The tyre industry is undergoing a profound transformation, driven by sustainability, digitalisation and material innovations. As manufacturers push the boundaries with high-silica compounds, recycled rubber and alternative materials like dandelion rubber, the mixing process faces increasing complexity. Traditional methods struggle to maintain efficiency, necessitating advanced technologies like HF Mixing Group’s Tandem mixing and smart solutions. With automation, and precision engineering, the industry is redefining efficiency and sustainability.

Tyres are a sheer example of impeccable chemical engineering. From passenger car radials (PCR) to off-the-road (OTR), these technical marvels can carry loads weighing tonnes even in the deadliest of roads. For centuries, they have been the backbone of logistics, transportation and more.

But making a tyre is not an easy task. It involves a tremendously meticulous process ranging from raw material selection to mixing compounds for deriving the exact formula that gives these rubber casings durability, elasticity and more.

As the global tyre industry undergoes a transition in every critical aspect, it also sees a change in compounds that go into mixtures. This in turn paves the way for upgradation in technologies.

According to HF Mixing Director of Product and Services, Nils Spier, “The growing use of silica in passenger tyres is reshaping the industry with specifications now reaching 100, 130 and even 180 parts per hundred rubber (PHR). Levels above 150 PHR have recently gained traction, particularly in the premium segment, where high-performance tyres demand lower rolling resistance and improved wet grip.”

On the other hand, he revealed to Tyre Trends that increasing silica content presents technical challenges. Standard single-mixer setups face limitations due to the need for adequate silanisation time. When more silica is added, the process becomes more complex and time-consuming. HF Mixing Group’s Tandem mixing technology addresses this by transferring the process from an upper to a lower mixer, preventing capacity losses and optimising mixing efficiency.

“Dispersion is another critical factor as silica’s inherent stickiness complicates processing. The upper mixer completes the dispersing task, utilising a geometry established in the industry for over 20 years. The latest-generation PES7 mixer builds on this, ensuring the same high-quality results. Once the compound moves to the lower mixer, further refinements occur. A specialised bottom mixer rotor TRC, developed to enhance cohesion and compacting, helps mitigate issues where certain components tend to crumble. Without this step, batches risk fragmenting into plates and uneven portions, complicating further processing. The Tandem mixer’s rotor system ensures that the full batch remains intact, facilitating smooth transfer onto a mill or twin-screw extruder,” he added.

In a nutshell, the Tandem mixing technology allows tyre manufacturers to accommodate higher silica content without compromising processing efficiency or final product quality.

HF’s latest advancements in mixing technology are delivering notable efficiency improvements, particularly in intermeshing rotor systems. The PES7 rotor, introduced around two years ago, has now been successfully deployed at multiple customer sites, showing strong results in both new and retrofit applications. The rotor upgrade offers an increased mixer empty volume plus higher possible fill factors, resulting in a 10–15 percent increase in throughput without compromising cycle time or product quality.

UPGRADING MIXING TECHNOLOGY THROUGH SMART DIGITAL SOLUTIONS

According to Spier, “Tandem and the smart digital mixing solutions represent a holistic approach to optimising the mixing process. The smart final mixing solution is a software and service concept developed by HF, designed to work in close collaboration with customers. The process begins with defining the customer’s target recipe and process parameters, followed by calibration tests conducted on-site.”

Calibration tests involve capturing the fingerprint of the mix including rotor speed, drive data, temperature control unit settings and ram seating time. This data is then processed through the company’s proprietary algorithms and material models, which simulate various mixing scenarios to identify optimal process parameters.

The simulation models predict key variables such as batch temperature development at different rotor speeds and the impact of ram lift adjustments to improve compound aeration. This approach eliminates the need for extensive design of experiment, accelerating the optimisation process without compromising on productivity of the production equipment.

The smart mixing solution is specifically designed for HF mixers as the company has precise knowledge of the machine parameters, cooling surfaces and other mixer-specific properties. The validation trials conducted post-simulation have demonstrated cycle time reductions up to 20 percent, translating into significant efficiency gains for manufacturers.

Moreover, the company’s smart mixing approach optimises key parameters to enhance energy efficiency and quality in the mixing process. Cycle time is a primary focus with proprietary algorithms minimising unnecessary processing steps while ensuring uniform distribution and dispersion of the curative package.

Rotor speed plays a crucial role as it must be adjusted at different phases of mixing. A higher speed may be beneficial in the initial dispersion stage, but excessive speed leads to rapid temperature increases, negatively affecting compound properties. The company’s models balance rotor speed, energy efficiency and temperature for optimal results.

Lastly, fill factor is essential for both quality and efficiency. Overfilling can result in uneven mixing and longer processing times, while underfilling reduces throughput and jeopardises batch quality. The company’s Smart Final Solution ensures that the fill factor is set to an ideal level for maximum quality and throughput.

TECHNOLOGICAL INCLUSIVITY

The company’s approach to smart mixing is currently data-driven and reliant on process specialists, but the role of artificial intelligence (AI) in this field is expected to grow. “While AI has the potential to make autonomous decisions and process adjustments in the future, we still integrate human expertise alongside digital tools to ensure process reliability. Factors such as installed downstream equipment, mixer conditions and on-site variations must be considered, which currently require operator input. However, we are already exploring AI-driven solutions such as predicting batch temperature, optimising carbon black incorporation and refining oil dispersion, which could eventually enhance process automation,” informed Spier.

While digitalisation is a key part of the company’s transformative roadmap, AI’s role is still in development. Instead of full AI automation, it employs advanced models and algorithms that run extensive simulations to optimise mixing conditions without compromising quality. These models provide real-time feedback on the best possible process adjustments, delivering improvements in efficiency, quality and consistency.

Alluding to whether older mixers installed 5 to 10 years ago can be retrofitted with recent upgrades, he noted, “There is a possibility of retrofitting smart solutions to enhance its capabilities. Rather than relying solely on AI, we offer in-line process monitoring, where historical mix data is used to establish a reference baseline with tolerance bands. This allows for real-time adjustments.”

The mixing process is fully automated with step-related control systems defining key parameters such as mixing time, specific energy input and rotor speed per step, batch temperature to ensure precision and consistency. Every mixing step can be supported by HF’s unique intelligent controller technology such as intelligent Ram control iRam, the HF constant temperature controller or iXSeal Dust Stop Lubrication Controller.

PROCESS ADAPTATION

Tyre makers are increasingly experimenting with alternative materials, such as recycled rubber and dandelion-derived compounds, which significantly impact the mixing process. Adjustments are necessary to maintain efficiency and quality, as non-traditional materials alter torque curves and require parameter modifications.

Moreover, different category of tyres requires different mixing processes due to variations in tread compound formulations. Passenger car tread compounds typically differ from OTR formulations, necessitating specific dispersion techniques to achieve the desired performance characteristics.

With that said, it is prudent that companies adapt to changing processes fuelled by market demand. “The company provides a range of rotor solutions to optimise these mixing processes. Tangential rotors are designed to enhance master batch dispersion, especially the NST rotor, ensuring uniformity in the compound. ZZ rotors are mainly used for final batch production, offering precision in mixing the final formulation. In addition, the ZZ rotor geometry has proven strong performance in Master Batch Silica Processing. Additionally, intermeshing rotors are employed to manage specialised compounds, providing better control over the mixing process for unique material requirements,” revealed Spier.

Furthermore, material innovations are significantly impacting the mixing process, requiring process adaptations to maintain efficiency and achieve consistent final results. The use of alternative materials such as recycled rubber or non-traditional sources like dandelion rubber, rCB and other recycled materials alters the torque curves during mixing. These changes necessitate adjustments to mixer parameters, ensuring optimal dispersion and processing without compromising product quality.

To support customers in navigating these challenges, HF’s process experts collaborate closely with them through the technical centre in Germany and worldwide operating process engineers. By testing new processes before full-scale industrialisation, the company helps identify and resolve potential issues in advance.

INDUSTRY SHIFTS

The shift towards premium tyres is shaping the European, Asian and North American markets differently. In Europe, manufacturers are increasingly focusing on premium and OTR tyres while scaling back production of 15–17-inch models and consolidating operations.

This shift is driving higher demand for advanced compounds and increased silica usage. However, capacity expansions remain limited with most investments directed towards equipment upgrades rather than new production facilities.

In Asia, particularly in India and China, greenfield projects are on the rise due to strong automotive demand. This expansion reflects the region’s growing role in the global tyre industry as manufacturers invest in new facilities to meet both domestic and export needs. North America, on the other hand, is seeing a mix of replacement investments and selective large-scale expansions with companies balancing modernisation efforts and strategic growth.

Beyond these key regions, North Africa, specifically Algeria, Morocco and Egypt, is emerging as a new manufacturing hub. This region is gaining traction in the global tyre industry, an area where it previously had little presence. With increasing investment and infrastructure development, North Africa is positioning itself as a competitive player in tyre production.

With many manufacturers shifting to smaller campaign to accommodate different tyre recipe, flexibility in the mixing process has become essential. HF’s automation system is designed to handle these challenges by allowing quick modifications to production plans.

Manufacturers can adjust torque, batch sizes and compound quantities without causing disruptions. Additionally, the manufacturing execution system ensures seamless execution, making even short production runs of 5 to 10 batches efficient and cost-effective.

MARKET EXPANSION

Besides Europe, Asian markets such as China and India remain key growth locations for the company. As manufacturers in these regions adopt new technologies to meet evolving industry standards, the demand for efficient and adaptable mixing solutions continues to rise.

“We continue to invest heavily in innovation and research and development to grow in the Asian market. Allocating three percent of our revenue to innovation and 4.5 percent to development, the company ensures that 35 percent of its projects focus on sustainability. By maintaining technology leadership, we deliver high-quality, high-functionality equipment that supports the growth of new and established manufacturers in the region,” informed Spier.

While HF is known for its high-precision machines used by top-tier tyre manufacturers, it also caters to tier 2 and tier 3 players. The company supplies to many smaller manufacturers.

On the context of sustainability, Spiers noted, “Sustainability is a core focus of our research and development strategy, aligning with the ambitious environmental targets set by tyre manufacturers worldwide. We integrate sustainability by developing energy-optimised mixers with efficient drive setups, introducing new hydraulic power units that significantly reduce power consumption and implementing incremental efficiency improvements such as enhanced heat management to extend machine longevity.”

Lastly, the company provides comprehensive service beyond commissioning, including operator training, process optimisation and trouble-shooting, round-the-clock support via ticket and hotline systems and fast-response local service teams across China, South-East Asia, India, North America, North Africa and Europe.

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Titan International has elevated Kendra Mann to the role of Director of Aftermarket Sales for the Titan and Goodyear agricultural tyre lines. In this capacity, she becomes a key member of Paul Hawkins’ North American aftermarket leadership team, where she will oversee strategic direction and operational execution within the aftermarket channel. This appointment underscores Titan’s ongoing commitment to strengthening its agricultural aftermarket presence as the company continues to focus on growth and dealer alignment across North America.

With over two decades in the tyre industry, Mann brings extensive expertise to her new position, including the last eight years spent at Titan. Her previous roles there ranged from OEM Account Manager to Field Sales Manager overseeing a multi-state territory, where she drove aftermarket expansion. Prior to joining Titan, she spent 15 years at GCR Tires and Service managing commercial tyre operations. In her latest capacity, she will work closely with field sales, product management and dealer networks to ensure seamless coordination across the Titan and Goodyear agricultural portfolios.

Looking ahead, customers can expect a sharper focus on aligning field support with sales and marketing strategies, reinforcing the dealer partnerships that form the backbone of daily service. Through this leadership change, Titan aims to enhance responsiveness and deliver a more cohesive experience across the agricultural aftermarket channel.

Paul Hawkins, SVP of Aftermarket Sales, said, “Kendra has earned this. She understands the business, she understands the customer and she knows how to move the needle for our aftermarket business. This is the right person in the right role at the right time for Titan agriculture.”

Scott Sloan, Global Ag/LSW Product Manager, said, "Kendra has built valuable relationships in the field. She knows how dealers operate and what customers need on the ground. That perspective is going to make a real difference in how we execute across the ag aftermarket."

Kim Boccardi, VP of Marketing, said, "Kendra is the kind of person who makes everyone around her better. She's put in the work, she knows the industry, and watching her step into this role is exactly what you hope to see. Titan is better with her joining our leadership team."

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Linglong Tire has announced a leadership transition, with Zhou Lingkun appointed as President and CEO as of 16 March 2026. Assuming full operational command, his primary objective is to refine the company’s corporate governance structure. Meanwhile, former President Wang Feng, whose family retains controlling shares, continues as Chairman of the board.

A 1974-born graduate of Zhejiang University, Lingkun brings a robust background from global consulting and IT firms, including Arthur Andersen, IBM and Hewlett-Packard. His most recent role was President of the Enterprise Technology and Performance Business Group at Deloitte China, where he also served as a board member.

This strategic appointment separates operational leadership from familial shareholding, positioning Lingkun to steer daily management while leveraging his extensive international expertise to drive organisational efficiency.

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KraussMaffei Group is set to implement a leadership transition at its US subsidiary, KraussMaffei Corporation (KMC). Brett Greenhalgh, President of KMC, will retire at the end of May 2026, marking the conclusion of his tenure. His departure will also see him step away from the industry and leave United States for a three-year period, during which he and his wife will devote themselves to a church mission project of deep personal significance.

Over the past two years, Greenhalgh has served as a pivotal leader for KraussMaffei, providing steady direction for the US organisation. His foresight in preparing for the future is evident in his deliberate cultivation of an internal successor, John Fini, ensuring a seamless transition grounded in business continuity and institutional knowledge. Taking the helm on 1 June 2026, Fini brings a customer-first philosophy forged through extensive hands-on operational experience. Currently serving as Vice President of Digital Solutions and Service North America, he has been a member of the KraussMaffei Corporation leadership team since 2022.

Fini’s background includes leading large, multidisciplinary teams, strengthening service and aftermarket capabilities and driving gains in operational performance, employee engagement and financial results. Prior to joining KraussMaffei, he held roles at Rehrig Pacific Company, a California-based family-owned plastics manufacturer and longtime KraussMaffei customer, where he improved operations across multiple manufacturing sites. A New York native, Fini holds a Bachelor of Science in Mechanical Engineering from the University of North Carolina at Charlotte.

Brett Greenhalgh

Greenhalgh said, "I am grateful for my time at KraussMaffei and for the collaboration with such a dedicated team in the US and internationally. Stepping back and giving my life a new direction has not been an easy decision. But I look forward to serving our church community together with my wife Janice. As a teenager, I participated in a similar project that profoundly shaped my life and values. Now I want to give others the same opportunity to experience something similar. The next three years abroad will be an exciting and rewarding time for both of us."

Alex Li, CEO, KraussMaffei Group, said, “We thank Brett for his exceptional dedication and strategic foresight. Thanks to the early identification of John Fini as an internal successor, we can ensure seamless continuity in serving our customers with the reliability and quality they expect. The strong collaboration between our US and European teams has been instrumental in advancing KMC’s success, and this partnership will remain a key pillar of our future development. While we regret Brett`s decision to step down, we fully respect and support his choice to pursue a personal mission close to his heart. We wish Brett and his wife all the very best for the years ahead.”

Fini said, “KraussMaffei’s success has always been driven by its people, its technology and its customers. I’m honoured to lead this organisation and build on the strong foundation our teams have created together. I would like to thank Brett Greenhalgh for the coaching, guidance and support as part of a thoughtful, long-term leadership transition designed to ensure continuity and sustained growth.”

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LAUGFS Corporation (Rubber) Ltd, a prominent Sri Lankan manufacturer and exporter of high-quality industrial solid tyres, has announced a significant leadership transition, naming Chinthaka Wegapitiya to the role of Managing Director and Chief Executive Officer. Wegapitiya’s ascent to this top executive position follows a tenure within the company where he previously held the responsibilities of General Manager and Chief Operating Officer. His background is rooted in deep expertise across both operational management and long-term strategic planning, providing a strong foundation for his new mandate.

In his current capacity, Wegapitiya is entrusted with the comprehensive leadership of the organisation’s strategic direction, tasked with steering the company towards an expanded global presence while working to increase its competitive market share. His purview encompasses the oversight of sophisticated, high-tech manufacturing operations, with a particular focus on the production of premium solid tyres.

Beyond operations, he is responsible for directing international marketing initiatives and strengthening the company’s brand identity in competitive global markets. Innovation also falls under his leadership, driving research and development efforts to create advanced engineering solutions and tailor products to precise customer specifications, all while championing sustainability initiatives within the global rubber export industry.

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