There couldn’t be any industry that isn’t implementing, or at least knowing about, automation. And if there’s actually one, then it has probably been living under a rock. The tyre industry has already opened its doors to automation, and this helps make tyre manufacturing more sophisticated and reliable. The tyre manufacturing process itself has been experiencing constant changes – from different tyre sizes and constructions to targeting less usage of energy. Automation must be on every tyre company’s to-do list, if it hasn’t adopted it already. Don Heelis, Sales Manager, Cimcorp, gave Tyre Trends more insights on the different aspects of automation in the tyre industry and its absolute requirement, when we met him at the Tire Technology Expo 2022 in Hannover, Germany. Read on…

The philosophy of tyre manufacturing has changed dramatically. A part of the change in that philosophy relates to automation implementation in the tyre manufacturing process. However, we also find more technical perspectives being adopted and taken into account at new, modern tyre factories today.

This technical perspective can be considered to be coming from a few different areas, one of them certainly being from the actual production part of the tyre factory. Therefore, with production machinery, mixers, extruders and tyre building machines, the level of technology being implemented in these processes is increasing. Moreover, these processes are getting more sophisticated.

The other aspect of this is integrating the production across all the different areas (another factor for the dramatic change in the modern tyre factory). In the past, the different areas of production were not necessarily well connected. However, today we see them getting connected a lot more – and this is being driven and enabled by technology.

This is where companies like Cimcorp come in – who happen to provide material handling and automation technology so that different tyre manufacturing processes are better integrated.

Explaining this, Don Heelis, Sales Manager, Cimcorp, said, “When you produce your work in process, what you’re producing is in synchronisation with what’s being produced in other areas of the factory. This helps minimise the work in process and have a manufacturing process that’s more efficient.”

Going the modular way
But how does one integrate different machines and processes in the plant with all the different machines and manufacturing processes involved? Heelis let us in on this.

“The trick is to implement the automation and connectivity in a modular way,” he revealed and went on, “That way, the connectivity is physical and mechanical but involves software as well. Thus, we take an approach where the modules are flexible and can connect to various inputs and outputs; however, the module is in itself standardised. Hence, the modules can work for different factories – only the interconnection needs to be flexible.”

The green tyre
While implementing automation, one, of course, would want to implement it where they get the biggest value. “Traditionally, that has been in the palletising area – in managing and handling the finished product. Basically, palletising, storing and retrieving the finished product,” Heelis informed us and continued, “This is where everyone has traditionally looked in the past. However, a lot of focus has been put on the green tyre area in the past 10 years. That includes green tyre handling, storage and retrieval and its automatic delivery to the curing process.”

A green tyre is work in process – simply put, a tyre that has not been cured. “A green tyre is made up of a number of components. It’s built on a tyre-building machine,” Heelis further told us. “Once a green tyre is built, it is buffered, followed by being cured – and automation machines are required in order to do this. Hence, this is a key element of the modern tyre factory.”

He added, “This has been an area of key focus where productivity and simplicity can be gained. In fact, the whole process can be done with less plant floor space. Ultimately, factories that want to be competitive have to implement automation technologies in that area.”

Increased efficiency
There are many brownfield factories out there that have to modernise and be viable for the future. One of the key areas that they need to modernise and automate in is green tyre handling. Heelis asserted, “By having an automated storage and retrieval system, one can track and trace all of the work in process. Plus, one is able to store in a manner that maximises the quality of the green tyres. And then, one can deliver them from the storage system to the curing process in a very systematic and accurate way. This way, when a particular green tyre is needed in the curing area, it can be delivered there in the appropriate amount of time.”

“In this methodology, when the green tyre arrives at curing, it is at that point in time when it is needed, and the production does not have to stop,” Heelis further shared. “If this can be achieved, then the curing process can be run more efficiently; the efficiency can go from 80 percent to over 95 percent. In theory, one can increase the output of their factory by 10 percent. In such a case, one can imagine how many tyres can be produced in a factory by following this methodology.”

Automation – its role during the pandemic and inflation
While automation tends to bring in efficiency, how have companies managed to keep up their competence and productivity during the thorny period of the Covid pandemic? The pandemic has definitely brought some insights to the tyre industry from a management point of view, like it did to many other sectors. According to Heelis, automation has come to the rescue of the tyre industry in the pandemic as well.

“One important thing that the industry learnt from the pandemic was that it has a risk to its ability to produce products,” he mentioned and went on, “The absence of automation will make any company in the industry highly dependent on the labour force, which might not be available to keep the production going. On the other hand, with automated processes, a company is less at risk to events like a pandemic.”

Another issue we are dealing with right now in the global economy is inflation. Inflation equals to costs going up – from the cost of materials to the cost of labour. “Nonetheless, a company can mitigate some of the impacts of inflation if it has embraced automation. In fact, the ones who automated their brownfield factories three to four years ago are in a much better position today than their competitors who had not,” Heelis pointed out and went on, “This is because the former can mitigate some of the inflation costs, is less dependent on the workforce and is able to produce better-quality products – and at a higher level of efficiency at that. We know that there is a tremendous shortage of people in the workforce in the US right now. Therefore, automated companies have a significant competitive advantage.”

From the tyre industry’s challenges due to the pandemic and inflation, we turned to the challenges Cimcorp itself faces on the commercial side. Heelis responded that, commercially, the current challenge for them is being a low-cost, high-quality producer – which one has to be in order to compete in the market. “Furthering this challenge is how we become a low-cost, high-quality producer and stay that way. And from our perspective, the way to get there is through innovation and technology,” he stated.

Automation in the Asian tyre industry
CIMCORP opened up an office in India roughly three years ago. With its presence in the country and Asia, Heelis told us that the tyre companies in Asia are no stranger to automation and are implementing it. “As a move forward, the mentality is that if you want to be a world-class manufacturer and build a new factory, then you build the factory with automation. And this is a global perspective,” Heelis asserted.

Cimcorp’s customers in Asia range from traditional tyre manufacturers to new manufacturing entrants in the industry, so it’s a mix. Throwing further light on this, Heelis said, “We all know the traditional manufacturers like Bridgestone, Michelin, Goodyear, Continental and more. But beyond these, there are new companies emerging. And these new companies have an advantage in some ways because they are not constrained by the old ways of thinking. They are forward thinking, with a clearer mindset to do things in the current environment – the environment of automation and technology.”

“Moreover, the manufacturers who don’t invest in automation, and try to run the company with practices that were developed in the 1960 and 70s, will not be able to survive or compete,” he further added. “Their market will eventually consider them to be non-competitive, non-global and unable to produce the quality expected of them.”

Cimcorp has plans for India as well. “Our strategy is to continue to grow our business in India with the domestic tyre manufacturers, and we have been successful at that,” Heelis shared and went on, “When I say domestic, that goes for manufacturing facilities within India, from Apollo Tyres to MRF to JK Tyre to Goodyear to Michelin. Thus, we plan to continue to build our business with those factories and customers from an automation perspective, and then from a full customer service point of view.”

The other aspect comes to brownfield factories. Heelis averred, “With brownfield factories, whether in North America or Asia, the cost of automation is the same; there may be different payback scenarios between the two. However, it stands true that no matter where a company is present in the world, if it is operating a brownfield factory, then it needs a strategy to modernise. And the strategy to modernise is based on implementing automation.”

Automation in brownfield factories – what will it take?
The strategy to modernise when automating a brownfield factory is especially challenging in an already existing system. Therefore, when automating a brownfield factory, one of the most important considerations is to not interrupt their day-to-day production, Heelis cited. He mentioned that the factory has to continue making its certain number of tyres each day. Hence, a strategy that enables the factory to do that is needed – while concurrently implementing automation there.

“Besides, when you implement automation, you have to be able to do it in a standardised way,” Heelis further enlightened and continued, “This can be done with the help of flexible automation modules that can work in a lot of different scenarios. Therefore, you can deal with different brownfield factories depending just on how you arrange your automation modules. Thus, you can come up with a custom solution for every different brownfield factory out there with the help of a modular approach and on the basis of how you connect those automation modules together.”

Service provided
From providing standard modular systems to hardware to software, Cimcorp strategically has a service aspect to its business – Success Services. Therefore, the approach from its service side is to enable its customers to be as successful as possible.

“That could be achieved by providing a 24/7 support. So if the customers contact us due to an issue they are facing in the solutions provided by us, we are available at any time of the day or night to support them,” Heelis revealed and added, “We can do it remotely. In fact, as technologies emerge further, we’ll see how we can do this more remotely with virtual techniques. Here, their serviceperson could be using special tools, which enables our people (who are remote) to actually be in virtual situations in our customers’ plants. In such wise, we can be more responsive and be as if we are in place in real-time in order to provide a service.”

Tyre warehouse automation or manual operation – making the choice
Nevertheless, Cimcorp does not just stop at its 24/7 services or providing its automation solutions for tyre manufacturing processes. It goes beyond that – to the finished product warehouses. However, interestingly, that depends to a degree on which part of the world the automation is needed in; while some areas will need automation that is well advanced, some areas will use a more manual operation.

Heelis explained, “There are some key factors that determine whether the facility/area in question needs to be automated or not. For example, the cost of real estate. If it’s a manual operation, then that typically involves a very large warehouse, say around 100,000 sq mt.”

“For automating, on the other hand, you require lands that are much smaller,” Heelis further highlighted. “For instance, land is very expensive in Japan. Thus, one wouldn’t want a very big footprint warehouse over there. Which means, you go vertical wherever land is expensive.”

“On the flip side, land is very cheap in some areas and inexpensive to build the generic building (like in some areas of the US). So there is less incentive to go vertical with automation there,” he added. “But there might be other factors that could dominate.”

Choosing automation over manual operation – why?
While some main factors do influence the decision if a warehouse is going to be a fully automated one or a semi-manual one, an automated one is always preferred. For clear reasons.

“The benefit of an automated warehouse is that everything is extremely well controlled,” Heelis informed. “What’s more, you have complete control of your product – you know exactly where it is, how much of it you have and you can get on-demand access.”

“As for a semi-manual warehouse, there are fork trucks, people moving things around and putting them in different storage locations,” Heelis further clarified. “This process is much more manual, involves a lot more interaction and is time consuming. Therefore, you have much less control over the process.”

Automation – a need not to be confused as a luxury
The automotive industry has been one of the earliest industries to adopt automation. So it’s high time that tyres, an integral component of any vehicle, did so too. It’s clear that automation, today, is not a luxury but a need. No company can afford to not have it. No tyre company must be limited to older technologies, and they must invest in automation for the long term. This would not just help tyre manufacturers meet their customers’ demands without any delay, but also help modernise the industry with the world’s rapidly changing technologies.

The order book for Curemaster is strong with a surge in orders during the first two months of the year. The executive anticipates continued momentum throughout the year, driven by increasing global demand for advanced, sustainable curing solutions.

FORWARD INTEGRATION

According to Rudman, digitalisation is playing a crucial role in enhancing the efficiency and reliability of curing presses. “Digitalisation provides real-time visibility into production processes, allowing manufacturers to monitor efficiency and product quality continuously. With a clear overview of operations, manufacturers can identify inefficiencies and ensure production targets are met. The HF XPLORE digital portal offers access to critical data at all times. It provides insights into machine health, predictive maintenance alerts and production performance. The system helps track efficiency, detect potential failures and optimise operations by identifying areas for improvement,” he said.

Artificial intelligence is also slated to play a key role in electrical heating, ensuring stable temperature control within the platens. Machine learning is being developed for predictive maintenance, helping to forecast bladder life and detect potential failures before they occur. These technologies are part of the company’s development roadmap, focusing on improving reliability and efficiency in curing press operations.

He also noted that as tyre compounds evolve, curing requirements will change, making electrical curing a more suitable solution. Unlike steam-based systems, where temperature is directly linked to pressure, electrical curing allows independent control of both factors. This flexibility is crucial for processing new materials that may not tolerate traditional curing conditions.

“In steam curing, the relationship between pressure and temperature is fixed. For example, achieving a temperature of 200 degrees Celsius requires increasing the pressure to 20 bar. With electrical curing, temperature and pressure are completely separate, enabling curing at lower temperatures while maintaining the necessary pressure levels. This capability is particularly significant for future materials, which may require curing at 160 degrees Celsius but at much higher pressures,” explained Rudman.

The shift towards electrical curing is expected to gain momentum, particularly for high-end and specialised tyres that demand more advanced curing strategies. While steam curing will continue to be used for lower-segment applications, the upper range of the market, especially where sustainability and material innovations are key factors, will require the precision and adaptability that electrical curing provides.

OVERLAPPING TECHNOLOGIES

There is a clear trend in the market where customers are seeking more customised solutions rather than standard off-the-shelf curing presses. Manufacturers now have unique requirements including features like electrical curing, digitalisation, automated loading and unloading and seamless integration with factory infrastructure and tyre transportation systems. As a result, the demand for tailored solutions is increasing, making flexibility a key factor in the adoption of new curing technologies.

“Curemaster is designed with upgradeability in mind, ensuring that tyre manufacturers do not have to replace entire presses when looking to modernise operations. Even older HF curing presses that have been in service for more than 20 years can be upgraded to electrical curing without altering the mechanical structure. This allows manufacturers to transition to more efficient curing technology while retaining the existing equipment. At the same time, the new Curemaster is available as a fully electric system from the outset, offering a ready-made solution for greenfield projects,” averred Rudman.

Nonetheless, the biggest business potential currently lies in retrofitting existing curing presses rather than selling entirely new equipment. “Many customers prefer upgrade kits that allow them to transition to electrical curing while maintaining current production setup. While greenfield projects present a significant opportunity for new fully electric presses, the greater demand at present is for retrofit solutions, as it provides a cost-effective way to improve efficiency and sustainability without major infrastructure changes,” he added.

PROCESS OVERVIEW

Most curing press suppliers have introduced electrical curing solutions. There are two main approaches to electrical heating, which are electromagnetic (induction) heating and resistive heating.

Electromagnetic heating method involves placing a coil outside the tyre to generate heat. However, there are concerns about how this method interacts with the tyre’s internal bead wire and breaker package. Since the long-term impact of electromagnetic fields on tyre integrity has not been fully tested or verified, there are still some uncertainties regarding its effects on tyre quality.

In contrast, resistive heating, which the company employs, places coils directly inside the plate, ensuring controlled and targeted heating. This method eliminates any risk associated with electromagnetic interference and allows precise temperature application only where needed. While both technologies are viable, resistive heating offers greater reliability and consistency in maintaining tyre quality.

“One of the key advantages of electrical curing is its rapid heating and cooling capabilities. The nitrogen used in the process can be heated from 20 degrees Celsius to 250 degrees Celsius in less than 20 seconds and cooled back down in the same time frame. This is achieved through continuous nitrogen circulation, where the system directs the flow through either the heater or the cooler as needed. In terms of curing time, electrical heating currently matches steam curing with a typical cycle of 10 minutes per tyre. However, there is significant potential to reduce curing time by 10 to 15 percent as electrical systems can operate at higher temperatures and offer more precise control over the process,” informed Rudman.

Nonetheless, steam curing has a predominant risk of mishaps in the bladder, which could lead to an explosion. The Curemaster is designed with a fully encapsulated dome, ensuring that any pressure build-up remains contained. If a failure occurs, the pressure is released downward instead of sideways, reducing the risk of injury.

The locking system is also unique. Even if there is a total power or hydraulic pressure loss, the press cannot open unintentionally. This containment and locking mechanism ensure a high level of safety during operation.

CHALLENGES AND OPPORTUNITIES

According to the executive, the biggest challenge in the curing press business comes from cost competition as lower-cost manufacturers pose a significant pricing challenge. However, from a technological standpoint, the company offers unique features that set it apart from competitors. While competitors may have cost advantages, HF’s focus on advanced technology, automation and digitalisation allows it to capture market share by offering superior functionality and efficiency.

The passenger car and truck segments remain the company’s primary focus owing to the highest growth potential. Additionally, the company sees an emerging opportunity in motorcycle and bicycle tyre curing, particularly with electric heating technology. HF is among the first to introduce electrical curing for these segments, positioning itself as an industry leader.

While HF is active in the passenger and truck segments, it has opted not to enter the off-the-road tyre market due to its relatively small size and intense competition. The segment still relies heavily on traditional mechanical presses, making it less attractive for innovation-driven solutions.

The company continues to refine the Curemaster lineup by introducing new materials, insulation techniques and design concepts. The company is particularly focused on increasing automation to enhance efficiency and reduce operational costs.

Beontag, one of the world’s largest manufacturers of self-adhesives and smart tags such as RFID, NFC and BLE, has entered into a collaboration with Kumho Tire to develop RFID-enabled tyres for commercial and passenger vehicles.

The partnership will see new Kumho tyres use Beontag's TyreTag RFID technology. Traceability will be possible with the RFID-enabled tyres from the point of origin to recycling and disposal. Following years of research and development, according to both the companies, the new RFID-enabled tyre is very robust and dependable, able to survive high temperatures and pressures over the course of years of intensive use. The new TyreTag-enabled tyres' traceability will also adhere to the forthcoming Ecodesign for Sustainable Product Regulations (ESPR), which will need Digital Product Passports (DPPs) and be in force for tyres starting in 2028–2030.

Thiago Horta, Global VP of Digital Transformation, Beontag, said, “We are extremely proud to share what we have achieved in our partnership with Kumho Tire. Through rigorous testing, we have worked hard to develop the necessary technology and durability capabilities in these RFID-enabled tyres; I look forward to continuing this journey with Kumho Tire for years to come”

Jihon Park, Assistant Manager with Kumho Tire, said, “Kumho Tire has been producing RFID-enabled tyres since 2013. Beontag’s technical expertise and collaborative approach were instrumental in helping us meet our rigorous standards and enhance our technology. We look forward to delivering even greater quality and reliability to our customers around the world.”

Goodyear has launched the Value Simulator, an online tool designed to assist fleet operators in visualising the possible financial and environmental advantages of upgrading their mobility and tyre solutions. The simulator is now available on the company's truck tyre website and is a component of Goodyear Total Mobility, the company's end-to-end solution for commercial fleets.

According to Goodyear, the tool takes into account typical fuel consumption and cost, fleet size and breakdown frequency, vehicle mileage and maintenance trends and the kind of transportation and route profile. After data is entered, the simulator instantly estimates the potential decrease of CO2 emissions, maintenance and fuel costs, and annual breakdown-related cost savings. Additionally, customers can customise simulations according to their own fleet characteristics.

The CO₂ reductions are based on theoretical fuel usage using EU tyre label values as a baseline; real savings may vary depending on factors including driver behaviour, vehicle condition and road conditions. Additionally, based on user interaction, the simulator suggests appropriate Goodyear goods and services. These recommendations can be used as a springboard for talks with Goodyear's staff in order to do a more thorough study and develop a customised fleet plan.

Maciej Szymański, Marketing Director Commercial at Goodyear EMEA, said, “At Goodyear, we are committed to supporting transport fleets in maximising efficiency, increasing competitiveness and promoting sustainability. The Goodyear Value Simulator confirms our dedication to customer-centric solutions and helps fleet managers to make informed decisions that aim to drive tangible benefits for their operations. With the Goodyear Value Simulator, fleets can visualise the potential financial and environmental impact of adopting Goodyear Total Mobility. From reducing breakdown costs to enhancing fuel efficiency, our solutions are designed to deliver real value to our customers.”

Webfleet, Bridgestone’s globally trusted fleet management solution, has launched its new flagship Driver Terminal, the PRO X, designed specifically for truck and van fleets.

By providing direct tablet access to Webfleet fleet management services, the PRO X links drivers and companies to streamline work administration. Fleets can utilise a variety of sophisticated Webfleet features, such as workflow management, electronic Proof of Delivery (ePOD) and two-way communication between drivers and fleet managers thanks to the pre-installed Webfleet Work App. They can also access other Webfleet services, such as Cold Chain, Remaining Drive Times and OptiDrive ranking, which allows drivers to view peer performance.

Van and truck fleets may enjoy the best-in-class professional navigation with the newest technology, like smart warnings for traffic or low-emission zones, major points of interest for trucks and EVs and live ETA reporting, with easy access to TomTom GO Fleet.  Additionally, when paired with OptiDrive, the motorist gets immediate feedback to help them drive better. Pre-installing maps is now simple, and they are updated automatically every month. With its wide anti-glare screen, sturdy construction, detachable battery and user-friendly controls for instant access to essential programmes, the new high-performance Driver Terminal helps professional drivers both in-cabin and on-site.

With an integrated Mobile Device Management (MDM) system that enables fully remote management of the devices' home screen, app auto-start and other features, it is configured for a quick roll-out in the field and can be tailored to fit various corporate demands. Because it is Android Enterprise Recommended and integrates Webfleet's and TomTom's expertise in sophisticated navigation, devices may be more rapidly customised to meet user demands. Beginning in March 2025, the PRO X will be sold in Europe, Australia and New Zealand, with other territories to follow later this year.

Annick Renoux, Vice President, Webfleet Europe, said, “At Webfleet, we are always committed to delivering smart solutions that enhance the working conditions and safety of our customers and their drivers, powered by the latest technology. That’s why we are proud to introduce the new PRO X – now with even more functionality to help fleet managers streamline their operations, boost efficiency and strengthen their connection with field teams like never before.”