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.

Michelin India is doubling down on the country’s fast-growing premium tyre segment, a niche yet rapidly expanding market. The company, which has been manufacturing radial commercial tyres at its Chennai plant, is now investing over INR 5.64 billion in a brownfield expansion to produce passenger car radial tyres at the same facility.

Today, Michelin India is not just a manufacturing hub but also a critical part of the global Michelin ecosystem, housing the company’s world AI headquarters and a state-of-the-art R&D centre, growing from a modest operation with fewer than 100 employees to a total workforce of nearly 3,000.

In an exclusive interview with Tyre Trends, Shantanu Deshpande, Managing Director, Michelin India, touches upon the company’s strategic priorities, the evolving tyre industry and its ambitious plans for the premium and electric vehicle (EV) segments.

He also sheds light on Michelin’s sustainability initiatives and how the company is leveraging India’s growing infrastructure and consumer preferences to solidify its position as a market leader in the premium segment.  The premium proposition:

Catering to discerning consumers

When Michelin first entered the Indian market, it was a niche player with a limited presence. The company’s initial focus was on introducing radial tyres to a market dominated by bias tyres. Over the years, Michelin has not only expanded its manufacturing footprint but also cemented its position as a leader in the premium tyre commercial tyre segment. 

“We started with TBR tyres (Truck and Bus Radial) over a decade ago,” Deshpande recalls. “Back then, the industry was dominated by bias tyres. Today, radial tyres account for almost 70 to 80 percent of the market, and we’re now seeing a shift from tube-type to tubeless tyres. This transformation has been driven by infrastructure improvements and the rise of e-commerce, which demands faster, more efficient logistics.” 

Currently, tubeless tyres have a 5-10 percent market share, while tube tyres own the rest.

Deshpande highlights the dramatic changes in India’s road infrastructure as a key driver of this evolution. “When I was a sales executive, the Delhi-Mumbai corridor took eight days to traverse. By the end of this year, it will take just 24 hours. Truck speeds have increased from 25-30 km/h to 40-50 km/h, and soon, they’ll reach 60 km/h, comparable to Europe. These changes have created a demand for high-performance tyres that can handle heavy loads and long distances,” he explains.

The rise of e-commerce has further accelerated this demand. “Some fleets are running 25,000 kilometres per month,” Deshpande notes. “This is a significant distance for trucks, and it underscores the need for tyres that offer durability, fuel efficiency and safety.” 

Michelin’s focus on premium tyres has been a cornerstone of its strategy in India. Deshpande emphasises that the company’s value proposition lies in offering a lower total cost of ownership (TCO) for fleet operators, particularly in the TBR segment. 

“Fuel accounts for 60 percent of a truck operator’s costs,” he explains. “Michelin intends to work with like-minded fleet operators who understand the value proposition of TCO. We are changing their tube radial tyres to tubeless radial tyres. For instance, our X Multi Energy Z+ tyre, with the lowest rolling resistance in the country, can save up to 15 percent on fuel compared to traditional tubeless radial tyres. This is a game-changer for fleet operators who understand the importance of TCO.”

Cost per kilometre Vs total cost of ownership

Deshpande elaborates on Michelin’s approach to cost per kilometre (CPK) and total cost of ownership (TCO), which are critical metrics for fleet operators.

“Cost per kilometre is one way to simplify invoicing, but it’s not the complete picture,” he explains. “While CPK focuses on the life of the tyre, we believe in a broader approach – total cost of ownership. A Michelin tyre not only lasts longer but also saves fuel, which is a significant cost for fleet operators. It’s important to look at the overall savings, not just the tyre’s lifespan.”

Michelin offers innovative service models to fleet operators, including on-site maintenance and diagnostics. “We have models where technicians are stationed at fleet yards,” Deshpande says. “We provide free diagnostics to identify issues like under-inflated or misaligned tyres, which can significantly impact costs. We then offer maintenance services to ensure optimal performance, and this is a paid service – it’s not free. We work with fleets to show them the cost savings we can bring per-truck, per-month basis.”

The company also invests in equipment like tyre fitting and alignment machines at fleet yards. “We bear these costs into our service offerings,” Deshpande adds.

Premium passenger radial tyres: New target

In the passenger vehicle segment, Michelin is targeting the growing demand for premium and luxury cars. In September 2024, Michelin India entered the passenger car radial tyre market with the launch of an INR 5.64-billion brownfield project in Thervoy kandigai, near Chennai. “This investment is over and above the existing investment of INR 28.40 billion for the company in our factory,” adds Deshpande.

“We believe there is significant potential in the passenger segment for several reasons. Over the last three years, the vehicle landscape in India has significantly changed,” Deshpande says. “Today, most new SUVs and cars are being launched with bigger tyre sizes, such as 16-inch or 17-inch. This shift aligns perfectly with our focus on premium tyres.”

According to Deshpande, the shift towards premium products extends beyond automobiles. “There is a growing demand for premium products across all walks of life, not just automobiles. This includes two-wheelers, luxury bags and other high-end items. Consumers are willing to pay for quality,” adds Deshpande.

Deshpande points to the changing profile of Indian consumers as a key factor driving this trend. “The Indian consumer is evolving,” he says. “Ten years ago, a Mercedes owner was typically an industrialist or a Bollywood star. Today, young professionals in their 30s are driving BMWs and Mercedes. Last year, close to 50,000 cars priced above INR 50 lakh were sold in India, and we expect this number to double soon.” 

Improved road infrastructure has revolutionised leisure travel habits. “10 to 15 years ago, travelling from Mumbai to Delhi by car was uncommon. It’s possible to drive from Mumbai to Nagpur in eight hours today,” Deshpande said. “People now prefer driving long distances rather than flying, which has significantly changed how consumers view their cars.”

Michelin’s Chennai plant is strategically focused on producing tyres for this premium segment. “We’re manufacturing sizes 16 inches and above at our Chennai plant,” Deshpande says. “We’re not interested in smaller sizes. Our goal is to cater to the top 25-30 percent of consumers who value quality and are willing to pay for it.” 

The company’s retail distribution strategy is equally focused on maintaining a premium experience. “A Michelin customer, such as a BMW owner, expects nothing less than a premium experience,” Deshpande explains. “We’re not aiming for a vast network of dealers. Instead, we’re focusing on well-branded shops that offer a superior consumer experience.” 

The company plans to open its premium retail shops for passenger car tyres in the top 15 to 20 cities to cater to the replacement market.

The EV opportunity: Balancing performance and sustainability

As the automotive industry shifts towards electrification, Michelin is positioning itself as a leader in EV tyres, and Deshpande also acknowledges the unique challenges and opportunities this transition presents. 

“EV tyres require specific designs, such as low rolling resistance and larger diameters,” he explains. “But it’s not just about range. Load-carrying capacity, noise reduction and durability are equally important. Michelin has mastered the art of balancing these performance criteria.” 

Deshpande dispels the misconception that EV tyres are fundamentally different from those used in internal combustion engine (ICE) vehicles. “Some of our tyres are excellent for ICE vehicles but even better for EVs,” he says. “We don’t design tyres purely for range. Instead, we ensure they deliver the right balance of performance, safety and comfort.” 

Michelin’s approach to EV tyres is already yielding results. “The tyres we’ve designed for ICE vehicles are being adopted by EV manufacturers globally,” Deshpande reveals. “In India, as the EV market grows, we’ll leverage our global expertise to cater to this segment.” 

Sustainability at the core

Sustainability is a key pillar of Michelin’s strategy, both globally and in India. The company’s Chennai plant is a zero-discharge facility that recycles all its water through rainwater harvesting. By the end of this year, the plant will be powered entirely by renewable energy. 

Deshpande asserts,” Our Chennai plant is one of the most high-tech and green facilities in the Michelin world. It’s a benchmark for safety, modernity and environmental responsibility.” 

The tyres manufactured in Chennai are exported to North America, Europe, Africa and the Middle East.

Michelin’s commitment to sustainability extends beyond its manufacturing processes. The company also focuses on developing tyres that increase fuel efficiency and reduce emissions. “Our X Multi Energy tyre, for instance, has a rolling resistance of just 4.5 kg per tonne, compared to the industry average of 6.5-7 kg per tonne,” Deshpande says. “This translates to significant fuel savings and a lower carbon footprint.” 

Premium two-wheeler segment: Another growing opportunity

Michelin India continues its presence in the two-wheeler tyre segment through a manufacturing arrangement with STL (Spinmax tyres Pvt Ltd), via an offtake arrangement.

Despite current import restrictions, the company eyes opportunities in India’s evolving motorcycle market.

“The two-wheeler segment is undergoing significant transformation,” says the Managing Director of Michelin India. “With the increasing launch of high-powered bikes like Royal Enfield and other global brands, along with Indian manufacturers producing world-class bikes for export, this segment presents a great opportunity.”

The company sees a natural overlap between its target markets. “The profile of consumers buying high-powered bikes often overlaps with those buying premium cars,” Deshpande thinks. Michelin plans to focus on motorcycles and scooters of 250 cc and above, where the company believes its brand visibility and value proposition are strongest.

The strategy mirrors Michelin’s approach in the passenger vehicle segment. The company maintains local outsourced manufacturing of two-wheeler tyres while exploring future expansion opportunities.

The French tyre maker continues to evaluate opportunities in India’s growing premium two-wheeler market as domestic manufacturers increasingly target global markets with higher-end models.

Michelin India: A place for global R&D & AI Centre

In addition to Michelin India’s manufacturing capabilities, it has also established a Global Hub in Pune focusing on next-generation technologies such as AI, data engineering, digital services and R&D centre, which supports research efforts for the Michelin Group worldwide. 

Deshpande is also optimistic about the role of Indian R&D in Michelin’s global operations. “Our Pune centre is not just supporting India; it’s contributing to global markets,” he says. “The talent here is recognised for its innovation and expertise, not just cost arbitrage. At our Global Competency Center in the city, the company isn’t just optimising tyres but redefining how they’re designed, manufactured and used. This is a proud moment for us.” 

As Deshpande puts it, “Michelin is not just selling tyres; we’re selling safety, comfort and peace of mind. In a market as dynamic as India, that’s a value proposition that resonates.”

The global tyre industry is undergoing a significant transformation, driven by the need for materials that reduce environmental impact without compromising performance. In a world where sustainability is essential, close collaboration with suppliers is critical to addressing these challenges.

For Synthos, Europe’s largest producer of synthetic rubber, the path is clear: develop advanced solutions that support sustainable mobility, promote circularity and work closely with tyre customers and partners to advance environmentally responsible tyre production and accelerate the transition to a net-zero future.

Synthetic rubber innovation

Synthos operates three state-of-the-art manufacturing facilities in Germany, Poland and the Czech Republic, with a combined annual production capacity of 760,000 metric tonnes, producing a diverse portfolio of elastomers, including SSBR (SPRINTAN ), BR (SYNTECA) and ESBR (KER and BUNA), which are essential to the tyre industry and a wide range of other technical applications. Supported by commercial offices across the Americas and Asia, Synthos supplies advanced solutions to global markets.

Tyres account for over 90 percent of their energy consumption during the use phase, primarily through vehicle fuel or electricity usage. Improving energy efficiency is therefore critical to reducing their environmental impact. At the same time, tyre wear particles are a key challenge, with longer-lasting tyres and enhanced abrasion resistance essential to addressing microplastic generation. For electric vehicles (EVs), these challenges are further amplified by increased weight and instant torque, which place greater demands on tyre performance.

As the world’s largest producer of functionalised solution styrene-butadiene rubber (SSBR), Synthos is tackling these challenges head-on. Its next generation of multi-functionalised SSBRs, developed under the SPRINTAN brand, features optimised low glass transition temperatures (Tg) to deliver lower rolling resistance for improved energy efficiency, alongside excellent abrasion resistance and wet grip. A standout example is SPRINTAN 918S, which entered full commercial production in 2024. Developed with proprietary technology, this highly functionalised SSBR combines exceptional wet and dry grip with enhanced energy efficiency and wear resistance, all while maintaining processability during compound production. Designed for summer, winter and all-season tyres, SPRINTAN 918S is particularly effective for EVs, where durability and efficiency are paramount.

With additional low-Tg SSBR grades in development, Synthos remains at the forefront of sustainable, high-performance materials for the future of mobility.

Investing in a green future

While leading in supply, Synthos’ commitment to sustainability sets it apart. Recognising the environmental impact of its manufacturing processes and products, Synthos is dedicated to minimising this impact throughout its operations, implementing measures to minimise waste and ensuring the efficient use of resources.

Synthos was the first in the industry to offer its entire synthetic rubber portfolio as bio/circular-attributed materials under ISCC PLUS certification, now supplied through its PLUS range. The company also prioritises transparency and traceability, providing detailed data from its production processes to help customers make sustainability-focused decisions. Each synthetic rubber grade is accompanied by a cradle-to-gate Product Carbon Footprint (PCF), enabling precise evaluation of its environmental impact.

Aligned with its Sustainable Development Strategy, Synthos has pledged to operate all facilities with carbon-free energy by 2028, investing in low- and zero-carbon energy sources. By reducing the environmental impact of its operations, Synthos is laying the foundation for a greener, more sustainable future.

Building strong partnerships

Collaboration is at the heart of Synthos’ approach to advancing sustainability and innovation. By working closely with partners across the tyre lifecycle, the company is driving circular innovation and addressing key challenges within the industry.

Through its partnership with Tyre Recycling Solutions (TRS), Synthos promotes the use of TyreXol™ rubber powder, derived from end-of-life tyres, in synthetic rubber formulations. This collaboration supports sustainable manufacturing by keeping valuable materials in circulation and reducing waste. A memorandum of understanding (MoU) with Sumitomo Rubber Industries further strengthens this initiative, with both companies focusing on the development, testing and application of TyreXol™ technology as part of their shared commitment to the circular economy.

Synthos has also signed an MoU with Kumho Tire, a leading South Korean tyre manufacturer, to jointly develop sustainable raw materials for tyre production. This collaboration includes research into neodymium-butadiene rubber using bio-based butadiene, aiming to expand the use of environmentally friendly synthetic rubber in tyre manufacturing.

Upstream, Synthos has partnered with OMV, an Austrian multinational integrated oil, gas and petrochemicals company, to secure a long-term supply of sustainable butadiene produced from circular feedstocks, such as used cooking oil and pyrolysis oil derived from end-of-life tyres.

Beyond these partnerships, Synthos is actively involved in leading industry initiatives, including the Alliance for the Future of Tires (AZuR) and the Circular Rubber Platform, further reinforcing its connections within the industry.

Focused on the mobility of tomorrow

The challenges of sustainability cannot be solved in isolation. As demand from leading tyre manufacturers for sustainable synthetic rubber continues to grow, Synthos is aligning with stakeholders across the value chain to deliver advanced, high-performance materials tailored to its customers’ needs, whether ISCC PLUS-certified materials, bio-based rubber or customised products developed in collaboration with its partners.

Through its dedication to innovation, renewable resources and strong partnerships, Synthos Synthetic Rubber is shaping a future where performance and sustainability work together, ensuring the tyre industry evolves responsibly.

Groeneweg is the global Global Marketing Director Synthos

Japanese tyre major the Yokohama Rubber Co in joint-research with Dr. Bo Nils Johan Persson have successfully developed in December 2024, the world’s first theoretical model to predict the rubber wear-rates on uneven road surfaces and the size distribution of wear particles.

Dr Persson is a leading a leading expert in the study of rubber friction and contact, contact, friction, wear and lubrication, including rubber friction. He is associated with Peter Grunberg Institute (Germany) and Lanzhou Institute of Chemical Physics (China).

He also runs a company called Multiscale Consulting (Germany) that supports companies in the rubber industry and beyond in addressing various challenges.

What’s more Dr. Persson’s unique approach to contact mechanics and rubber friction have been documented in numerous peer-reviewed academic journals and verified by other scientists, proving its effectiveness in solving a wide range of problems.

The new research was selected as the most noteworthy item and featured as the cover story in the 21 February 2025 edition of ‘The Journal of Chemical Physics’ published by the American Institute of Physics.
Yokohama Rubber known for its extensive track record in rubber research and advanced technological development capabilities, entered into a contract with Multiscale Consulting to collaborate with Dr. Persson in studying friction and wear on rubber and road surfaces.

The partners successfully developed what they claim is the world’s first theoretical model for multiscale (ranging from nanometre to centimetre levels) rubber wear behaviour on uneven road surfaces, for which theorisation had been difficult in the past. Experiments measuring rubber wear behaviour when sliding in both dry and wet conditions at different contact pressures and sliding speeds showed that the theoretical model’s predictions of wear-rates (mass loss per unit of sliding distance) and size distribution of wear particles aligned closely with the experimental results, confirming that the model could be used for such predictions.

Going forward, Yokohama Rubber plans to continue conducting research with Dr. Persson and Multiscale Consulting in order to pursue the development of tyres with high-level wear resistance.

In addition, Yokohama will continue to focus on reducing tyre wear, which is a leading demand for EVs to have reduction in environmental issues.

Yokohama India, a subsidiary of Japan's Yokohama Rubber Co., has begun manufacturing 20-inch tyres at its Bahadurgarh plant in Haryana state, expanding its local production capabilities amid growing demand for larger tyres in India's premium vehicle segment.

The company's latest offering includes the Geolandar X-CV (G057), a high-performance tyre designed for luxury SUVs, featuring an asymmetric tread pattern and advanced silica compounds. The tyres will be available through Yokohama's network of over 3,000 retailers across India.

"With improving road infrastructure and advancement in vehicle geometry, passenger segment vehicle are now opting for larger-inch tyres," said Gaurav Mahajan, Head of Marketing at Yokohama India. "Higher inch tyres also offer better handling and safety as they could accommodate advance braking systems. By expanding our local production capabilities, we are future-proofing our offerings---now with the capability to manufacture up to 24-inch tyres---ensuring that we continue to serve the premium segment with cutting-edge, high-performance products."

This development follows the company's recent introduction of 19-inch tyre manufacturing at the same facility. Yokohama India, which began operations in the country in 2007, opened its first manufacturing plant in November 2014.