HOW IT CREATES A FUTURE- PROOF TYRE MANUFACTURING…

Conventional tyre manufacturing systems require too much human skill and intervention, so the impact and consequences of digitalisation on the tyre industry are even greater. Standard manufacturing processes require strict monitoring, corrections and automation at every stage. Digitalisation offers numerous benefits for sustainable production improvements. They achieve measurable results in manufacturing, quality improvement, marketing and sales.

Tyre manufacturers monitor and automate their processes, reduce manual labour and gain real-time insights into production line status and performance. Barcode and QR code labelling streamlines production processes, enables efficient and cost-effective tracking and improves accuracy and efficiency. Traceability is simple and feasible, improving profitability and customer satisfaction.

Scanning simplifies the location, tracking of parts and materials and provides manufacturers with real-time insights into their production processes. RFID applications are gaining momentum in the passenger tyre segment, having already demonstrated numerous benefits in commercial applications.

Digitalisation technologies help quick identification of production defects in the final product and increase productivity with AI based scanning, inspection, real-time decision-making processes.

Digitalisation in the tyre industry is a gradual process that will improve performance, quality and profitability being on the way of real Industry 4.0 applications in tyre manufacturing. It continually opens up new opportunities to leverage data for better decision-making. Overall, digitalisation in tyre manufacturing is a powerful tool that unlocks the full potential of production. However, after implementation, continuous investment, as well as internal research and improvements, are required.

The tyre manufacturing industry is constantly evolving. Machines are becoming increasingly automated, more precise and data-driven. Recent advances based on the principles of Industry 4.0 include the aforementioned IoT, AI (artificial intelligence), robotics and sustainability.

Industry 4.0-driven digitalisation is based on the concept of the ‘digital twin’, meaning every machine is a data node. Data from every step (compound parameters, component dimensions, curing profiles) is collected for each tyre. This creates a virtual replica of the physical tyre, which is a ‘digital twin’ that enables complete traceability and data-driven process optimisation.

The role of humans is evolving from simple manual tasks to monitoring, diagnostics and data analysis. Robots, especially collaborative robots or cobots,

are taking over tasks such as final inspection and material handling. These revolutionary steps and concepts are having a major impact on manufacturing, optimising quality, performance, customer satisfaction and contributing to business success.

Modern mixing systems are increasingly replacing conventional tangential mixers. The intermeshing of the two rotors ensures more efficient and homogeneous mixing with better temperature control. This leads to higher mixing quality and consistency.

New mixing technologies, on the other hand, utilise ‘continuous mixing systems’, i.e. the continuous and simultaneous supply of all raw materials in precisely controlled quantities. The materials are continuously mixed in a series of specialised extruders and mixing units. At the end, a continuous stream of a perfectly homogeneous mixture emerges. This represents a revolution compared to conventional batch mixing. It improves energy efficiency, reduces the carbon footprint and enables unprecedented consistency and traceability.

Highly automated ‘multi-calender systems’ are equipped with multiple rollers that can simultaneously produce multiple layers (e.g. carcass ply, squeegee layer or inner liner) with extreme precision in thickness and width. Similar to extrusion lines with laser thickness control, these systems ensure 100 percent control and transmit data immediately to the extrusion head and calender roll clearances for automatic adjustment and maintenance of tolerances down to a fraction of a millimetre.

Thanks to the ‘multi-stage transfer’, the tyre casing is transferred between drums for the various production steps automatically and without human intervention, automatic cutting and splicing prevent deviations in quality. RFID technology integrated fully assures correct recipe and security in component application.

The robotic application and component preparation, such as with 6-axis robots, is now widely used for the fast and precise gripping and placement of complex components such as bead and apex assemblies.

Electric vulcanising presses are equipped with intelligent mould controls, whose integrated sensors monitor temperature and pressure in real time across multiple zones. The AI system dynamically adjusts the vulcanisation cycle (time, temperature, steam pressure) to ensure perfect curing of each tyre and compensate for any mould or material deviations.

Furthermore, predictive maintenance is now essential to avoid unplanned production downtime. Vibration, temperature and pressure sensors installed on manufacturing machines monitor all machine functions and alert when maintenance is required. High-precision servomotors, replacing pneumatic or hydraulic systems, work with servo-electric robots and are used in various production phases with submillimetre precision, reducing energy consumption and maintenance requirements.

The most visible technological advances in finishing and inspection lines today are fully automated with full sensitive cameras, AI-integrated and non-destructive testing (NDT) machines. Automated high-resolution X-ray machines scan each tyre to detect hidden defects such as trapped air, steel cord separation, or bead wire issues. Shearography and holography – being traditional but now equipped with intuitive, incredibly fast and precise modes – use lasers and intelligence to detect underlying defects or separations by measuring stress-induced deformations.

Uniformity and force variation measurement systems utilise AI algorithms to not only identify a tyre as ‘good’ or ‘bad’ but also diagnose the root cause of the deviation. Robotic trimming and polishing machines automatically locate and remove burrs (excess rubber) from the tyre using precise grinding tools – a traditionally manual and laborious task.

Of course, the future of tyre manufacturing, driven by advanced digitalisation, IoT and robotics, is rapidly evolving into a model for a smart, autonomous and sustainable industry, often referred to as ‘Tyre Industry 4.0’.

This transformation isn’t just about doing the same things faster; it will fundamentally change tyre design, production, sales and even performance. Tyre production facilities will become more autonomous, adaptable, efficient, predictive, personalised and, as expected, more sustainable.

Industry 4.0 and AI-powered digitalisation will accelerate sustainability. Precision manufacturing minimises material waste through the use of high-precision components. AI can easily manage energy consumption throughout the factory. IoT sensors monitor the overall condition of tyres, ensuring fast tyre changes, safety and performance.

This transformation will lead to safer, more efficient and more environmentally friendly tyres.

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Balkrishna Industries Ltd. (BKT) has expanded its partnerships in India’s premier men’s T20 cricket league to eight teams, adding Royal Challengers Bengaluru for the upcoming season as it seeks to strengthen its position in the country’s consumer tyre market.

The company said its BKT Tyres brand would continue as Official Tyre Partner to Kolkata Knight Riders, Sunrisers Hyderabad, Rajasthan Royals, Mumbai Indians, Gujarat Titans, Punjab Kings and Lucknow Super Giants, alongside the newly added Bengaluru franchise.

The move comes as BKT advances its entry into India’s consumer tyre segment, using the tournament as a platform to expand visibility and engage a broader customer base, including commercial operators and private vehicle owners.

The partnerships are structured as long-term arrangements, incorporating stadium branding, broadcast integrations, dealer activations and digital campaigns aimed at strengthening fan engagement.

Rajiv Poddar, JMD of BKT, said: “Partnering with sporting institutions has always been central to BKT’s philosophy of Growing Together with communities. Cricket is one of the most influential cultural forces in India, uniting people across geographies, generations and backgrounds. Our continued partnerships as the Official Tyre Partner under the BKT Tyres brand allow us to connect with audiences in a meaningful way while strengthening our presence in the tyre segment. Through this association, we will further amplify our ‘Elevate Your Drive’ campaign featuring Ranveer Singh across broadcast and digital touchpoints, bringing the campaign’s message of ambition, progress and forward momentum to millions of viewers. These collaborations reflect our commitment to building long-term relationships founded on teamwork, performance and shared aspirations.”

Venky Mysore, Chief Executive of Kolkata Knight Riders, said: “BKT Tyres is not just a partner they are a brand that shares our relentless pursuit of performance. This renewed association is a testament to the trust we have built together and the ambition we carry forward. As BKT accelerates its growth in India's consumer market, the Knight Riders brand gives them the platform, the passion, and the global scale to make that journey count. At Knight Riders Sports, we do not build partnerships for visibility alone we build them for impact. This collaboration is precisely that: two performance-driven organisations, aligned in purpose, investing in a future they intend to win together.”

Rajesh Menon, Chief Executive of Royal Challengers Bengaluru, said: “Royal Challengers Bengaluru is proud to welcome BKT Tyres as our Official Tyre Partner. At RCB, we believe in pushing boundaries, embracing ambition, and creating meaningful connections with our fans, values that closely align with BKT’s ‘Elevate Your Drive’ philosophy. Together, we aim to accelerate our shared vision of excellence, resilience, and forward momentum both on and off the field.”

K Shanmugam, Chief Executive of Sunrisers Hyderabad, said: “We are happy to continue our partnership with BKT Tyres as part of this T20 cricket league. This collaboration reflects a strong alignment of values, bringing together a shared focus on excellence, performance, and consistency. Together, we move forward with clear intent, committed to raising standards both on and off the field, while delivering a meaningful and engaging experience for fans.”

Alok Chitre, Chief Operating Officer of Rajasthan Royals, said: “We are delighted to partner with BKT Tyres for the sixth year, with a shared energy and drive for performance that continues to strengthen our association. Their commitment to sport, and cricket specifically, reflects a clear focus on the growth of the game and its fan ecosystem in India. As we advance in scale and influence, we look forward to building on this partnership in a meaningful way this year as well.”

A Mumbai Indians spokesperson said: “BKT Tyres has been a valued long-term partner of Mumbai Indians, and this continued partnership reflects a shared commitment to consistency and performance. We look forward to building on this partnership through the season.”

Colonel Arvinder Singh, Chief Operating Officer of Gujarat Titans, said: “Gujarat Titans are pleased to continue the association with BKT Tyres. Partnerships like these reflect a shared commitment to performance, consistency and long-term growth. Such collaborations provide a strong platform for teams and brands to connect with fans across the world, and we look forward to building on this association while continuing to engage meaningfully with our supporters and striving for excellence both on and off the field.”

Satish Menon, Chief Executive of Punjab Kings, said: “We are very happy to continue our journey with BKT Tyres. They have been a loyal and valued partner for the Punjab Kings over the years. Their commitment to excellence matches our ambitions, and it is always a pleasure to work with a brand that understands the pulse of the sport and its fans so well.”

Vinay Chopra, Chief Executive of RPSG Sports Private Limited, said: “At Lucknow Super Giants, we believe that strong partnerships are built on shared values of performance, resilience, and ambition. Our association with BKT Tyres reflects this synergy, as both brands are committed to pushing boundaries and consistently striving for excellence. As we gear up for another exciting season, we look forward to engaging our fans more deeply and creating meaningful experiences together through this partnership.”

BKT said its sports partnerships form part of a broader global portfolio spanning multiple disciplines, aimed at reinforcing brand visibility and consumer engagement.

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Goodyear India Limited said its board has taken note of the resignation of Abhishek Arora as Director – Human Resources, India, with effect from April 20, 2026, and approved the appointment of Vishal Dhingra as HR Director, South Asia from April 21, 2026.

Arora, who will also cease to be a senior management personnel member on April 20, 2026, resigned to explore external growth opportunities, according to the company.

The board approved Dhingra’s appointment following the recommendation of the Nomination and Remuneration Committee. He will assume the role as a senior management personnel from April 21, 2026.

Dhingra has more than 25 years of experience in human resources. He joined Goodyear in July 2020 as Director HR – India and currently serves as HR Director – ASEANZ. Prior to this, he held roles at PepsiCo, India, GlaxoSmithKline Consumer Healthcare Limited, Eicher Tractors and Ballarpur Industries Limited.

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India has concluded that imports of emulsion styrene butadiene rubber (ESBR) of the 1500 series from the European Union, Japan, South Korea, Russia and Thailand were dumped, following an anti-dumping investigation initiated in March 2025.

The Directorate General of Trade Remedies (DGTR), under the Ministry of Commerce and Industry, found that dumping margins across all subject countries were above the de minimis threshold and “significant”.

The investigation was launched after Reliance Industries Limited filed an application alleging injury from imports of the product, which is widely used in tyre manufacturing and other rubber goods. The authority determined that the application met the requirements for standing, with support from Indian Synthetic Rubber Private Limited.

The product under consideration, ESBR-1500, is primarily used in tyres due to its abrasion resistance and ageing stability. The DGTR concluded that domestically produced material is comparable to imported goods and can be used interchangeably.

The period of investigation covered October 2023 to September 2024, with injury analysis spanning four financial years. During this time, imports from the subject countries rose overall and accounted for more than 90 per cent of total imports throughout the period.

The authority found that import volumes were highest during the investigation period and had increased relative to domestic production and consumption.

Dumping margins varied by country. Imports from the European Union and Japan were found to have margins in the range of 10–20 per cent, while Russia showed higher margins of 20–30 per cent. South Korea and Thailand recorded lower ranges, generally between 0–10 per cent for cooperating producers and up to 10–20 per cent for others.

The DGTR conducted a cumulative assessment of imports, concluding that goods from the subject countries compete with each other and with domestic production in the Indian market.

On injury, the authority determined that increased imports had affected the domestic industry through price suppression and declining profitability. It noted that while demand for the product rose steadily, the domestic industry’s financial performance weakened over the same period.

The DGTR also rejected arguments that the injury was caused by internal inefficiencies or raw material volatility, stating that such fluctuations were global and not specific to India.

The authority concluded that dumped imports had caused material injury to the domestic industry, establishing a causal link between import volumes and the deterioration in financial performance.

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Fornnax Technology, a global leader in recycling equipment manufacturing, has officially brought Sushil Upadhyay on board as the new Head of its Service Department, a leadership transition that takes effect immediately. With a professional background spanning over 26 years, Upadhyay arrives with extensive experience drawn from multiple multinational corporations. Throughout his career, he has successfully managed and coordinated large, cross-functional teams comprising more than 300 professionals. Within his new capacity at Fornax, his primary focus will involve steering strategic transformations within the service domain, with the objective of optimising equipment reliability, maximising value across the lifecycle of machinery and elevating the sustained performance of the company’s worldwide installed base of industrial recycling solutions.

In the coming year, the service division under his leadership is set to concentrate on a series of clearly defined operational objectives. Key among these is the effort to curtail instances of unexpected machinery downtime by integrating both preventive and predictive maintenance approaches. The team also intends to roll out measurable performance benchmarks for service delivery, which will include tracking metrics such as speed of response, Mean Time to Repair (MTTR) and overall equipment uptime. Moreover, there will be a concerted push to reinforce the availability of spare components by optimising regional warehousing and distribution processes.

Further developments on the agenda involve the creation and delivery of well-structured training modules targeting technical expertise and workplace safety, aimed at enhancing the capabilities of service personnel. In parallel, the organisation plans to introduce digital tools designed to boost transparency in operations and enable customers to more effectively monitor service activities. These combined efforts underscore Fornnax’s commitment to evolving its service infrastructure in response to growing demands for efficiency and reliability.

Jignesh Kundaria, Director & CEO, Fornnax, said, “Our people are the true engine behind our innovation and execution. As we scale globally and expand our footprint across diverse recycling applications, cultivating a culture of excellence remains central to our strategy. In 2026, we are intensifying our focus on talent development, leadership growth and building a high-ownership, high-accountability environment that drives continuous improvement across engineering, manufacturing, and service. This will set new benchmarks in the industry, and I believe Upadhyay will play a crucial role in this journey.”

Upadhyay said, “Fornnax’s strong positioning in high-capacity shredding solutions and its commitment to sustainable recycling deeply resonated with me. The company’s engineering strength and rapid growth trajectory present a powerful opportunity to build a world-class service organisation. In an industry where machine reliability directly impacts customer profitability, service becomes a direct driver of customer success. I am excited to elevate Service from a support function to a strategic growth enabler, which is specifically focused on uptime, lifecycle value and long-term partnerships.”

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