All industry leaders. One roof. One vision.

Around 400 stakeholders from the global tyre and rubber industry converged on Chennai for the third edition of the Global Tyre and Rubber Conference (GTRC), held over two days on 17 and 18 June 2026. Against a backdrop of geopolitical strain, an accelerating shift to electric vehicles and the steady thrust on artificial intelligence into every layer of manufacturing, the gathering offered an unusually candid read on where the sector stands – and how anxious and ambitious it has become about what comes next.

Mike Norman, Chief Commercial Officer of VMI Group, called it a special moment for the industry, pointing to geopolitical disruption, rising competition from China, regulatory upheaval, the EV transition and the arrival of AI as forces reshaping the business. “This is a special event for the tyre and rubber industry. The times are difficult and there are disruptions – geopolitical in nature – that are a matter of concern and underline the changing nature of the business,” he said, adding that “the technological advancements are creating new opportunities to improve efficiency, quality and performance.”

CHANGE OF TYRE MANUFACTURING ERA

The conference’s most sweeping remarks came from Arun Mammen, Chairman of ATMA India and Vice Chairman & Managing Director of MRF, who argued that growth in the sector will not simply arrive – it must be built through bold investment, scientific rigour and the courage to transform, in step with India’s Viksit Bharat 2047 ambitions.

Mammen’s central claim was structural: for more than a century, tyre engineering has rested on three pillars – durability, grip and cost. “That era is ending. The convergence of sustainability imperatives and autonomous, shared and electric vehicles megatrends are forcing a complete reimagination of what a tyre must be,” he said.

He argued that electric vehicles demand a fundamentally different tyre – one engineered for ultra-low rolling resistance to preserve range – and that this requirement collides with Indian road realities, where only about three percent of the network qualifies as national highway. That gap, he said, calls for India-specific innovation and a regulatory framework that does not trade away safety in the pursuit of sustainability.

Mammen went further, describing a future in which the tyre itself becomes intelligent. “The tyre of tomorrow will no longer be a passive mechanical component, it will be an intelligent system embedded with sensors, TPMS that will enable real-time tracking of pressure, temperature, wear, road friction, predictive maintenance and optimised fleet performance that saves lives,” he said, adding that unlocking this potential would depend on deep, sustained collaboration between OEMs and tyre manufacturers.

On the factory floor, Mammen said Industry 4.0, AI, IoT and digital twins are transforming tyre manufacturing through process optimisation and predictive quality control. He also highlighted the shift from steam-based curing to electric and induction systems, with green hydrogen emerging as a future option.

On raw materials, Mammen noted the growing need to reduce dependence on petroleum-derived inputs. He highlighted India’s natural rubber expansion, with four major tyre companies helping establish 200,000 hectares of plantations, alongside a broader push towards bio-based materials, recycled content and a circular economy.

Mammen also pointed to renewed interest in retreading and the need for more resilient, localised supply chains, including domestic production of advanced manufacturing equipment. He concluded that India’s tyre industry now has an opportunity to lead the sector’s next phase of transformation.

Peter Haan, Head of Global VM Tire at Siemens AG, a visionary tyre veteran who has played a transformative role in advancing automation, digitalisation and technological innovation in the global tyre industry, received the Tyre Trends Lifetime Contribution award. “I would like to thank my dear friends in the Indian tyre industry, my partners and customers because I learned over the years that it is all about partnership,” he said in accepting it.

SESSION ONE: BUSINESS & EMERGING TRENDS

The opening panel, moderated by Latha Chembrakalam, CEO of AutoAscend, brought together Mammen, Norman and Ian Wilson, CEO of HF Group.

Mammen described a tyre industry facing sustainability pressure, the EV transition and raw-material constraints simultaneously – a convergence upending the economics of a capital-intensive business, since EVs change the game entirely. Building new facilities takes time and heavy capital, he said, arguing for a balance between existing plants and advanced new ones, and realistic targets for green tyres given that EVs demand an entirely new specification, technology and material set. Staying close to markets matters amid geopolitical shifts, he added: global technology matters more than global manufacturing footprint, and sophistication in tyre machinery will require more data analysts, cybersecurity specialists and other skilled talent.

Norman described China as a non-legacy market that has become a major disruptor, forcing costly upgrades to technology and facilities. “We are taking a platform approach for our machines right from the development stage to ensure scalability and retrofitting,” he said. EV adoption, he noted, is outpacing the industry’s ability to keep up, though VMI’s machines already handle the lighter, tougher tyres EVs require; cell-style manufacturing may help, even if it complicates large-scale short runs, making flexibility and modularity essential. He warned that scarce skilled manpower will push more automation and, in turn, more complex machinery, and that legislation – fast-arriving – is being underestimated.

Wilson pointed to Chinese auto OEMs building greenfield facilities in Africa as a signal of changing demand. “Chinese auto OEMs are setting up greenfield facilities in Africa, indicating a demand and change for tyre makers,” he said, adding that “new tech developments like AI are set to enhance tyre development and production.” Replacing steam curing with electric systems, he added, could bring significant improvement, alongside attention to the energy efficiency of recyclability; lower rolling resistance in EV tyres is also reshaping how silica is used in compounding.

Sanjay Chatterjee, Director General of ATMA, used his address – ‘Indian Tyre Industry – Towards a Resilient and Atmanirbhar Tomorrow’ – to cite Prime Minister Narendra Modi’s remark that Indian tyre exports crossed INR 273.12 million in the last fiscal year despite headwinds, reaching more than 172 countries. “Robust tyre production and growth, natural rubber production, ERP regime and other regulations are driving Indian economic growth,” he said.

SESSION TWO: MANUFACTURING EXCELLENCE

Chaired by V K Misra, Technical Director of JK Tyre & Industries, this session opened with Dr Gerard Nijman of KraussMaffei Extrusion posing a pointed question in his talk, ‘50 Years Of Tyre Component Extrusion: Did The Piggyback Multiplex Head Reach The End Of Life?’ He explained that multiplex and rollerhead lines use a piggyback configuration to produce roughly seven to eight components, but that drawbacks – limited flexibility, capped head pressure, hydraulic dependence, poor accessibility, an over-engineered locking concept and difficulty swapping heads – mean that “it is therefore necessary to question whether it has reached the end-of-life.”

Nicola Fedele, Managing Director and Board Member at Rodolfo Comerio, described calendering as “the heartbeat of tyre production,” adding: “There are innovations (friction-free lamination) and breakthroughs (less material use and fast change over time) in the global tyre market that is worth USD 256 billion.” He said eliminating the accumulator from the calendering process delivers superior quality control and a basis for automation.

Karsten Jung of Troester GmbH & Co. KG addressed EV mobility as a megatrend driving stiffer, higher-silica compounds. “An acquisition (SC OTOMASYON) made last year is helping push automation, involving an autobook system, truck tyre spraying line and more,” Jung said. Saravana Kumar S, Managing Director of Troester India, described the company’s regional push on extrusion performance. “Much regarding regional integration is being done in terms of extrusion performance, including refurbishment, retrofitting etc.,” the MD of Troester India said.

SESSION THREE: ADVANCEMENTS IN TYRE MANUFACTURING

Chaired by Ravin Kurian, Senior GM of Product Development at MRF, this session started with the presentation of Dr Robert Hula of Vipo a.s. on bead and apex solutions, which he called among the most important components in a tyre since its inception. “Precision manufacture as a new standard is paving way for intelligent bead manufacturing and predictive maintenance process with the use of greener materials,” he said.

Robert Thomas Irwin, Vice President of Sales & Marketing at The Steelastic Company, traced the industry’s evolution from bias to radial to EV to high-performance and premium tyres. “The shift from bias tyre to radial tyre to an EV tyre to a high-performance and premium tyre is creating a need to integrate extrusion tech with conventional calendaring,” he said, citing quicker changeovers, reduced work-in-process, better traceability and labour optimisation as benefits.

SESSION FOUR: GOING GREEN & SUSTAINABLE

This session, chaired by C Harimohan, Head of Corporate R&D (Materials and Compounding) at Yokohama OHT, opened with Colin Clarke of Schill+Seilacher (Struktol), Director – Technical Sales, Schill+Seilacher (Struktol) GmbH, who argued that emerging vehicle concepts, energy-efficiency demands and higher load-bearing requirements are driving major shifts in compounding formulations. “The use of resins is increasing relative to oils in certain applications and products such as Struktol VP 1831 are witnessing growing demand as they provide excellent Silica dispersion and superior metal release,” he said.

Ralph Boehm, Senior Manager, Kuraray Europe GmbH, described the company’s liquid rubber as “a reactive plasticiser that reduces Mooney viscosity while maintaining high quality and performance,” noting two new silane-modified butadiene rubber grades suited to silica-based tread compounds and truck-and-bus radial tyres for summer and winter use.

Dr Roberto Blanco Trillo, Global Business Development Manager, Allnex, discussed sustainable cord adhesion. “The Allnex Alvonol PN870 resin enhances rubber-brass adhesion and enables excellent cord adhesion without cobalt and resorcinol to be a truly sustainable solution,” he informed.

Srikanth Chakravarthy, Managing Director of Eonix, representing China’s Zenith Steel Group, described it as operator of the world’s largest steel-cord facility. “The Zenith Steel Group in China has the biggest steel cord facility in the world with continuous capex. It is highly competitive with strong economies of scale and focusing on efficiency through vertical integration, making steel cords. It is investing in highest level of automation, making steel cords through intelligent manufacturing encompassing six plants.”

DAY TWO, SESSION FIVE: AI INTEGRATION IN THE TYRE INDUSTRY

Dr Sujith S Nair, Vice President of R&D at CEAT’s Centre of Excellence, chaired this session. In his presentation on the subject ‘In the tyre market, evolution never stops’, Marcel Berkers, VP Global Sales Tyre & Rubber, VMI Group, framed technology evolution as fundamentally about smarter machines enabling efficient use of material and energy. “The practical approach of VMI is lowest cost-per-tyre within spec,” Berkers said.

Peter Haan argued that AI in the tyre industry still has considerable distance to travel, with challenges spanning shop-floor integration and scaling across visual quality inspection, anomaly and object detection, automation programming, process optimisation and predictive maintenance – challenges he said Siemens’ shop-floor AI industrial suite is designed to democratise and scale.

Harsh Vardhan, Global Head of Digital Innovation at Apollo Tyres, spoke on industrial AI’s path from automation to autonomy. “Continuous RoIs are being registered as humans and AI collaborate,” he said, adding that “AI is set to be a force multiplier in terms of business value, CFT collaboration process, governance fusion, AI and deep-tech diffusion, and RoI.” He noted Apollo has assembled a dedicated team to integrate and scale AI, with the real competition now centred on scale versus speed – measured in cycle-time reduction and energy savings.

SESSION SIX: THE ART OF TESTING

This session, chaired by Unnikrishnan P K, Global Head of R&D Tyre Testing at Apollo Tyres, featured Dr Shaun Immel of Ametek’s MicroPoise Measurement Systems on autonomous tyre-defect detection through X-ray image analysis. “The processing works in real plants with most X-ray machines using AI and deep learning to find defects and classify a tyre objectively,” he said, citing faster setup for new defect types, clearer colour-coded visualisation of tyre structure and improved air-bubble detection that lowers misclassification and cost.

Informing that his company has over 480 installations and offers offline profile inspection (with high precision for tyre companies using laser sensor), online profile inspection, extrusion (non-contact and high precision inspection suitable for tread) and width sensor for non-contact and high precision width measurement, Lubos Hodal, Head of Sales Department, Micro-Epsilon, said on the subject ‘New technology in tyre inspection’ that they also have mould inspection system for curing, avoiding noise and blind spots; letter completeness inspection during curing; final finishing solutions such as a central marking line, colour marks on sidewall and tread and retrofit programmes for PCR and TBR. Pragnesh Mori, Managing Director of Micro- Epsilon India, said, “We are designing measuring systems and software through our Indian assembly facility in Pune. The application team there works with the European team to develop new solutions.”

Michael Mueller, Senior Sales and Key Account Manager, ZF, addressed high-speed uniformity measurement and its bearing on quality and comfort in R&D and virtual tyre development. “High speed uniformity measurement marks a new trend in terms of comfort that includes typical HSU tests, the properties gained, the effect of speed ramp versus constant speeds, resonant frequency and different road conditions,” he said. He also said that ZF developed an advanced 2026 HSU solution accounting for tyre noise, vehicle weight, road conditions, user expectations and virtual simulation.

SESSION SEVEN: SUSTAINABILITY WAY FORWARD

Chaired by Dr Sarat Ghosh, Vice President of R&D and Technology at Birla Tyres, this session opened with Anil Nair of HF Group on electrical tyre curing. Curing demands are rising alongside tyre size, he said, and EV tyres in particular require low rolling resistance, spurring innovation. “The USP of electric curing is independent control, a key advantage in terms of de-coupling temperature from pressure. The electric curing press promises higher profit,” he said.

Aki Nurminen of Black Donuts spoke on manufacturing costs, describing cost as historically a unit-economics problem, now increasingly shaped by raw materials, maintenance, fixed costs and depreciation. “Boiling down to sustainability, cost and market reality where about 90 percent of the 600 tyre industries globally are over 19 years old, the implications in terms of automation or the lack of it, the lack of efficiency and how the new entrants are taking advantage of better tech that ensure lower costs are beginning to show up in an addressable market for tyres that is growing,” he said, noting Black Donuts’ Nemus bio-based pre-mix filler.

Priyank Potnis of Planex, the Indian partner of Regom, addressed circularity and traceability for end-of-life tyres. “Regom’s technology identifies tyre specs for end-of-life tyres, including automatic evacuation of a good tyre,” he said, adding that the company has developed two machines supporting traceability, circularity and ESG compliance amid the disposal of an estimated three million tonnes of end-of-life tyres under a rapidly evolving regulatory landscape.

SESSION EIGHT: PROCUREMENT UNDER PRESSURE

The closing panel, moderated by Chakravarthy, brought together Nikhil Puri, Senior Vice President of Direct Procurement at Yokohama, and Ramanan Balasubramanian Venkat, Vice President of Procurement at Ascenso Tyres, to discuss the pressures facing tyre-maker procurement teams.

“Retaining control over the supply chain remains a constant challenge, necessitating a need for pro-active engagement, both internally and externally, with various stakeholders to ensure agility and responsiveness,” Venkat said. AI and data-driven analytics increasingly shape procurement decisions, he added, though the open question is how much reliance those tools warrant given how quickly situations can shift in ways analytics may not anticipate. He described India’s tyre ecosystem as uniquely positioned given the investment underway, arguing the industry needs a long-term perspective, close collaboration and a supplier base both locally rooted and globally capable – while flagging the shortage of natural rubber as reason to accelerate adoption of greener, sustainable alternatives.

“Dividing into pre-Covid and post-Covid eras as supply chains underwent a real litmus test leading to a fundamental shift in mindset, forcing companies to go back to the drawing board and rethink their sourcing strategies, reliance on a sole supplier has been largely abandoned and new relationship built to enhance resilience,” Puri said. The ability to modify supply chains at short notice, he added, became a critical post-pandemic capability, driving regional diversification, stronger risk management and mapping of vendors’ own supply chains, with AI now positioned to take procurement further – including predicting disruptions such as weather events.

Puri also pointed to digital twins as improving understanding of container load capacity and logistics efficiency, and suggested AI combined with augmented reality could further improve warehouse operations. He framed India’s position as a sweet spot, backed by a young population and strong growth potential, pointing to the country’s diversification of crude-oil sourcing as an example of a broader ‘glocal’ strategy – one that includes friend-shoring, or sourcing from trusted, friendly nations to build more resilient supply chains.

Not only the conference delegates but GTRC also witnessed a significant increase in the exhibitors’ participation. The exhibition area consisted of 37 stalls, with some of the participating companies taking multiple booths and some of them sharing them with their overseas principles. The response was overwhelming and marked a surge over the last edition of the conference, cementing the GTRC as a global tyre event.

Conference chairman Tom Thomas closed proceedings by thanking speakers, delegates and stakeholders and acknowledged the event’s sponsors. The next edition of GTRC will be held on 23–24 June 2027 at the Chennai Trade Centre in Chennai, India.  

CEAT’s Chennai and Halol plants are the only tyre facilities globally with two WEF Global Lighthouse Network inductions, and the company has also won the Deming Grand Prize for manufacturing excellence.

Yet 30 km from Mumbai, CEAT Specialty’s 49-acre Ambernath plant tells a different story: tyres too heavy for automation, built instead around nitrogen curing, induction presses and orders as small as one unit – a bet that sustainability will win markets in Europe and America.

The stakes: an INR 5 billion investment in all-steel radial technology, capacity expansion to 160 tonnes/day and a Camso manufacturing deal Tolani pegs at up to USD 1 billion – turning a manufacturing constraint into a competitive edge.

Amit Tolani, Chief Executive of CEAT Specialty, does not talk about tyres the way most executives talk about their products. He talks about them the way an engineer talks about a puzzle that keeps changing shape. “The way to look at it is that the manufacturing processes that we follow – how modern they are, how capable they are, how technically efficient – that’s what matters,” he says, sitting inside the plant that has become the nerve centre of CEAT’s off-highway tyre (OHT) business.

That plant – the Ambernath facility, a division of Mumbai-headquartered RPG Group’s CEAT Limited – is not a conventional tyre factory. It builds tyres that can weigh up to over 600 kilogrammes, tyres too large and too heavy for the automation that has transformed the passenger-car tyre business. And it is this constraint, as much as any strategic masterplan, that has shaped how CEAT Specialty has chosen to compete.

A PLANT THAT CANNOT SIMPLY COPY THE ROBOTS

Ask Tolani why Ambernath has not adopted the wall-to-wall robotic automation seen at CEAT’s Chennai or Halol facility, and the answer is refreshingly unglamorous: physics. “PCR tyres can be lifted by an ordinary human being, or a forklift, or robots,” he explains. “For these tyres, which are 600–700 kg, it’s very difficult to have a conveyor that can just lift them.” In the processes that do lend themselves to automation – mixing, calendering, curing – Ambernath’s equipment, he insists, is ‘as modern as the Chennai plant. More modern’. The plant intends to formalise that claim in the coming months by pursuing Industry 4.0 certification.

Where the physical limits of scale end, digital ones have taken over. A SCADA system tracks steam lines running beneath the plant floor. Where a leak once required a worker to walk the line, take manual temperature readings and diagnose the fault, artificial intelligence now flags the location almost instantly. “The point time taken to identify the problem is close to zero,” Tolani says. Every tyre carries a digital identity from raw material to finished good; a single scan reveals the batch, the machine, the operator and the timestamp behind it. AI is also being trained on the plant’s visual tyre inspection – traditionally a human, eyeball-driven task – using high-resolution cameras to catch defects, and on optimising mixing recipes and cycle times, the invisible chemistry that determines how a tyre performs in a paddy field or a quarry.

CURING WITHOUT STEAM

The most technically striking claim to emerge from Ambernath concerns curing – the energy-intensive process of vulcanising rubber under heat and pressure that has, for a century, meant steam. “This plant has already started using nitrogen curing on one of the lines,” Tolani says. Alongside it sit two proof-of-concept induction curing presses – a steam-free process, while the nitrogen conversion has come via LMT. “There are two presses that are already commissioned here,” he says. “We’ve already started working in that direction, where we want to take a lead in this space.”

The bulk of the plant’s newest investment, however, is going into something more conventional in principle but strategically significant in intent: all-steel radial off-the-road tyres. CEAT Specialty has committed INR 5 billion to this latest phase of expansion, representing a decisive shift in product architecture. Where a car’s tyres are universally radial, only 60–70 percent of truck tyres have made that transition, and agricultural and OTR applications lag further still – agriculture because usage is seasonal, OTR because a fabric-belted bias tyre still does much of the heavy lifting. All-steel radial construction changes that calculus by delivering higher load-carrying capacity and greater comfort, attributes increasingly demanded not only by Indian buyers but, crucially, by European and American customers. “It’s for demand from the European market, the US market – and the Indian market is also growing in such a handsome fashion that we want to cater to it,” Tolani says.

LEAN BY DESIGN, NOT BY SLOGAN

CEAT’s manufacturing philosophy is inseparable from its most prized accolade: in 2017, CEAT became the first tyre company outside Japan to win the Deming Prize, the world’s most prestigious award for total quality management; in 2023, it became the first tyre company anywhere to win the Deming Grand Prize, a distinction held by only 33 organisations globally as of 2025. Inside CEAT, this discipline is branded QBM – Quality Based Management – a homegrown fusion of Total Quality Management, the Toyota Production System and Total Productive Maintenance.

“We are a Deming Grand organisation. That means we follow the philosophy of lean manufacturing – not to use resources or have any wastage in the process,” Tolani says. That philosophy is embedded, quite literally, in the plant’s straight-flow layout, which runs from raw material storage through mixing, stock preparation, tyre building, curing and final finish in a single unbroken line. Even small batch sizes, he says, are produced without the wastage, excess labour or lost efficiency – what the plant’s internal vocabulary calls ‘Muri’ – that might otherwise creep in.

That same lean instinct underpins one of Ambernath’s more unusual competitive claims: a minimum order quantity of one. In an industry historically built around economies of scale, the plant will build a single speciality tyre to a customer’s specification without demanding batch aggregation – a capability the company says few OHT plants worldwide can match. Self-managed teams on the shop floor plan and execute changeovers themselves, allowing a highly automated, digitally traceable line to pivot rapidly to low-volume, customised orders. A related innovation, branded Unistage, builds and shapes an agricultural or OTR radial carcass into its final toroidal form on a single drum rather than the conventional two-stage process, reducing the handovers.

AN R&D CENTRE BUILT FOR SPEED, NOT SCALE

CEAT Specialty operates a dedicated in-house research and development facility at Ambernath, distinct from the group’s broader R&D infrastructure, and Tolani is candid about why. Tolani says, “This business is very, very different. There is no Pareto here – no 80/20 rule where a handful of product sizes serve the bulk of demand. Because farm and off-highway equipment come in such a long tail of sizes and configurations, and because the plant supplies numerous international OEMs directly, the time taken to develop, validate and commercialise a new tyre has to be compressed.”

“We needed a dedicated facility, closer to the manufacturing, so that we can quickly pilot, quickly turn around,” he adds. A new Compound Laboratory, opened in September 2025, now anchors materials science work spanning OTR, agricultural and industrial segments, while AI-assisted testing has trimmed, by Tolani’s estimate, roughly a third off the time from concept to market. The centre’s pipeline currently spans all-steel OTR tyres, a newly launched forestry range, very high flexion (VF) agricultural tyres and expanding work in earthmoving and material handling.

CAMSO ACQUIRED FOR BRAND, CHANNEL AND CATEGORY

CEAT Specialty’s move into Camso – a name Tolani values at up to USD 1 billion in brand potential across agricultural tracks, power sport tracks and material handling – may be its most consequential strategic bet. “It was a natural fit for us in terms of completing our portfolio,” he says. Ambernath, built in 2018 solely for agricultural radial tyres, gains through Camso’s new OEM ties (Massey Ferguson, John Deere) and construction-channel access across South America and Europe.

Under a three-year Michelin agreement, CEAT can currently manufacture and sell only compact construction tyres and tracks under Camso, taking over end-consumer sales in that segment – with other categories opening up once the term ends. The impact is already visible: standalone, CEAT Specialty’s off-highway mix is 85:15 agriculture to non-agriculture; with Camso’s, it shifts toward 50:50.

THE NUMBERS BEHIND THE AMBITION

Ambernath is running at 105 tonnes a day, at 92–95 percent utilisation – ahead of schedule. A further phase, due within 45 to 60 days, will lift capacity to 160 tonnes. Camso, still integrating, runs at roughly 50 percent.

Off-highway tyres make up close to 20 percent of CEAT’s speciality revenue, with the agriculture-to-non-agriculture split narrowing from 85:15 to near 50:50 once Camso is included. Domestically, Tolani credits GST reforms for a strong OEM market, led by Mahindra and TAFE, while mining stays flat – a segment Camso’s construction heritage should help lift as the new all-steel OTR line comes online.

When the World Economic Forum inducted CEAT’s Chennai facility into its Global Lighthouse Network in January 2025, it made the Indian tyre-maker the first tyre brand in the world to hold two such honours – Chennai following in the footsteps of the company’s Halol plant. Add to that CEAT’s Deming Grand Prize, awarded by the Union of Japanese Scientists and Engineers for sustained excellence in Total Quality Management, and the company finds itself in rarefied company: one of only a handful of manufacturers worldwide, and the only tyre brand to hold both distinctions.

Behind these accolades sits a quieter, harder story – one of culture change, shop-floor scepticism and years of disciplined, incremental investment in artificial intelligence, the Industrial Internet of Things and automation. In an interview with Tyre Trends, Jayasankar Kuruppal, Senior Vice President, Manufacturing at CEAT, spoke on what these recognitions actually mean on the factory floor, and where the company believes manufacturing is headed next.

AWARDS AS A BY-PRODUCT, NOT THE GOAL

CEAT’s Chennai plant has posted striking numbers since its digital transformation began: a 54 percent improvement in dispatch turnaround, a 25 percent uplift in labour productivity, an 18 percent reduction in cycle times, a 31 percent improvement in operating cost and a 47 percent cut in Scope 1 and 2 emissions. Yet Kuruppal is quick to reframe the narrative around these achievements.

“The awards are lagging indicators, not the goal. What actually matters is what they force us to build: a common language for problem-solving across every plant, real-time visibility into quality and efficiencies and a workforce that trusts data over gut-feel,” Kuruppal said.

“That discipline shows up directly in the numbers – tighter process capability, better efficiencies and faster changeovers leading to shorter lead times. There is a commercial dividend too: global OEMs increasingly audit manufacturing maturity, and being part of the WEF Global Lighthouse Network gives us instant credibility in those conversations,” he added.

WHAT’S REALLY DRIVING THE INVESTMENT

CEAT has been pouring capital into AI, IIoT and automation across its plants. Is this cost pressure, premiumisation or a simple need to stay globally competitive? Kuruppal’s answer suggests it is all three, each playing a distinct role.

Kuruppal explained, “Quality, cost and efficiency is what gets the funding approved. Premiumisation is what’s shaping which lines we automate or upgrade first – you cannot hold the tolerances a premium radial demands with manual, operator-dependent processes.” According to him, global competitiveness, meanwhile, sets the ambition. “We’re not benchmarking ourselves against the best tyre plant in India anymore – we’re benchmarking against the best factories in any industry,” he added.

Asked to rank the three forces, he summarised neatly: competitiveness sets the ambition, premiumisation sets the sequencing and cost discipline keeps the whole effort honest.

REPLICATING HALOL AT CHENNAI: CULTURE OVER CODE

Chennai’s transformation built directly on lessons learned at Halol, the world’s first tyre facility inducted into the Lighthouse Network. And when asked what proved hardest to replicate, the technology, the culture or getting the underlying processes right, Kuruppal said, “Technology was actually the easiest part to copy. A use case that works at Halol can be re-deployed at Chennai in weeks.”

But the real difficulty, as per Kuruppal, was culture, people and change management. At Halol, habits such as daily data reviews, operator ownership of quality metrics and a managerial focus on coaching rather than firefighting were built steadily over several years. Chennai, by contrast, has had to replicate that trajectory on a compressed timeline, with a workforce encountering these practices for the first time.

“We had to resist the temptation to just parachute in dashboards and call it digital. We spent real time getting the underlying process standardisation right first, because AI on top of an unstable process just gives you a faster route to the wrong answer,” Kuruppal said.

Jayasankar Kuruppal, Senior Vice President, Manufacturing, CEAT

WHERE THE RETURNS SHOW UP – AND WHERE THEY HAVEN’T YET

The productivity and dispatch gains at Chennai, he explained, hit the balance sheet in different ways. The productivity improvement lowers conversion cost per tyre and improves absorption of fixed costs as volumes grow. The dispatch improvement is more of a customer-experience story: less finished-goods inventory sitting idle, and OEMs and dealers receiving faster, more predictable delivery windows – ‘which matters a lot when you’re chasing premium and export business’.

Not every initiative has paid off yet, however. Kuruppal was candid about the areas still short of return, singling out ‘some of the more exploratory AI use cases – like computer-vision pilots – which need more data cycles before the accuracy justifies scaling them further’.

QUALITY, MAINTENANCE, OUTPUT: AI TOUCHES ALL THREE

Rather than picking a single area where artificial intelligence delivers most value, Kuruppal argued that its power lies in the way it now touches quality, maintenance and output simultaneously – and that these reinforce one another. “Better quality data feeds better predictive-maintenance models, which reduces unplanned downtime, which directly lifts output,” he said. The most immediate impact shows up in more consistent product quality, higher yields and earlier detection of equipment issues. He pushed back, though, on the idea that AI at CEAT is a single flagship project: “On our floor, it’s dozens of narrow, specific use cases, each solving one operator’s or one supervisor’s actual problem.”

JUSTIFYING THE SPEND IN A MARGIN-TIGHT BUSINESS

Tyre manufacturing is not a business with room for indulgent technology spending, and Kuruppal was clear that CEAT does not fund innovation for its own sake. “Every use case has to show a clear line to quality, efficiency, cost or capacity enhancement before it gets budget,” he said. The company deliberately starts small – piloting on a single line, proving value with real production data, and scaling only what works – a discipline that means ‘the savings from scaled use cases fund the next round of pilots’. He offered a broader rationale too: in a commodity-adjacent business where raw material costs sit largely outside a manufacturer’s control, manufacturing capability itself becomes the differentiator. “If we can’t always control input costs, we can control how efficiently and consistently we convert them into tyres,” he added.

CHENNAI PLANT WIDENS ITS PREMIUM PUSH

CEAT on Oct. 1 announced an expansion of manufacturing capabilities at its Chennai plant across passenger car and SUV, commercial vehicle and two-wheeler tyres. The company said the move targets premium customers in India, Europe and North America.

What’s new

Cars and SUVs: The plant now makes the SportDrive SUV ZR22. CEAT said this makes it the first Indian tyre company to manufacture 22-inch tyres in India. It also makes the 4SeasonDrive+ all-season tyre and the CrossDrive RT rugged-terrain tyre, built for the U.S. market.

Trucks and buses: The plant can now produce seven advanced truck and bus radial sizes, including wide-base tyres that can replace dual-tyre setups, and low-profile sizes. CEAT is also scaling light truck steel radials in 15-, 16- and 17.5-inch sizes.

Two-wheelers: The SportRad Racing Slick range targets track use, and SportRad ST is a sport-touring range for motorcycles above 650cc.

“This investment strengthens our ability to compete in premium segments with products developed and manufactured in India,” CEAT managing director and CEO Arnab Banerjee said.

The 163-acre plant in Sriperumbudur, Kanchipuram, runs on connected machinery and real-time analytics. It also has a 9 MW rooftop solar installation and operates as a zero-liquid-discharge facility.

FROM PILOT TO SCALE: AN OPERATING-MODEL PROBLEM

With a large share of CEAT’s lines now running as ‘smart lines’, when asked what changes when a company moves from isolated pilots to scaling technology across multiple plants, the CEAT executive explained, “The problem changes completely. A pilot is a technology and data-science problem – get the model working, prove the use case. Scaling is an operating-model problem – standard work, training, change management, IT infrastructure that can handle load across sites and governance so every plant isn’t reinventing its own version of the same solution.”

CEAT has built what he calls a central playbook – reusable architecture, common data standards and the ability to roll a proven use case out to a new plant in weeks rather than months. “Just as importantly, ownership shifts: at pilot stage, a project team owns the initiative; at scale, it must become the plant’s own way of working, run by operations rather than a digital team sitting alongside it,” he added.

BRINGING 80 PERCENT OF THE WORKFORCE ALONG

CEAT reports that more than 80 percent of its workforce is now digitally enabled – a transformation Kuruppal admits did not come without resistance. “Yes, and I’d be understating it if I said otherwise,” he said. Crucially, he insists the resistance was never really about technology itself but about ease of operation. What worked, he explained, was making tools visibly useful to the person using them first – an operator seeing a dashboard that helps them hit their own target before it ever becomes a management reporting tool. CEAT invested heavily in shop-floor-specific training rather than generic digital-literacy courses and made a point of promoting from within, demonstrating that digital skills opened up better roles rather than closing off old ones. The company has also created new shop-floor roles beyond data scientists and engineers – ‘Business Translators’ and ‘Champions’ who act as torchbearers driving scaled implementation and wider blue-collar involvement.

CONSISTENCY, NOT JUST DEFECT COUNTS

Asked whether tighter process control has genuinely reduced defects, Kuruppal reframed the question around consistency. “Tighter process control means less batch-to-batch variation, which matters enormously in tyre manufacturing because so much of performance and durability comes down to material consistency through mixing, extrusion and curing,” he said. Real-time monitoring now catches drift early, rather than at final inspection – both a quality win and a material-efficiency win, in the form of less scrap and rework. The habit that has changed most, he said, is that quality data now drives daily decisions on the shop floor, rather than featuring only in a monthly review.

MANUFACTURING FOR A PREMIUM, ELECTRIC FUTURE

CEAT’s push into premium tyres calls for a step-change in manufacturing discipline. “Premium tyres are far less forgiving of variation, so the shift starts with tightening process capability across every stage – not just final inspection. That means more precise equipment, better process capability and closed-loop control,” said Kuruppal. In this context, flexibility takes on a different meaning: a wider SKU mix, smaller batch sizes and faster changeovers are pushing the company towards more modular manufacturing, alongside a workforce increasingly weighted towards process engineering expertise.

Electric vehicles introduce an additional layer of complexity. EV tyres must carry greater weight, handle instant torque and operate more quietly, tightening specifications around structural strength, noise and rolling resistance beyond those of conventional tyres. On the shop floor, that translates into new compound formulations requiring precise mixing, reinforced construction demanding tighter control of building machines and significantly lower tolerance for micro-variation.

CEAT’s existing leadership in the e-two-wheeler tyre segment, Kuruppal noted, is already feeding lessons – particularly on noise and efficiency – into how the company prepares lines for growing e-four-wheeler volumes in India.

SUSTAINABILITY AND RESILIENCE, BUILT IN

Sustainability, once a separate reporting exercise, is now ‘a line item in almost every manufacturing decision’, with energy and emissions sitting alongside cost and quality when evaluating new processes or equipment – Chennai’s 47 percent emissions reduction being the clearest proof point. Resilience, too, has become as much a data problem as a sourcing one. “Real-time visibility into inventory, machine health and production schedules means we can see a disruption coming and reschedule around it rather than reacting after a line has already stopped,” Kuruppal said, pointing also to greater flexibility in shifting product mix between lines and earlier warning signals from digitised supplier and logistics data.

SPEED AS A COMPETITIVE WEAPON

Manufacturing speed and flexibility, Kuruppal argues, have become one of CEAT’s most important competitive dimensions, as OEMs compress their own development cycles and expect tyre partners to match their pace – faster prototyping, faster line trials, faster ramp-up to volume. Chennai’s faster dispatch turnaround is part of the same story. “It’s not just about making tyres faster; it’s about the whole chain from order to delivery being more predictable and quicker,” he said.

GROUND STILL TO COVER

For all its Lighthouse credentials, Kuruppal was refreshingly honest about the distance still to travel. “Being part of that network is genuinely humbling. You see factories in electronics and consumer goods running end-to-end AI-driven planning and quality systems at a level of maturity we’re still building towards – particularly in advanced analytics for demand-and-production planning and in scaling generative-AI use cases beyond pilots,” he said. CEAT’s strength, he believes, lies in shop-floor execution and quality; the next frontier is connecting that data seamlessly across the full value chain, from raw-material sourcing to the end customer.

MANUFACTURING AS A GROWTH DRIVER

Perhaps the most striking shift Kuruppal describes is a change in how manufacturing itself is perceived within the business. “Traditionally, manufacturing was viewed in this industry as a cost centre that executes what sales and product teams decide,” he said.

“Today, our manufacturing capability is directly opening up premium and export opportunities, because global customers evaluate factory maturity as part of their sourcing decision. It works in the other direction too, shaping which premium and EV products the company can confidently commit to launching. Manufacturing has moved from being an execution function to being a genuine input into growth strategy,” he added.

WHAT COMES NEXT

Looking ahead, Kuruppal frames the next horizon as connecting what CEAT has built plant-by-plant into a single, integrated digital thread – spanning raw-material and demand planning, production and distribution – so decisions are optimised end-to-end rather than site-by-site. Generative AI, he said, is increasingly being explored for process and equipment troubleshooting and knowledge capture, making the expertise of CEAT’s best engineers accessible across every plant. Sustainability, meanwhile, will be designed into new lines from the outset rather than retrofitted. “The common thread is moving from isolated smart use cases to a genuinely integrated smart manufacturing system,” he explained.

THE ONE NUMBER THAT MATTERS

Answering the question on if he could track just one metric across every CEAT plant, what would it be, he admitted, “If I’m honest, no single number tells the whole story, but if forced to pick one, it would be Overall Equipment Effectiveness – OEE.”

“As a composite of availability, performance and quality, a healthy and rising OEE generally signals that machines are running, running at the right speed and producing good tyres – which is really the definition of a plant working as it should,” he said. It has its limits – OEE alone won’t reveal a lapse in safety culture or the pace of digital adoption – which is why, in the end, Kuruppal names two figures he watches above all: OEE and safety indicators.

Tana Oy has appointed Panu Ärölä as its new Territory Business Manager, a role he will assume on 2 November. In this capacity, he will focus on strengthening customer and distributor relationships across designated markets while contributing to the company’s ongoing expansion within the waste management and recycling sector.

Ärölä returns to Tana after previously serving as Sales Manager, where he developed expertise in distributor network growth. His background includes extensive international experience in sales, marketing, business development and strategic leadership. Most recently, he held the position of Head of Sales and Marketing at Jet-Tekno Oy, overseeing customer relationship development and business growth initiatives.

Gerd Schreier, VP – Sales, Marketing & Channel Development, said, “We are delighted to welcome Panu back to Tana. His industry knowledge, customer focus and experience in international sales make him a valuable addition to our team. We look forward to working with him as we continue to develop our business and create value for our customers and partners.”

Stephan Sielaff took over as chief executive of the Schill+Seilacher Group on 1^st October , as the chemicals group seeks to strengthen links between its businesses and focus more closely on customer needs.

Sielaff brings about 30 years of experience in developing international businesses and organisations. His previous roles include positions at Unilever, Symrise, Archroma, Lenzing AG and SSI SCHÄFER Plastics.

His priorities at Schill+Seilacher include getting closer to customers, encouraging greater knowledge-sharing across the group and making better use of capabilities across its businesses and locations.

“A good product alone is no longer enough. What matters is the value we create for our customers,” says Stephan Sielaff.

The group said it would seek to share knowledge, pursue opportunities jointly and strengthen connections between its locations and business areas.

Sielaff's appointment is intended to support a more integrated approach across the group as it develops its businesses in the years ahead.