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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Seasoned tyre industry executive Manish Maharaj has embarked on a new professional chapter, joining Balkrishna Industries Ltd (BKT Tires) in a senior leadership capacity after a distinguished 11-year tenure with Apollo Tyres Ltd.

In his new role at BKT Tires, Maharaj has been appointed General Manager and Head of Business Finance, where he will focus on enhancing financial strategy, driving performance-driven growth, and building scalable systems to support BKT’s global expansion ambitions.

“I am thrilled to begin a new chapter with BKT Tires,” said Maharaj.

Maharaj’s career at Apollo spanned multiple strategic roles in one of the world’s leading tyre manufacturers, most recently serving as Regional Chief Financial Officer for South East Asia, the Middle East and Africa, and later as Business Head for South East Asia. In these capacities, he led multi-market commercial and financial operations, driving robust business performance across diverse cultural and economic environments.

At Apollo, Maharaj was responsible for charting growth strategies in fast-evolving markets, strengthening distributor partnerships, and reinforcing brand positioning across key ASEAN economies. His leadership coincided with initiatives to expand premium brand presence in Thailand, Malaysia, Philippines & South Korea and foster deeper retail engagement across the ASEAN region.

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Anyline, a prominent provider of AI-driven mobile tyre inspection technology, is entering a new phase of growth under a new leadership structure. Christoph Braunsberger has been appointed Chief Executive Officer, assuming the role immediately. He succeeds Co-Founder Lukas Kinigadner, who will now serve as Chief Revenue Officer, concentrating on worldwide sales growth, partnership development and expanding the company's global customer base.

Braunsberger originally joined the company in 2019 as Chief Financial Officer and Managing Director. His extensive background in finance, strategy consulting and investment banking, including prior experience at PwC, equipped him to establish the operational foundations necessary for international scaling. He was instrumental in leading the company's expansion into the United States, overseeing significant funding initiatives, and serving as President of its North American operations.

This executive transition occurs as the company experiences rapidly accelerating enterprise adoption across multiple sectors. Logistics, manufacturing, retail and the public sector are all key markets, with the automotive industry representing a particularly strong growth area. The proven industrial scalability of the technology is demonstrated by a recent milestone of 100 million tyre scans conducted globally. This achievement reinforces the robustness of the computer vision platform, which is designed to address a wide spectrum of visual inspection and data capture needs for large-scale commercial and industrial clients. The leadership change is designed to sharpen the company's focus on an AI-centric operational approach, leveraging its current commercial momentum and broadening application across diverse industries.

Lukas Kinigadner, Co-Founder and Chief Revenue Officer, Anyline, said, “This leadership transition reflects where Anyline is today. Our AI platform has achieved clear product-market fit across industries, with strong and accelerating traction in automotive. The company is on a clear path towards profitable growth. Christoph is the right CEO for this phase, and I’m excited to concentrate fully on driving revenue, partnerships and customer impact.”

Braunsberger said, “Anyline’s AI is already delivering real-world impact at scale. My focus is on building on that momentum – strengthening our operating model, scaling efficiently and deepening collaboration with customers and partners as global AI adoption accelerates.”

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A new phase of strategic collaboration has begun between FARREL POMINI of the HF GROUP and WF RECYCLE-TECH, following the acquisition of a majority stake by the former. Headquartered in the UK, WF RECYCLE-TECH has developed a unique, patented pyrolysis process for transforming end-of-life tyres into valuable materials like recovered carbon black and oil. A central component of this system is FARREL POMINI's own Farrel Continuous Mixer (FCM), which efficiently processes tyres for both mechanical and chemical recycling.

This deepened partnership, building upon a minority investment made in 2021, is designed to rapidly expand the global commercialisation of this sustainable technology. The move solidifies FARREL POMINI’s commitment to pioneering circular economy solutions for the rubber and plastics sectors worldwide. By enabling greater global support and accelerating adoption, this milestone underscores the aligned vision of all involved organisations to drive innovation in sustainable industrial practices.

Paul Lloyd, President, Farrel Corporation, said, “We are delighted to deepen our partnership with WF RECYCLE-TECH and take this important step toward further commercialisation of their proven pyrolysis system. This acquisition aligns with our long-term strategy to support sustainable solutions that address global challenges.”

Jo Dennis, Managing Director, WF RECYCLE-TECH, said, “We are very pleased to become majority-owned by FARREL POMINI and HF GROUP. Being part of the HF GROUP organisation allows us to leverage a strong global support network, deep technical expertise and long-term investment commitment. This partnership significantly strengthens our ability to scale our pyrolysis system and deliver solutions to customers around the world.”

Ian Wilson, Co-CEO, HF GROUP, said, “This acquisition reflects HF GROUP’s strategic focus on enabling technologies that drive sustainable industrial growth. By combining WF RECYCLE-TECH’s patented pyrolysis process with FARREL POMINI’s technology expertise and HF GROUP’s global infrastructure, we are creating a powerful platform to address the worldwide challenge of end-of-life tyre recycling.”

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In a strategic expansion of its global footprint, Bekaert has agreed to acquire Bridgestone’s tyre reinforcement operations in China and Thailand, encompassing the tyre cord production facilities in China (Bridgestone (Shenyang) Steel Cord Co., Ltd) and Thailand (Bridgestone Metalpha (Thailand) Co. Ltd.). This move significantly strengthens the market leadership of Bekaert’s Rubber Reinforcement division, its largest business unit, which has led the global tyre cord sector for decades. The acquisition, set for completion in the first half of 2026 pending regulatory approvals, is a continuation of the division's proven strategy in integrating the captive production of major global accounts.

This transaction reinforces the enduring strategic partnership between Bekaert and Bridgestone, a leading tyre manufacturer. As part of Bridgestone's mid-to-long term plan to boost competitiveness through collaboration, the deal includes a long-term supply agreement ensuring continued provision of high-quality tyre reinforcement. For Bekaert, the integration of these two established production facilities enhances its manufacturing presence and solidifies its position in the tyre cord market.

Financially, the acquisition is projected to contribute approximately EUR 80 million in annual consolidated sales for Bekaert. The purchase involves a cash consideration of EUR 60 million, which will be drawn from the company's existing cash reserves. By securing these key assets and a lasting supply partnership, Bekaert not only expands its operational scale but also deepens its trusted supplier relationship with a pivotal global account.

Yves Kerstens, CEO, Bekaert, said, “Bekaert and Bridgestone share a longstanding strategic partnership built on mutual trust and collaboration. When the transaction closes, we are delighted to welcome the plant teams to Bekaert and remain committed to joint growth and innovation with Bridgestone. The acquisition is also a clear signal of strengthening our global leadership position in the tyre reinforcement industry.”

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