was Chief Manufacturing Operations at Pidilite Industries.
He holds a bachelor’s degree in mechanical engineering from Nagpur University and a postgraduate diploma in business management from the Institute of Business Management and Research, Pune University. The company said there are no relationships between Ghawghawe and the directors of PCBL.
CarbonX Co-Founder Daniela Sordi Appointed Fellow of Netherlands Academy of Engineering
- By TT News
- January 08, 2026
CarbonX has announced that Daniela Sordi, its Chief Technology Officer and co-founder, has been appointed a Fellow of the Netherlands Academy of Engineering, the country’s leading body representing excellence in engineering, technology and applied scientific innovation.
Sordi is one of 15 experts selected for the Fellowship, which recognises engineers who have demonstrated significant impact in their fields and who contribute to major societal transitions.
Sordi is internationally recognised for her work on advanced three-dimensional structured carbon materials designed to improve lithium-ion battery performance. She has more than 17 years of experience across research and industry, translating chemistry and materials science into manufacturing technologies.
At CarbonX, she has led the development of battery materials that the company says charge faster, last longer and are up to five times more sustainable than conventional synthetic graphite. Under her technical leadership, the company has secured funding from the European Innovation Council Accelerator and advanced efforts to strengthen Europe’s autonomy in energy-storage materials.
“Daniela’s appointment to the NAE is an outstanding recognition of her ability to bridge groundbreaking science with high-impact industrial innovation,” said Rutger van Raalten, chief executive of CarbonX. “Her work lies at the core of our mission to enable cleaner, more efficient, and more sustainable energy technologies on a global scale.”
The appointment also highlights Ms Sordi’s role as a visible advocate for engineering careers, particularly for women entering deep technology and advanced materials. Her career is frequently cited as an example for students pursuing technical and innovation-led professions.
The Netherlands Academy of Engineering brings together senior engineers from academia, industry and applied research. Its members contribute to national and international innovation agendas and advise on technological responses to challenges such as climate, energy, health and digitalisation.
Toyo Tires Breaks Barrier With Concept Tyre Using 96.5% Sustainable Materials
- By TT News
- January 08, 2026
Toyo Tires has achieved a new benchmark in sustainable tyre design with a concept model composed of 96.5 percent renewable and recycled materials. This marks the company’s highest sustainable content to date, surpassing its own previous 90 percent sustainable concept and demonstrating ongoing progress in substituting traditionally hard-to-replace components without sacrificing performance.
The materials are categorised as either renewable, constituting 61.5 percent of the tyre, or recycled, making up the remaining 35 percent. Renewable inputs are derived from biomass and plants, including specialised rubbers, polyester fibres, silica from rice husk ash and oils. The recycled portion incorporates carbon black, steel components and a novel CO₂-derived rubber developed with the University of Toyama. A key technical breakthrough involved successfully integrating recycled sulphur and zinc oxide, which are vital to the tyre manufacturing process and have historically presented significant replacement challenges. This integration was accomplished using the company’s established production and compounding expertise.
This concept represents a critical step toward Toyo Tire’s publicly stated goals of utilizing 40 percent sustainable materials by 2030 and achieving full 100 percent adoption by 2050. Beyond its material composition, the tire has also earned a top-tier ‘AAA’ rolling resistance rating in Japan. This high rating signifies extremely low energy loss during operation, which can help extend electric vehicle driving range and reduce overall lifecycle greenhouse gas emissions.
Moving forward, Toyo Tire intends to advance its research and technical development with the objective of transitioning these innovative material applications and design principles into future commercial products. This effort is part of the company’s broader commitment to fostering a more sustainable mobility ecosystem.
Shakti Cords Appoints Purushothama Kini As Managing Director
- By TT News
- January 07, 2026
Shakti Cords Pvt. Ltd has appointed Purushothama Kini as managing director of Shakti Cords and its group companies, marking a leadership transition at the textile reinforcements manufacturer.
Kini brings more than three decades of experience in the industrial and technical textile sector. His background includes manufacturing excellence, operational transformation, quality systems and global customer engagement.
The company said his leadership experience in driving sustainable growth, strengthening processes and supporting organisational development would be a key asset as Shakti Cords continues to position itself as a reliable partner to customers.
Shakti Cords was established in 2003 and manufactures textile reinforcements for the rubber industry. Its product range includes single-end dipped cords, industrial hose yarns and single-end tyre cords made from polyester, aramid, PVA, nylon 6/66 and rayon. These materials are used in power transmission belts, industrial hoses and performance tyres.
The company said the use of high-modulus, low-shrinkage dipped cords and high-tenacity braiding yarns improves strength and operational performance across these applications.
Shakti Cords, as per the company website, has a total production capacity of 3,000 tonnes a year for single-end dipped cords and dipped industrial hose yarns. It holds the largest share of the Indian market for dipped single-end yarns and cords.
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