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.

Discount Tire has earned a prominent position on Glassdoor's Best Places To Work 2026 list, ranking 14th in Consumer Services and within the top 100 US employers. This distinction is awarded to organisations with over 1,000 employee reviews on Glassdoor and a minimum rating of 3.5. For the Scottsdale-based retailer, with more than 1,250 locations nationally, the honour underscores a long-standing commitment to its workforce.

The company cultivates a people-first culture for its over 30,000 employees by providing substantial career growth, thorough training, leadership development and competitive benefits. This philosophy, centred on serving others and empowering personal goals, previously earned Discount Tire top Glassdoor rankings from 2018 through 2021. The latest recognition reaffirms its status as an employer dedicated to fostering a supportive and progressive workplace.

Dean Muglia, Chief Executive Officer, said, "We treat our people like family. We're honoured to be recognised by both current and former employees and Glassdoor as a best place to work. We strive every day to deliver the most inviting, easy and safe experience possible for our people and our customers."

Michael Zuieback, Executive Chairman, said, "Through six and a half decades of growth, our primary commitments have stayed true: We want to take care of people and help make more dreams come true.”

Radar Tyres has entered a significant, multi-year global partnership with Cricket South Africa, a strategic move to build its brand within a sport enjoyed by a worldwide audience. This alliance grants the company headline sponsorship for the Proteas Men’s and Women’s T20 International sides, alongside associate partnership status for their ODI and Test matches. Radar will also be the headline partner for South Africa’s Under-19 national teams.

The collaboration provides substantial visibility, featuring exclusive logo placement on both match and training kits, with the new T20I apparel already unveiled. For Radar, this investment is a key step in leveraging high-profile platforms to enhance global brand recognition, all while maintaining its commitment to providing high-quality, value-driven tyre products.

G S Sareen, President and CEO, Omni United, said, "Becoming the Global Partner of the Proteas marks a significant milestone in Radar Tyres' global brand journey and reflects our belief in sport as a powerful platform to build brand equity, strengthen dealer support, enhance trust and credibility and connect with households worldwide. Through this partnership, we are able to engage with cricket fans both locally and globally while reinforcing Radar Tyres' as a reliable, performance-driven brand committed to delivering premium-performance at an accessible price point."

Pholetsi Moseki, Chief Executive Officer, CSA, said, "CSA is extremely proud to partner with Radar Tyres, an organisation that shares our values and commitment to excellence. This partnership is a significant milestone, securing support not only for our senior teams but for our junior teams as well. This partnership reflects our deliberate approach to working with like-minded organisations, guided by a long-term vision of developing the game, supporting our players and delivering memorable experiences for fans. Radar Tyres' support also reinforces CSA's commitment to excellence and inclusion, strengthening our ability to drive high performance across all levels."

For the second consecutive year, the Alliance for the Future of Tyres (AZuR) has been shortlisted for the German Award for Sustainability Projects, following its 2025 win. This renewed nomination underscores the jury’s recognition of AZuR as a pioneering force in sustainability, particularly for its dedicated efforts to advance tyre retreading as a core component of a circular economy. The 2026 award ceremony will be held under the patronage of Brigitte Zypries on 17 September in Berlin.

AZuR’s multifaceted initiative extends well beyond theoretical advocacy. Its work gained significant international attention with the Retreading Summit, held in September 2025 at KRONE Trailer in Werlte. This event convened experts from industry, politics, academia and media for two days of intensive dialogue on the potential, challenges and necessary policy frameworks for tyre modernisation, leading to the launch of concrete action plans. Furthermore, the alliance drives progress through strategic communications and direct support for flagship projects, such as the new passenger car tyre retreading facility established by Rigdon in Pfaffenhofen.

Central to AZuR’s mission is transforming public perception by demonstrating that worn tyres are valuable resources, not waste. Through ongoing awareness campaigns, it highlights the substantial ecological and economic benefits of retreaded tyres, which can be refurbished multiple times to conserve raw materials, reduce climate impact and offer cost-effective solutions. The German Award for Sustainability Projects, judged by a panel chaired by Prof Dr Claudia Kemfert of DIW Berlin, evaluates entries based on their innovation, impact and relevance to a sustainable future. AZuR’s repeated shortlisting affirms that its model for a tyre circular economy is a replicable and exemplary system with groundbreaking potential.

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.