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.

Hana Technologies, Inc. (Hana RFID), a global leader in the design and manufacturing of embeddable RFID tyre tags, has become the first RFID company to join the Circular Rubber Platform. This development aligns with Hana RFID’s mission to drive innovation in tyre traceability and reinforces the company’s long-standing commitment to sustainability and circularity in the tyre and rubber industry.

Hana RFID has been at the forefront of RFID-enabled tyre traceability since 2005, facilitating smooth tracking from cradle to grave and promoting circularity. Hana's RFID tyre tags, which are embedded during manufacturing, provide each tyre a distinct digital identity, facilitating complete lifetime tracking from manufacture and use to recycling and reuse. Hana hopes to promote RFID usage in sustainable tyre lifecycle management by working with leading companies in the sector, which will eventually save waste and increase resource efficiency.

Using radio frequency identification (RFID) technology, an RFID tyre tag is a tiny, embedded device that tracks, monitors and controls tyres. In addition to providing smooth connection with inventory monitoring, fleet management systems and other digital applications, such as the European Digital Product Passport (DPP), these tags produce digital twins of tyres. Hana's RFID solutions empower the whole tyre ecosystem to expedite fleet management, improve inventory control, optimize maintenance, and create creative business models that increase sustainability and efficiency.

Val Peters, VP – Marketing, Hana RFID, said, “We are excited to join the Circular Rubber Platform as the first RFID company in this initiative. RFID technology is essential for advancing a circular economy in tyre manufacturing, and we look forward to collaborating with partners across the rubber sector to drive sustainability on a broader scale.”

Enrico Koggel, Co-Founder, Circular Rubber Platform, said, “RFID technology is key to enabling a circular rubber economy. RFID enables seamless tracking from production to end-of-life recycling by connecting material and production data into each rubber product. It provides traceability and easy identification and allows for smart sorting of materials and efficient recycling to ensure responsible reuse, remanufacturing, recycling and waste reduction. We are therefore very happy to announce Hana as a new member of the Circular Rubber Platform, with the technology and experience they can provide to the platform. We look forward to sharing knowledge on RFID and working out opportunities for this technology in rubber industries that require Digital Product Passports in the near future, such as footwear.”

TÜV SÜD has expanded its test laboratory in Frankfurt am Main and unveiled new testing facilities at an Open Lab Day at the site, giving customers and employees an exclusive insight into the new state-of-the-art testing environments. The expansion strengthens TÜV SÜD’s position as a leading provider of independent testing and certification services.

Car charging plugs can now be tested in the lab to assess features like weather resistance, mechanical strength and electrical safety. To guarantee the endurance and durability of charging plugs and other parts, the new lab can also conduct crash testing on them. The inclusion of performance testing for tiny batteries is another significant development. Basic functional analysis will be the main emphasis of these tests at first, but in the second part of the year, comprehensive safety and performance evaluations will be included. Similar to this, power tool testing capabilities have been greatly increased to give manufacturers an even more thorough evaluation of the calibre, robustness and safety of their goods.

The capability to ascertain the biogenic carbon content of materials is an additional highlight of the expansion. These assessments support the implementation of sustainable manufacturing methods by giving businesses evidence of the utilisation of renewable raw resources. In order to make sure that packaging and other materials fulfil the strictest safety regulations and don't leak dangerous compounds into food, the testing infrastructure for materials that come into contact with food has been increased at the same time. It's also important to note the recently added ability to evaluate welding fume filtration systems, which may undergo a thorough performance assessment and will soon be certified.

TÜV SÜD is now able to provide an even greater variety of chemical testing services to make sure that products satisfy the most recent regulatory standards thanks to the expansion of its Frankfurt laboratory. With standardised testing for compounds including PFOS, PFOA, C9-C14 PFCAs, and PFHxS, there is a special emphasis on PFAS analysis. Due to the laboratory's expansion, even more businesses may now make use of its extensive testing knowledge, which includes services related to durability testing, risk assessment and certification for a range of product categories.

Walter Reithmaier, CEO, TÜV SÜD Product Service GmbH, said, “By expanding our laboratory in Frankfurt, we are responding to growing demand for product testing and certification. Our new testing capacities will set new standards in safety, sustainability and performance. We look forward to supporting our customers with state-of-the-art testing technology and professional expertise.”

Chicago-based Koala Technologies (KTL), a leading automotive testing, measurement and evaluation tools provider, has launched Te.Sense Bloom – a breakthrough in non-destructive rapid tyre deflation testing. The company has introduced the base kits starting at USD 20,000.

The solution the company claims is fully compliant with FMVSS 110 and emerging EV stability test standards. The Te.Sense Bloom allows passenger vehicle manufacturers and tyre makers to cost-effectively reuse solutions, thereby optimising test programmes while reducing waste.

Currently, the rapid tyre deflation tests often rely on a vehicle being driven over special roadway cleats at defined speeds. This method sees tyres destructively punctured and destroyed by the cleats, and internal inflation pressure is quickly reduced to atmospheric pressure. At times, these tests aim to ensure that the tyres are safely seated on the wheels post rapid deflation, wile at times it is to evaluate vehicle stability in terms of tyre failure.

The company stated that this tests however require destroying multiple tyres, not only leading to waste but may also corrupt certain vehicle dynamics tests that call for a single, targeted tyre failure.

On the other hand, with Te.Sense Bloom, the industry can use non-destructive controlled, rapid deflation for the selected tyres. Using a controllable central air ejector valve with a volume and a flow capacity that simulates a sudden tyre press loss. While the method sounds simple and frugal, the innovation lies in relation with the turn-key nature of Te.Sense Bloom. Automotive testers and engineers get a repeatable set up method, easy in-car operation and simple connectivity with data acquisition systems. As part of its comprehensive supply to Te.Sense Bloom customers, KTL even offers a wheel setup service to simplify test preparations.

The other advantage of Te.Sense Bloom is that the tyre deflation event can be triggered from inside the vehicle or remotely that further expands test scenario possibilities. It can be used for testing tyre inflation pressures up to 100 PSI and speeds up to 140 kmph (87 mph). The real-time tyre inflation data at 100 Hz has a claimed data accuracy of +/-0.1 PSI.  

Kenneth Martin, Head of Tyre Testing at the Transportation Research Center, said, “We have significant experience with rapid tyre deflation tests, using all types of methods, and we’re looking forward to evaluating KTL’s Te.Sense Bloom, since it represents a turn-key, non-destructive solution. There’s definitely some baseline justification for test equipment like this because it fundamentally means consuming fewer tyres. But Te.Sense Bloom’s inherent connectivity opens some other doors also, since triggered and monitored rapid tyre deflations are becoming an area of interest for vehicle stability testing, especially in EV space.” 

The first U.S.-specification kit has been delivered to the Transportation Research Center in Ohio for initial evaluations.

Being compliant with EV stability testing standards the Te.Sense Bloom is already being used by OEMs globally such as Huawei AITO, SAIC Motor Corp and GAC Motor to conduct regulatory tests such as GB/T 38796-2020 (Performance Requirements and Test Methods of Automobile Blow-out Emergency Safety Device).

Mike Lee, Founder and President, KTL, added, “Koala Technologies is excited to introduce Te.Sense Bloom into new markets, beginning in 2025. Bloom has been widely adopted for vehicle development testing in China over the last several years, becoming a must-have tool for many OEMs and key suppliers. It’s one example, among many, of an excellent, trusted, useful automotive testing device that no one knows about outside China. A part of our mission at KTL is to shine a light on some of these exciting technologies that are currently available, but not widely known. Another part of our mission is to help customers achieve their goals more efficiently and at a lower cost. We look forward to the upcoming testing at the Transportation Research Center in Ohio, and we hope that Te.Sense Bloom proves to be a good fit for automotive development programmes in the U.S and beyond.”

Bridgestone Corporation has developed a new Tyre and Road Wear Particles (TRWP) vehicle collection method aimed at understanding the environmental impact of TRWP. The solution was also displayed at the Tire Technology Expo 2025, held in Hannover, Germany, from 4 to 6 March.

TRWP is made up of a blend of road pavement components and tread (tyre surface). In order to comprehend the particle size distribution, dispersion behaviour, and environmental impact – as well as to create effective collecting techniques – Bridgestone is actively engaged in a number of TRWP research projects. The company is dedicated to comprehending TRWP and lowering its generation through these initiatives.

Utilising the B-Mobility testing facility at the Bridgestone Innovation Park in Kodaira, Tokyo, the company has created a state-of-the-art technique that makes it possible to gather TRWP effectively. Bridgestone has used laser light scattering in conjunction with a high-speed camera to visualise the dispersion of particles like TRWP. Based on this, the company has developed a device that effectively catches TRWP and covers the whole tyre. Additionally, the technique made it possible to collect TRWP effectively in a state that removes the effects of exhaust pollutants and broken dust by employing autonomous driving and an electric car with regenerative braking.

Through the Tire Industry Project (TIP), which is part of the World Business Council for Sustainable Development (WBCSD), Bridgestone has been researching the physical and chemical properties of TRWP and their implications on the environment. In addition to the continuous co-creation and internal R&D cooperation, Bridgestone is speeding up its efforts to evaluate TRWP's environmental consequences by collecting it effectively and with a high recovery rate using its recently developed collection technology.