Bansal Wire Industries, India’s largest stainless steel wire manufacturing company, is charting a dynamic course in the Indian tyre market with innovative solutions aimed at enhancing performance and sustainability. Leveraging its expertise in the automotive sector, the company is introducing advanced steel cords and bead wire products designed to improve tyre efficiency, rolling resistance and fuel economy.

Bansal Wire Industries is optimistic on capitalising on the growth of the Indian tyre market as tyre makers endeavour to offer more efficient rubber wheels. The Delhi-based conglomerate is planning to introduce products within its tyre-industry portfolio that will improve performance. The company already caters to the automobile industry with products spanning outer and inner spring, circlips and washer categories.

Speaking to Tyre Trends on upcoming products, Managing Director Pranav Bansal iterated, “Our modern manufacturing setup enhances product performance; this is particularly in line with current industry trends as we move towards producing super tension and super tensile plus steel cord products. These innovations are expected to improve rolling resistance and reduce tyre weight, both of which contribute to better fuel efficiency and performance. We are actively embracing complete digitalisation and bringing more automation into our processes, helping us increase efficiency and ensure product consistency.”

He added, “We pride ourselves in being the only Indian company manufacturing steel cord for the PCR and TBR sectors with offerings in normal tensile, high tensile and super tensile (ST). Additionally, we have expanded our bead wire manufacturing capabilities with facilities in both South and North India and we continue to explore innovations to serve the evolving needs of the tyre industry.”

Alluding to the reason behind expanding into the tyre industry, he noted, “Our expansion into the tyre industry is driven by the increasing demands of durable, high-quality materials and products, as supported by industry research reports done by Invest India, among others. By diversifying our product portfolio, we aim to meet this demand for efficient materials. By focusing on high-quality steel cords and bead wires, we help improve tyre performance, which in turn enhances vehicle stability, handling and safety, especially under challenging road conditions.”

“The Indian tyre industry has witnessed a significant growth over the past few years, which is driven by an exponential increase in production, domestic sales, exports and overall revenue. An integral growth factor in this is the increase in the ownership of vehicles, which further aids the tyre industry. Additionally, the surge in demand for tyres for trucks and buses, fuelled by expanding mobility and industrialisation, has given a boost to the sector,” he added.

The company caters to over 5,000 customers, offering more than 4,000 different wire products across industries such as automotive, infrastructure and consumer durables. While its primary market is India, the manufacturer also exports products to over 50 countries. The US and Europe are among its largest markets, where it continues to see significant demand for products.

Industry talk

Bansal mentioned that the increasing demand in the automotive industry, domestically, presents tremendous opportunities for the company. “Our high-performing products allow us to constantly evolve. However, challenges like fluctuating raw material prices as well as the changing regulatory requirements could impact. Expansion internationally, specifically in regions like the US and Europe, provides significant opportunities, but geo-political risks and trade regulations could challenge the operations on a global level,” he noted.

Alluding to the strategies implemented by the company to meet the growing demands, he iterated, “In the automotive and tyre industry, collaboration with stakeholders is key to driving innovation and meeting the growing demand for high-quality wire products. We focus on building strong partnerships with manufacturers, suppliers and research institutions to align our solutions with industry needs. Regular engagement through industry forums, trade shows and feedback mechanisms allow us to understand evolving requirements and deliver solutions that enhance performance, safety and sustainability. By participating in joint development projects, sharing technical expertise and staying updated on emerging trends, we ensure our products remain at the forefront of technological advancements.”

Quality and sustainability

The company has manufacturing facilities for bead wire in both South and North India. The production capacity at its South India facility is 50 kilotonnes per year, and at the North India facility, it is 30 kilotonnes per year. Additionally, it has a pilot manufacturing site for steel cords in North India, which currently has a production capacity of 20 kilotonnes per year. The company plans to gradually scale up this capacity to meet the growing demand of the tyre industry. 

Commenting on quality measures implemented to derive industry-grade materials, he explained, “We are committed to ensuring the highest product quality and will soon be the only company in India with dedicated in-house research and development wing for both steel cord and bead wire. Our research and development facility spans 12,000 square feet and is equipped with state-of-the-art equipment to drive innovation. To achieve 'First Time Right' production, we have conducted extensive gap analyses of our processes and implemented all necessary improvements. Additionally, our manufacturing facilities are equipped with cutting-edge machinery, all integrated with a complete digital interface to capture real-time data, ensuring the highest standards in production and quality.”

The company also puts focus in the principles of circularity with several initiatives. “Sustainability is a core focus area for us and we are addressing it in several ways. Our use of renewable energy has reached 70 percent in some of our plants and we are dedicatedly moving towards water positivity in many of our facilities. We are exploring the use of green steel in both our steel cord and bead wire products. To further reduce our environmental impact, we are investing in energy-efficient machinery and continuously seeking ways to minimise emissions across our operations,” said Bansal.

Future course

According to Bansal, the company is anticipating several key trends that will influence its business, including a strong focus on product innovation to enhance performance and quality. “We are committed to show resilience to maintain operational stability in dynamic markets. We work dedicatedly to improve the customer experience through feedback and satisfaction while also fostering diversity and inclusion within our workplace culture. Sustainability and corporate social responsibility remain priorities, alongside embracing technological advances to optimise our operations and product offerings for the future. These trends will guide our growth and ensure we stay ahead in a competitive market,” explained Bansal.

Besides, the company is also focused on significant growth opportunities through the establishment of new facilities and capacity expansions. “Our new manufacturing site in North India for both steel cord and bead wire has a current steel cord capacity of 20 kilotonnes per year with plans to scale it to 200 kilotonnes per year over the next five years. In bead wire, we now have two new state-of-the-art manufacturing facilities in South and North India with a combined production capacity of 80 kilotonnes per year, ensuring that we are well positioned to meet the increasing demand from our customers in the coming years,” concluded Bansal.

In an exclusive interaction with Tyre Trends, Dr Manish Jaiswal, Director, National Automotive Test Tracks (NATRAX), shares the key developments taking place, how the organisation is supporting the domestic tyre industry, upcoming trends and future plans.

At present, what are the services that you’re providing for the tyre industry at NATRAX?

NATRAX is a proving ground where vehicles and all their components are tested on our various tracks. A proving ground is essentially a place where a vehicle must prove itself under various challenging terrains. It needs to test and certify itself, as well as support development activities. Our tracks cater to durability, acceleration, braking, noise, endurance, high speed, grip handling and wet-grip conditions.

Tyres are the only point of contact between a vehicle and the surface. Therefore, for vehicle dynamics testing, the tyre industry is a crucial component. NATRAX supports tyre industry in terms of the testing requirement for acceleration, braking, cornering, handling and noise.

What about homologation?

We support the tyre industry in various ways when it comes to homologation. One of the key activities is tyre labelling, in line with the new AIS 142 requirements. Every tyre must be labelled, similar to safety ratings. This labelling involves testing for rolling resistance, wet handling, wet grip and noise.

All these activities take place at NATRAX, making us the default agency for tyre labelling. We are also planning to procure a rolling resistance machine, which should arrive in a month or two. Once that happens, the entire set of tyre labelling activities will be conducted at NATRAX for both commercial vehicles and passenger vehicles. This is one of our significant new developments.

What are the latest demands from the tyre industry?

We are in close contact with tyre manufacturers for various activities. One key demand is for wet handling and aquaplaning tests, for which they currently need to go abroad because such facility does not exist in India. Wet handling and aquaplaning on curves are critical safety features. For instance, when a thin film of water forms on the road, the tyre can lose its adhesion to the surface, so it’s vital to test grip in such conditions.

We are planning to build a special-purpose track for wet handling and aquaplaning and are requesting government funding for this. Once established, this will prevent the tyre industry from needing to go overseas for these tests.

Another growing concern is tyre wear and its environmental impact. Previously, emissions were only considered in terms of tailpipe emissions, but tyres also contribute to microplastic pollution and other wear particles that spread through road contact. We are collaborating closely with the tyre industry to find solutions – whether through a tyre wear machine or a specially designed track. This could become a major project, but we are committed to addressing this need.

Are you supporting tyre makers for their products designed for exports?

Tyre manufacturers often have to go to agencies in Japan and Germany for comfort testing. Developed markets have very different requirements because the driving conditions vary significantly from those in India. Comfort and ride quality are far more important in developed markets.

We are discussing how to address this need domestically. While it’s not an immediate concern, we must eventually ensure that the tyre industry can conduct 100 percent of their testing in India. Some tests, like those for snow and ice conditions, will always be challenging to replicate here due to cost and environmental factors. However, most other tests are within our long-term plans.

Has simulation reached a maturity level where it can replace physical testing?

Simulation has evolved significantly over the last 25–30 years, but we haven’t yet reached a point where it can fully replace physical testing. The complexities of vehicle systems – including OEM products, components, tyres, control systems, road conditions and driver behaviour – make complete reliance on simulation difficult.

India also faces challenges in developing high-fidelity simulation models. Accurate virtual replication requires the integration of confidential data from various partners, which is not easy to achieve. Nonetheless, we are planning for the future by developing the right simulation environment and infrastructure, such as high-fidelity simulators and virtual testing benches. This will help reduce dependence on track testing and streamline product development.

Do EV tyres require separate on-ground testing?

EV tyre testing largely follows the same procedures as conventional tyre testing, with standards remaining consistent across both types.

However, from a manufacturing and design perspective, EV tyres often use different materials and designs – including rubber, elastomers, fabric and steel – tailored to meet OEM requirements. These differences may eventually call for specific tests, but the current standards remain aligned.

In developed markets, there are separate summer and winter tyres. Do you think India needs this distinction?

Fortunately, India does not experience the extreme temperature variations seen in countries like the US, Canada or parts of Europe. In those regions, temperatures can range from 30 degrees Celsius to -10 degrees Celcius, necessitating different tyre types for safety and traction.

In India, extreme cold weather is limited to specific areas like Kashmir and only for brief periods. Given this, the added cost of maintaining separate summer and winter tyres is not justifiable.

What are NATRAX’s immediate investment plans?

While we have not worked out the exact figures, we are in the process of investing significantly (in 2025) in form of rolling resistance machine and upgradation of two-three tracks for tyre industry requirements. Our immediate future plans include significant investments for a new wet handling and aquaplaning track.

We maintain close communication with the tyre industry, prioritising their requirements to support their growth and development.

Which companies are you currently working with?

We collaborate with almost all Indian tyre manufacturers and are also engaging with multinational and global tyre brands. The goal is to develop their R&D ecosystems in India.

As international players shift their development activities to India, local testing becomes inevitable. This shift will allow NATRAX to play a crucial role in supporting their R&D and testing needs.

What is the lead time for tyre makers to approach NATRAX for testing, and how long does testing typically take?

Many tyre manufacturers have teams stationed at NATRAX around the clock, so there is no lead time. Testing happens daily.

If they have special requirements, they approach us and we are usually able to accommodate them. Approximately one-third of our track usage comes from the tyre industry. With our 50-kilometre proving ground – the largest in India and one of the largest globally – we operate at an entirely different scale.

As we expand our facilities for ADAS (Advanced Driver Assistance System) and connected vehicle testing, even more tyre industry testing will take place at NATRAX. We aim to become the go-to solution for all tyre industry needs.

The tyre industry is navigating a complex landscape of rising material costs, geopolitical uncertainties and fierce competition. In response, manufacturers are turning to automation, Industry 4.0 and AI-driven solutions to enhance efficiency and reduce operational expenses. Advanced testing and measurement systems are pivotal in this transition, offering cost-effective quality control, streamlined production and improved consistency. However, integrating these innovations poses challenges, including adapting to evolving tyre designs and meeting stricter OEM requirements. This article explores how technological advancements in tyre testing are reshaping the industry, ensuring performance precision and economic viability in an increasingly competitive market.

Increasing raw material prices, geopolitical crises, rising freight costs and stronger competition have led tyre companies to find ways to lower operational costs. Technological breakthroughs like automation, Industry 4.0, etc. are a boon in disguise in this hour of need. While automation is not a new concept, its usage gradually increases within the tyre industry, riding on the back of other advancements.

Micro-Poise Measurement Systems Division Vice President & Chief Technology Officer Dr Shaun M Immel believes that the ever-increasing need for automation and data connectivity to support Industry 4.0 is driving tyre manufacturers to adopt advanced measurement systems that lower inspection costs, enhance consistency and provide critical data for analytics.

“Simultaneously, manufacturers seek improved equipment throughput while maintaining high measurement quality to meet tightening tyre screening requirements. The growing variety of electric vehicle (EV) tyre designs necessitates greater measurement system flexibility to support a larger number of stock-keeping units (SKUs). Additionally, customers increasingly require user-friendly systems that accommodate inexperienced personnel by presenting simple-to-use and highly automated products,” he added while speaking exclusively to Tyre Trends.

The tyre testing industry has significantly transformed over the past five years. Automation cuts measurement and inspection costs while improving consistency and predictability, allowing manufacturers to redeploy labour to higher-value tasks. It also enables precise, data-driven decision-making by replacing subjective human evaluations with quantifiable metrics, ensuring better process control and continuous improvement.

As tyres grow larger and heavier, automation presents new challenges, but advancements in artificial intelligence (AI), faster processing power and GPU technology are making implementation more feasible and cost-effective. These innovations are fuelling a resurgence in automation, enhancing efficiency and providing manufacturers with deeper insights into production quality and performance.

However, he noted that while including sustainable materials within tyre compounds is strong founded within tyre makers, it is not likely to affect testing strongly. “The shift towards sustainable materials in tyre manufacturing is reshaping the industry. While this evolution may impact tyre design materials and manufacturing processes, it will not significantly alter the core processes of final finish testing. Testing equipment focuses on force variation, dynamic balance, X-ray analysis and geometry measurement, and it remains largely unaffected as long as tyre sizes stay within standard categories. However, as manufacturers integrate new compounds and materials, potential changes in tyre behaviour may lead to adjustments in testing methodologies to address emerging manufacturing challenges,” said Dr Immel.

PARADIGM EVOLUTION

The tyre industry is undergoing a strategic shift. Top-tier manufacturers are moving away from mass production to focus on high-performance and premium tyres, consolidating production into specialised plants for passenger, truck and OTR tyres. This shift is driven by increasing competition from Asian manufacturers dominating the mass-market segment. At the same time, some Asian players are pushing into the premium space, intensifying competition at the high end.

This evolving landscape reinforces the demand for precision testing, high measurement quality and faster throughput. “Our longstanding partnerships with tier-one manufacturers position us well in this premium market, particularly in the 18-inch-and-above segment, where measurement accuracy and reliability are critical and where Micro-Poise’s measurement systems excel. As the industry diversifies, we continue to enhance our equipment’s flexibility and feature set to meet the evolving needs of both established premium brands and emerging challengers,” said Dr Immel.

Furthermore, Dr Immel noted that the testing industry is undergoing significant advancements with a strong focus on increasing throughput while meeting increasingly stringent quality requirements. “Tyre manufacturers face tightening OEM screening limits, necessitating greater accuracy and repeatability in measurement systems to ensure precise and proper classification of tyres for various markets. Traditionally, higher throughput and improved measurement repeatability are a trade-off, but the industry is now working to improve both simultaneously, requiring innovative approaches,” he said.

“A notable shift, particularly influenced by EVs, is the growing demand for higher frequency content in geometry and uniformity measurements. As EVs eliminate engine noise, tyres have become the dominant source of road noise, prompting manufacturers to analyse higher-frequency variations that could contribute to unwanted sound. These variations, often linked to tread design and tyre construction, are now being examined more closely for tyre-to-tyre variation to mitigate its impact,” he added.

He also contended that regulatory trends and market dynamics are driving further changes beyond noise control. The rise of EVs has significantly expanded the number of SKUs manufacturers must manage, pushing the need for greater equipment flexibility and quicker changeover.

“With tyre designs evolving rapidly, testing systems must adapt through quick-change tooling and advanced marking capabilities to accommodate frequent model shifts. At the same time, manufacturers continue to push for higher throughput without compromising measurement and inspection performance, reinforcing the need for cutting-edge solutions that balance speed, accuracy and adaptability in an increasingly complex landscape,” he added.

MEASURING PARAMETERS

According to Dr Immel, the time required to measure and assess a single tyre depends on the type of test(s) being conducted. A typical measurement cycle may range between 15 and 30 seconds, depending on the tyre size, the required tyre ‘warmup’ time, and the measurements being performed. The key to high-quality final finish equipment is to ensure high throughput while maintaining the measurement performance necessary for accurate quality assessments.

Explaining the quality measurement process, he said, “Quality measurement in tyre testing hinges on two fundamental aspects, accuracy and repeatability. Accuracy refers to each measurement’s ability to reflect the tyre’s true assessment value and characteristics, a non-trivial task given the inherent variability in production tyre measurement. Manufacturers rely on these values to determine whether a tyre meets quality standards or should be scrapped.”

Repeatability, on the other hand, measures measurement consistency. Sophisticated technology minimises measurement variations of production tyres, ensuring that the system can effectively differentiate between acceptable and defective products. The financial impact of incorrect classifications, whether approving a faulty tyre or rejecting a good one, is substantial, making excellent system measurement performance a critical factor in reducing long-term operational costs.

Answering what tyre screening limits are acceptable to the market, he said, “The acceptable limits are proprietary to each tyre manufacturer. Each manufacturer receives screening limits from original equipment (OE) manufacturers and select replacement market dealers. These OE and replacement screening limits vary across players. Beyond that, tyre companies often impose stricter internal limits to enhance quality, improve customer perception or differentiate products.”

Alluding to whether the industry is more concerned about variation in passenger car tyres than in TBR or OTR tyres, he explained, “The industry is indeed more focused on variations in PCR, but I believe that’s largely due to volume. Passenger car tyres are produced in significantly higher numbers, and since they are consumer-facing products, expectations are much higher. People notice and care about ride quality, so manufacturers focus heavily on minimising tyre-to-tyre variations.”

“However, even in the TBR segment, certain types like steer and drive tyres undergo strict testing and must meet high standards. Steer tyres, in particular, incorporate advanced technology because they directly impact vehicle handling and safety. Trailer tyres, on the other hand, face less scrutiny since they directly affect ride comfort. That said, manufacturers across all segments are under continuous pressure to tighten tolerances. OEMs and fleet operators are always pushing for lower limits, forcing tyre makers to improve,” he added.

The company is advancing tyre grading technology with a data-driven approach that moves beyond traditional tyre metrics. Developing and integrating alternative measurements aims to refine performance assessments, ensuring a closer correlation between lab results and real-world ride quality. This shift could boost product yields while maintaining more stringent standards, enabling a ‘smarter’ assessment of tyre quality.

When asked about the causes of early tyre failure and how geometry plays a role in identifying defects, he explained that issues in ply splicing during manufacturing can lead to structural weaknesses. If the ply material splice is left open, missing ply cords create a bulge defect when the tyre is inflated under high pressure.

This bulge, a critical measurement in quality control, appears radially along the sidewall and is a standard defect monitored by tyre manufacturers. If the bulge exceeds acceptable limits, it can cause the inner liner to become voided, leading to slow air loss and deflation – an irreparable but not necessarily catastrophic failure mode.

Dr Immel also noted that the company has developed several features to enhance flexibility. “We have an automatic rim change feature with adaptable tooling that streamlines adjustments. We’re also exploring innovations to improve changeover efficiency further. One of our key advantages is that when a tyre enters the system – even if it’s a single unit – we can immediately identify it, load the correct parameters and process it without any cycle time penalty. Unlike other machines requiring manual adjustments and extra cycle time, ours can handle small lot sizes and frequent model changes seamlessly,” informed Dr Immel.

When asked whether every tyre produced on the line is measured, Dr Immel explained that almost all OE tyres undergo screening to meet strict screening limits. For the replacement market, tyre manufacturers screen a varying percentage of products, depending on customer requirements and market strategy. While nearly 100 percent of OE tyres is tested, the extent of screening for replacement tyres varies across manufacturers and customers.

PRODUCT CATALOGUE

Micro-Poise Measuring Systems’ ASTEC FX system evaluates critical parameters such as force variation, while Micro-Poise’s TGIS FS system evaluates tyre runout and sidewall appearance. While these factors primarily influence ride comfort rather than direct safety, they play a role in detecting defects that could lead to premature tyre failure. “Some of these defects have been monitored for decades, forming an industry benchmark,” noted Dr Immel.

When discussing the process of force variation measurement, the executive compared a tyre to a system of parallel springs, where each section should ideally have the same spring constant or stiffness around the tyre. However, variations in manufacturing such as splices, component alignments and positioning errors can create inconsistencies, making certain areas stiffer or softer than others, resulting in a variation of the force the tyre induces into a vehicle while driving.

A load wheel presses into the tyres while it rotates to detect these variations, measuring force fluctuations. Higher force readings indicate stiffer areas, while lower ones suggest softer regions. This data is analysed using Fourier analysis, breaking it down into harmonics to help manufacturers ensure that force variation at certain frequencies remains within acceptable limits.

The US-headquartered company’s ITMS FX (Integrated Tire Measurement System) minimises testing cycle times while integrating and maintaining excellent measurement quality across force variation, dynamic balance and geometry measurements. In high-volume manufacturing, any cycle time advantage can significantly impact overall throughput, driving up the overall equipment value for the customer. “It’s always about how fast you can get the process done – get one tyre out, bring the next in and repeat,” Dr Immel explained.

Beyond speed, system reliability is equally important. Fully automated testing systems need to run continuously with minimal stoppages. “If a fault occurs, recovery must be instant,” he added. However, increasing speed without sacrificing measurement quality presents an inherent challenge.

The company’s Tire Geometry Inspection System (TGIS FS) integrates proprietary tyre-optimised 3D sensors to inspect sidewall geometry accurately. The system employs three strategically placed sensors in fixed locations – one each on the top lateral, radial and bottom lateral surfaces – to complete a full geometric scan in a single tyre revolution. The result is a micron-resolution contour of the entire tyre. This data supports defect detection, dimensional measurements and process optimisation. The system is adaptable across Micro-Poise’s force variation (uniformity), dynamic balance machines and various competitive equipment.

The company is reinforcing its position as the ‘automation partner of choice’ for tyre manufacturers, supported by the fact that it has always focused exclusively on final finish solutions. The company is driving towards fully automated ‘Lights Out’ operations, ensuring maximum efficiency and cost-effectiveness across all its products.

Key advancements include revolutionary throughput enhancements that significantly improve final finish processes without adding costs, ease-of-use innovations that simplify complex systems for less experienced operators and increased flexibility through automated changeovers to address the growing number of SKUs in tyre production.

Additionally, it is advancing automated inspection and defect detection by helping its customers shift from manual to autonomous inspection, which encompasses more precise numerical measurements, reduced errors and a reduction in overall inspection costs.

A major breakthrough in this area is the integration of AI and deep learning (DL) into its Coll-Tech Automatic Defect Recognition (ADR) software for tyre X-ray image analysis. Showcased at the 2024 Tire Tech Expo, the latest advancements have dramatically improved defect detection accuracy and responsiveness to customer configuration and customisation requests.

“Previously, algorithmic versions required extended response times for adaptation and modification, but the AI-driven enhancements have eliminated this delay. Multiple manufacturing facilities are now operating their ADR-equipped X-ray systems without human inspectors, allowing personnel to be redeployed elsewhere while significantly reducing inspection expenses. The transition to full autonomous inspection is a learning process that requires adaptation, but the investment yields substantial positive financial returns. Micro-Poise’s ADR system allows our customers to control the pace and number of steps in the journey to full autonomous inspection. To facilitate adoption, we offer image evaluations, follow-up consultations and in-plant demonstrations,” said Dr Immel.

Beyond inspection advancements, Micro-Poise has also improved tyre grinding systems, enhancing both functional system performance and the visual appearance of ground tyres.

Historically, tyre grinding – used for force variation and geometry optimisation – has been instrumental in converting rejected tyres into OE-grade products. However, some manufacturers hesitate to adopt grinding due to concerns about visible grind marks. Micro-Poise has addressed these concerns by refining the grind appearance and adding new functionalities that turn tyre grinding from an art into a precise science. These innovations increase product yield, improve tyre grading and deliver a strong return on investment for manufacturers. With AI-driven defect detection, automation advancements and improved tyre yield solutions, Micro-Poise is setting new standards for efficiency, accuracy and cost savings in the final finish stage of tyre manufacturing.

The company continuously refines its technology, balancing cost efficiency with high performance. “Customers request additional features based on unique measurement methodologies and defect detection requirements,” Dr Immel said.

Customers expect the machines to operate for decades. Mechanically, the company’s systems are built for longevity, but electronics and software evolve much faster. To address obsolescence, the company offers modular control system upgrades bundled with new features, ensuring customers gain added value while modernising their equipment and extending its lifecycle.

In the context of retrofitting, Dr Immel said, “We design machines to accommodate sensor and measurement upgrades, enabling customers to integrate new parameters without replacing entire systems. The balance lies in designing robust mechanical structures while allowing flexibility in electronics and software.”

ADDRESSING CHALLENGES

Developing intuitive, easy-to-use machines is an ongoing challenge. “Simplifying a machine while maintaining its capabilities is often harder than designing a complex system,” Dr Immel noted.

The company has invested in UX/UI enhancements to improve operator efficiency and ease of use.

Furthermore, the tyre industry is currently facing one of its most dynamic and challenging periods, driven by rapid technological advancements, shifting regulations, sustainability initiatives and the rise of EVs.

One of the biggest challenges is aligning new technologies with practical applications that benefit customers while ensuring their confidence in these innovations. AI and automation, for example, are transforming manufacturing processes, but their complexity can be daunting for tyre producers who must navigate ever-changing market demands.

Additionally, external factors such as tariffs, trade wars and regulatory changes add another layer of uncertainty, making it critical to choose the right technologies that will bring long-term value.

Sustainability is another key concern as tyre manufacturers work to reduce environmental impact through raw material innovations, renewable energy adoption and energy-efficient manufacturing processes.

While the company does not directly influence the chemical composition of tyres, it contributes to sustainability by designing testing and measurement equipment that uses less energy and air.

With AI-driven automation, faster cycle times and a strong focus on usability and upgradeability, it continues to push the boundaries of tyre testing technology. As the industry embraces data-driven solutions, the company remains at the forefront of precision measurement and defect detection.

FUTURE FOCUS

The industry is undoubtedly shifting towards fundamental measurement improvements and enhanced features like predictive maintenance, retrofitment and software upgrades.

“While reducing testing time and improving efficiency remain core priorities, there is an increasing demand for smart, automated solutions that can provide deeper insights into machine performance. Predictive maintenance is an exciting development area, but it is still in its early stages. The ultimate vision is to have intelligent software capable of real-time monitoring systems and predicting failures with precision. However, before reaching that stage, the focus is on establishing a solid data foundation and ensuring rapid recovery when issues arise,” averred Dr Immel.

To address these challenges, the industry is exploring soft sensor technology as a potential alternative to expensive hardware-based monitoring systems. These advancements could reduce reliance on physical sensors while still enabling predictive maintenance capabilities. As the industry moves forward, manufacturers must balance cost, efficiency and long-term viability to maximise the benefits of these innovations.

“The integration of AI and DL technologies is poised to continue, though adoption will likely be measured as manufacturers proceed with caution. While some advancements will prove transformative, others may fade over time. AI-driven systems can significantly improve productivity by shortening design and improvement cycles, making processes more efficient. Additionally, AI models can refine their accuracy over time through continuous feedback and training, leading to smarter and more effective applications in manufacturing,” he added.

He also noted that one key concern is the potential burden on customers. Some AI implementations risk shifting performance optimisation responsibilities such as defect evaluation, labelling and training onto end users. While this may be expected in later stages of adoption, it presents a significant challenge in the early phases, making seamless integration into existing workflows critical.

Another significant area of advancement is tyre grinding technology. While some manufacturers hesitate to use grinding due to concerns over visual imperfections, it remains a valuable and financially beneficial process for refining tyres that exceed variation limits.

Recent innovations aim to standardise and automate grinding, transforming it from an art into a precise, science-driven method. These advancements make the process more efficient and user-friendly, ensuring higher-quality output without compromising visual appearance. n

Micro-Poise TGIS FS Geometry Sensor

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.

In 2025, Comerio Ercole proudly celebrates 140 years of activity – a monumental milestone that reflects not only the strength of its legacy but also the resilience, adaptability and innovative spirit that have shaped its journey since 1885.

From its origins as a manufacturer of machinery and industrial plants, Comerio Ercole has grown into a globally respected industrial group, fully integrated from design to commissioning, operating with precision, quality and commitment to technological advancement. Headquartered in Busto Arsizio and Castellanza, with over 55,000 square metres of operational facilities, Comerio Ercole remains a beacon of excellence in the tyre industry supplying high-performance complete rubber calender lines.

A legacy rooted in excellence

Built on generations of family leadership and continuous investment in knowledge and infrastructure, Comerio Ercole has positioned itself as a pioneer in patented calendering and mixing technologies, with machinery and solutions operating in India and on every continent. The company's ISO 9001, ISO 14001 and ISO 45001 certifications underscore its ongoing dedication to quality, sustainability and safety.

Over the decades, Comerio Ercole has cultivated long-term partnerships with key players in industrial innovation. These alliances – both technological and commercial – have enabled the company to develop tailored solutions for its clients, often in the form of turnkey plants, revamping services or customised IoT-enabled systems. The company's R&D activities, supported by two state-of-the-art laboratories, continue to lead the way in circular economy practices and recycling technologies, including processing of recovered rubber materials.

 

Engineering the future: INDUSTRY 5.0

As the industrial world enters the ‘Industry 5.0’ era, Comerio Ercole is embracing the future with agility. A new, dedicated Industry 5.0 department is now operational to support global customers with advanced IoT integration, teleservice and remote maintenance systems.

With a strong emphasis on ESG sustainability, digital transformation and the human-centric approach of Industry 5.0, Comerio Ercole continues to position itself at the cutting edge of modern manufacturing.

 

Circular economy & environmental commitment

In partnership with other Italian companies, Comerio Ercole is driving a new industrial standard for rubber recycling through the LOGOS patented plant – a compact devulcanisation solution that transforms vulcanised rubber waste into 100 percent reusable compounds for tyre and rubber production​. This new project is a clear signal: the company’s future is circular, and sustainability is more than a goal – it’s an operational strategy.

 

People, values, vision

At the heart of Comerio Ercole’s longevity is its people – over 200 highly trained technicians, engineers and professionals – and its values: quality, technology, reliability, competence and service.

Through continuous education and a company-wide ‘Quality Culture’, Comerio Ercole empowers its teams to meet the most demanding global challenges.

 

What’s next?

Comerio Ercole is not just preparing for the future, it’s building it. As it enters this new era, the company is focused on:

• Scalable IoT & AI solutions for every machine and plant
• Sustainable production models compliant with international ESG regulation
• Custom engineering projects
• Global partnerships to co-create innovation

 

As it looks to the future, Comerio Ercole stands not only as a symbol of Italian industrial heritage but also as a visionary leader shaping the future of manufacturing – a company ready to tackle tomorrow’s challenges with the same passion and precision that defined its first 140 years.