Jeremias Neuhaus: “One of the biggest challenges in adopting data-driven solutions in the tyre industry is the availability of data and convincing customers not just of the solution itself but of the value of data transfer and real-time monitoring."

The tyre industry faces a significant challenge in data availability with fragmented supply chains, a lack of standardisation and minimal digital infrastructure limiting operational efficiency. Despite the growing importance of predictive maintenance, many manufacturers still rely on manual processes, while competitive concerns and regulatory restrictions further restrict data sharing. This absence of real-time insights hampers decision-making, making operations reactive rather than proactive. However, digitalisation and advanced data analytics are gradually reshaping the landscape. Solutions like HF Xplore aim to bridge this gap, offering real-time monitoring and predictive capabilities that can drive efficiency, sustainability and cost reduction.

Data availability is a challenge in the tyre industry due to fragmented supply chains, lack of standardisation and limited digital infrastructure. Manufacturers, distributors and recyclers operate in silos, making data consolidation difficult. Many businesses still rely on manual processes, while competitive concerns and regulatory restrictions further limit data sharing. Tracking end-of-life tyres (ELTs) is particularly challenging, impacting recycling efficiency.  

However, data availability is crucial for optimising operations, sustainability and innovation. Real-time data enables predictive maintenance, helping fleet operators reduce downtime and improve safety.

Accurate tracking of tyre usage and recycling supports circular economy initiatives and regulatory compliance. It also enhances research and development initiatives for advanced tyre materials such as electric vehicles and off-the-road (OTR) tyres, ensuring better performance and durability.

Improved data transparency can drive smarter decision-making, cost efficiency and sustainability in the industry. Digitalisation and data standardisation are key to overcoming these challenges.

However, HF Group’s Global Head of Digital Solutions, Jeremias Neuhaus, told Tyre Trends, “One of the biggest challenges in adopting data-driven solutions in the tyre industry is the availability of data and convincing customers not just of the solution itself but of the value of data transfer and real-time monitoring. Many decisions in the industry are still based on gut feeling rather than data-backed insights. Our focus is to bridge this gap by providing transparency into machine performance, enabling customers to make data-driven decisions instead of relying on intuition. By implementing real-time monitoring, we can significantly reduce downtime and help customers optimise processes. Even in the first step of implementation, simply visualising machine health and performance brings immediate value. Customers receive notifications for potential issues, allowing them to take preventive action before costly breakdowns occur.”

“The biggest opportunity in this space lies in the fact that data-driven insights can drastically improve operational efficiency. Once machines are connected and data is flowing, customers gain a much deeper understanding of the equipment, leading to better decision-making and optimised production cycles. Predictive maintenance and AI-driven analytics will further enhance operations by identifying potential failures before they occur. This is particularly crucial as manufacturers aim to reduce carbon emissions and energy consumption while increasing efficiency. Our approach stepwise towards AI-powered predictive solutions bring even greater efficiency and cost savings,” he added.

A critical concern in the tyre industry is data security and confidentiality, given how secretive manufacturers are about the respective production processes. “We address these concerns by focusing strictly on machine data rather than the proprietary tyre-making process. Our solutions do not need the actual process details to provide valuable insights. Additionally, the real, detailed data remains visible only to the customer, ensuring that they retain full control. In cases where AI-driven analytics are implemented, we collaborate closely with customers to develop models tailored to specific needs without compromising sensitive production data,” revealed Neuhaus.

The company launched the HF Xplore few years ago as a condition monitoring solution purely for curing presses. One of the significant developments following the merger of HF Mixing Group and HF Tire Tech Group has been the integration of previous initiatives into a joint project, creating a common condition monitoring solution. As a result, HF Xplore is now available for both curing presses and mixer lines. This expansion allows the company to offer real-time monitoring and predictive insights across two of the most critical processes in tyre manufacturing curing and mixing.

MONITORING TYRE FORMULATIONS

Curing and mixing are fundamentally different processes in tyre making, which presents a challenge in making HF Xplore compatible with both. The solution is to split monitoring into two layers viz-a-viz a common monitoring framework and machine-specific components.

The common framework includes monitoring cycle times, alarms, key performance indicators (KPIs) and production progress – elements that apply to both curing presses and mixer lines. However, each machine type has unique components that require dedicated monitoring.

For curing presses, especially electric-curing, HF Xplore focuses on monitoring hydraulic power unit and the electric curing, which is a crucial aspect of efficiency and quality control. On the other hand, for mixers, the system focuses on critical mechanical components such as the RAM movement, feeding mechanisms and drop doors, which are key areas that directly impact mixing performance and consistency. The drop doors, for instance, play a crucial role   in ensuring a smooth transition of rubber to the downstream process, making their monitoring essential for operational reliability.

The user interface of HF Xplore is designed to maintain familiarity across different machines. The dashboard layout remains consistent, so users who are accustomed to using it for curing presses will find a similar experience when working with mixer lines. This consistency reduces the learning curve and makes the system more intuitive for users handling both curing and mixing equipment.

Behind the scenes, the company is investing heavily in data modelling to refine and improve predictive capabilities. The company is developing individualised, flexible data models tailored to each machine type.

These models analyse operational patterns, detect anomalies and provide real-time insights to minimise downtime. By combining machine-specific expertise with data-driven intelligence, HF Xplore continues to evolve into a powerful predictive maintenance and performance optimisation tool for the tyre manufacturing industry.

INTO DATA MODELS

HF Xplore captures machine data but doesn’t analyse it directly. Instead, the system applies background logic to determine whether values are within acceptable limits. Currently, its primary function is real-time status monitoring, giving users an overview of machine condition. However, future iterations will introduce predictive maintenance capabilities, allowing companies to anticipate and address potential failures before they happen.

“At this stage, HF Xplore detects and predicts issues but does not provide specific solutions. As the technology evolves, it will go beyond identifying potential failures to offering actionable recommendations. This shift will help businesses move from reactive maintenance to a more proactive approach, reducing downtime and improving operational efficiency. To refine predictive maintenance, the system is being trained with large datasets in collaboration with customers. Over time, this will enhance the system’s accuracy, enabling it to not only flag potential issues but also suggest corrective actions,” informed Neuhaus.

AI and machine learning will play a central role in the company’s future roadmap, following a structured three-step approach – visualise, analyse and predict.

The first step will provide real-time machine status and process transparency. In the analyse phase, the company’s solutions will move beyond monitoring to offer deeper insights. The system will evaluate performance trends, identify operational limits and provide status feedback. The final phase will be where AI and machine learning take centre stage by analysing vast amounts of historical and real-time data. AI models will identify patterns, forecast failures and recommend preventive actions.

Commenting on whether implementing HF Xplore for a curing press or a mixing system presents different challenges, he said, “While both require detailed monitoring, mixing systems are more complex due to the interconnected components including upstream and downstream processes. Unlike curing presses, which operate as standalone units, mixing lines require data collection across multiple machines for effective monitoring. However, HF Xplore benefits from deep integration with its own equipment, leveraging PLC data to ensure seamless functionality across different systems.”

But for this to be a reality, different data models are pivotal. “The data model is essential for structuring and standardising the information displayed on the dashboard,” informed Neuhaus.

RETROFITTING HF XPLORE

HF Xplore is compatible with both greenfield and brownfield machines, though older models with outdated PLCs may have limitations. “While we cannot retrofit machines that are using old automation solutions, HF Xplore can be integrated into machines from the past few years, especially for condition monitoring. With electric-curing, it also enables precise tracking of electric curing performance, enabling deeper insights,” informed Neuhaus.

“One key challenge is data governance and security. Traditionally, machine data remained within the plant, but HF Xplore connects operational technology with information technology, raising concerns about data ownership and security. To address this, we have implemented user-based access controls, IP-based security and data encryption,” informed the executive.

For tyre plants with a mix of HF and non-HF machines, HF Xplore offers a custom dashboard creator with low-code functionality, allowing users to integrate and visualise data from different machines in just a few hours. A flexible data model further ensures standardised visualisation, even when machine types vary. While full integration with non-HF machines may require additional work, HF Xplore provides a comprehensive plant-wide monitoring solution for optimising performance.

“HF Xplore can potentially integrate with machines from other companies, but it depends on data accessibility and PLC compatibility”, contended Neuhaus, who highlighted the flexibility and modularity of their solution. 

The Global Data Service Organisation for Tyres and Automotive Components (GDSO) has entered into a Memorandum of Understanding with the RAIN Alliance, a move designed to accelerate the harmonisation of electronic tyre identification and support broader digitalisation throughout the international tyre value chain. This agreement formalises a mutual commitment to advancing interoperable, scalable and globally consistent standards that can be adopted across the sector.

GDSO is responsible for establishing and promoting global data standards for tyres, enabling comprehensive lifecycle applications that serve a diverse group of stakeholders – from manufacturers and logistics providers to fleet managers, recyclers and regulatory bodies. The RAIN Alliance, in parallel, champions the widespread implementation of RAIN RFID technology within a framework that is open, standards-based and interoperable.

The growing importance of electronic tyre identification is underscored by its role in enabling traceability, meeting regulatory requirements, advancing circular economy goals and improving operational performance. Within existing standardisation frameworks, embedded RAIN RFID technology is currently the sole passive data carrier capable of supporting item-level traceability across the full lifespan of a tyre. This partnership seeks to align data standardisation efforts with the underlying identification technologies, thereby reinforcing the ecosystem necessary for reliable and scalable digital identification solutions worldwide.

Although GDSO acknowledges the established position and technical maturity of RAIN RFID, the organisation maintains a technology-agnostic stance. Its primary focus remains on developing robust and adaptable global data standards that foster an inclusive and resilient identification ecosystem. Such an approach supports ongoing innovation and ensures that all actors across the tyre value chain can participate effectively, regardless of future technological shifts.

Through this alliance, GDSO and the RAIN Alliance intend to drive globally aligned standards, enhance system interoperability, support digital use cases throughout the product lifecycle and contribute meaningfully to sustainability and circularity targets. This partnership reflects a shared strategic vision to strengthen the digital infrastructure underpinning the tyre industry.

Riccardo Giovannotti, Secretary General, GDSO, said, “I’m pleased to share that GDSO has signed a collaboration MoU with RAIN Alliance. The collaboration is grounded in a shared commitment to industry-wide standards and to advancing digitalisation across the tyre value chain. As the organisation leading the definition and deployment of global data standards for tyres, GDSO focuses on enabling cradle-to-grave use cases through interoperable and scalable solutions. Within today’s standardisation landscape, the embedded RAIN RFID (i.e. passive RFID) is currently the only data carrier standardised and technically capable of supporting item-level identification across the full tyre lifecycle, which makes this collaboration both relevant and timely.”

A new milestone in agricultural tyre technology has been achieved through the partnership of Titan International, Inc. and Cerebrum Sensor Technologies, Inc. Together, they have unveiled Titan Pressure Perfect (P2), a smart sensor system designed to transform how farm tyres perform and communicate. This system marks the emergence of a broader category known as Intelligent Tyre Solutions (iTS), developed jointly by the two companies.

At the core of Pressure Perfect (P2) is real-time monitoring of tyre pressure, temperature and load. This data enables continuous oversight and works seamlessly with onboard inflation systems, allowing automatic pressure adjustments while the vehicle is in motion. Whether shifting from roadway to field or responding to varying load demands, the system can reduce air pressure by as much as half. This flexibility helps lower soil compaction by up to 35 percent and has been linked to potential corn yield increases of four to six percent.

Pressure Perfect is compatible with all Titan and Goodyear Farm Tyre products and integrates with nearly all inflation management systems already in use. By supporting more precise tyre management, it contributes to longer tyre life, improved machine efficiency and reduced environmental impact through less ground disturbance.

The innovation draws on Cerebrum’s licensed portfolio of patented technologies, including advanced sensors, proprietary algorithms and sophisticated software capabilities. This technical foundation sets a new standard for intelligent tyre management in agriculture. While other industry players focus on replicating existing central tyre inflation and tyre pressure monitoring systems, Titan and Cerebrum are advancing a more comprehensive and forward-looking approach. Pressure Perfect reflects Titan’s longstanding engineering heritage and its continued commitment to leading the field through purposeful collaboration and applied innovation.

Dubbing it the ‘Holy Grail’ of innovations, Scott Sloan, Global Ag & LSW Product Manager for Titan, said, “This is the first system of its kind that delivers dynamic inflation management. Load, tyre pressure and temperature data are gathered by a single tyre-mounted sensor and integrated with tyre-industry load-inflation tables in real time. Imagine bringing together Central Tyre Inflation System (CTIS) and Tyre Pressure Monitoring System (TPMS) technologies, and now they can work together and talk to each other – all without operator intervention."

Anyline is displaying its AI-powered TireBuddy platform at the 2026 National Automobile Dealers Association (NADA) Show in Las Vegas (from 3–6 February), demonstrating how it brings objective, digital tyre inspections to automotive retailers. The technology, which standardises tread depth and condition assessments, is used by dealerships, reconditioning centres and independent shops to enhance operational consistency and customer transparency. At Booth 7649N, live demonstrations will show the system’s guided scanning and intuitive workflow, which technicians have adopted for its ability to generate clear, data-backed reports directly in the service bay.

A key adopter includes EchoPark, a national pre-owned vehicle retailer under Sonic Automotive, Inc., which utilises TireBuddy as part of its rigorous 190-point vehicle inspection process across multiple states. The platform provides repeatable measurements that strengthen technical recommendations and build buyer confidence by turning subjective checks into documented insights. Since its 2025 launch, the tool has been implemented by large-scale automotive groups seeking to improve decision-making and efficiency.

Anyline’s exhibition will focus on these real-world applications, showing how digitising tyre inspections creates a more transparent and trustworthy service experience. By replacing visual estimates with precise digital data, TireBuddy helps businesses streamline workflows, empower technicians and ultimately support safer, more reliable vehicle assessments for customers.

Christoph Braunsberger, CEO, Anyline, said, “Our goal with TireBuddy is to equip technicians with the tools they need to make accurate, fast and confident decisions, an important message we’re bringing to the forefront at this year’s NADA Show. By providing objective, AI-powered data, TireBuddy delivers a far clearer path to cost savings, operational efficiency and customer transparency for retailers – benefits that matter at every level of their operation.”

As urban areas around the world grow increasingly louder, traffic noise has emerged as a critical environmental and public health challenge. Recognised by health authorities as a major risk factor, this pervasive issue extends from European cities to megacities across Asia and Latin America. Continental is addressing this problem by pioneering tyre technologies that significantly reduce rolling noise, thereby contributing to quieter urban environments and enhanced in-vehicle comfort.

The transition to electric mobility has brought tyre noise into sharper focus. With the near-silent operation of electric motors replacing traditional engine sounds, the acoustic contribution from tyres becomes far more prominent, even at moderate city driving speeds. In response, Continental engineers have developed specialised solutions that target noise generation without compromising the safety, durability or performance of the tyre.

One such innovation is the Silent Pattern tread design, featured on models like the EcoContact 7. This technology disrupts the conventional, uniform arrangement of tread blocks that typically creates a rhythmic humming sound on pavement. By intelligently varying the spacing and angles of these blocks, the pattern breaks up this acoustic consistency. Furthermore, it is tuned to cancel out specific sound frequencies, akin to the principle behind noise-cancelling headphones. This results in a measurable reduction of traffic noise at speeds around 50 kmph, where rolling noise is most perceptible to pedestrians and residents.

For reducing noise inside the vehicle cabin, Continental employs its ContiSilent technology. This involves lining the inside of the tyre with a lightweight polyurethane foam that absorbs vibrations caused by the tyre’s contact with the road. By dampening these air vibrations, the technology can cut perceived in-cabin rolling noise by up to nine decibels – a reduction the human ear experiences as nearly halving the volume. This substantial increase in acoustic comfort is integrated into various product lines, including high-performance summer tyres, without affecting driving dynamics or efficiency.

The company’s commitment to low-noise mobility spans multiple vehicle segments. From the Conti Urban NXT for city buses to passenger car tyres like the EcoContact 6 Q and van tyres such as the VanContact A/S Eco, these products are designed to meet stringent noise standards. Consumers can readily identify these quieter options through regulatory labels, like the EU tyre label, which provides clear decibel ratings for external rolling noise. Through these continuous advancements in tread design and sound-dampening materials, Continental is systematically working to diminish the acoustic footprint of road traffic.

According to Achillefs Tsotras, head of Continental’s Tyre-Vehicle Interaction department, “Noise, especially traffic noise from cars, buses and delivery vehicles, is a major burden for people and the environment. With tyre technologies like ContiSilent and innovative tread designs, we are actively reducing rolling noise without compromising safety. This makes every ride noticeably quieter, benefiting drivers, pedestrians, residents and the environment alike.”