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. 

ZF has secured a significant milestone in the Indian automotive sector, receiving three major orders for its advanced test systems. The contracts, which encompass battery, tyre and e-axle testing, position the global driveline and chassis technology leader at the forefront of the nation’s drive to enhance road safety and establish more robust vehicle certification processes. This development aligns with India’s accelerating regulatory efforts to ensure that vehicle testing becomes more independent, rigorous and comprehensive, marking a critical step forward for the industry.

A key aspect of ZF's strategy involves a strong commitment to local manufacturing, with the company emphasising high levels of domestic content for its test systems in support of the ‘Make in India’ initiative. The firm’s extensive background in the field is underscored by its experience in testing over 100 million transmissions, a testament to the proven global reliability of its technology. This foundation of expertise is now being applied to address the specific safety and performance demands emerging in the Indian market.

With the rapid adoption of electric vehicles, battery safety has become a paramount concern, and ZF’s solutions cover the complete spectrum from individual cells to complete packs. These systems evaluate performance, endurance and environmental factors, including rigorous mechanical abuse testing, while adhering to a wide array of international and Indian standards. Furthermore, the company’s tyre testing capabilities are poised to play a crucial role as India prepares to enforce new mandatory regulations, including the BNVSAP and the AIS 142 TPMS Mandate. The ZF Tyre Efficiency Tester (TET.lab), recognised for its precision, offers a modular platform capable of testing everything from motorcycles to heavy commercial vehicles.

The company’s e-mobility test benches feature a high-performance drive module with a flexible, modular architecture designed to accommodate both conventional and electric drivetrains. These systems can be configured for various operations, integrating frequency converters and precision measurement technology for comprehensive testing. ZF’s deep expertise, already deployed by manufacturers and testing authorities worldwide, positions it as a key technology partner for India. As regulatory requirements tighten and the demand for quality escalates, the company is set to support the nation's ambition of building a safe and sustainable automotive ecosystem.

Akash Passey, President, ZF Group India, said, “Testing agencies are the final arbiters of vehicle safety, the bodies whose certification regulators and the public trust. Being chosen across three independent and Government agencies, for three distinct testing disciplines, is a powerful validation of ZF's accuracy, reliability and deep understanding of India's regulatory and testing landscape. ZF Group is proud to provide the technical foundation that makes world-class automotive safety infrastructure possible in India, not just for our OEM customers but also for Government and independent testing agencies.”

Thomas Trebitsch, Vice President, ZF Test Systems and Testing, said, “Over the past years, we have been focusing on the tyre industry in India and introducing our complete product portfolio to India. As the market develops rapidly towards regulations and safety, there is a strong need for robust and world-class testing technology. ZF brings its global competence and a deep understanding of the Indian auto industry to address its specific needs.”

As India’s industrial sector accelerates its shift towards cleaner energy, tyre manufacturers are emerging as a critical test case for integrating renewable power into continuous, high-load operations. In this conversation, Kuldeep Jain, Founder and Managing Director of CleanMax, outlines how demand from companies such as CEAT and Michelin is reshaping renewable procurement – from conventional solar contracts to hybrid, round-the-clock solutions – while positioning clean energy as both an operational necessity and a strategic lever for decarbonisation.

Industrial decarbonisation in India is entering a more operational phase, where renewable electricity is no longer a peripheral lever but an embedded component of manufacturing strategy. For CleanMax, this shift is most visible in energy-intensive sectors such as tyre manufacturing, where continuous processes, global supply-chain pressures and ESG commitments are converging to reshape how power is procured and consumed.

Kuldeep Jain, Founder and Managing Director of CleanMax, describes a market moving beyond cost arbitrage towards structural integration of clean energy. Demand from tyre manufacturers – long characterised by high, stable electricity loads – is now influencing both project design and procurement models, pushing developers towards hybrid and round-the-clock renewable solutions. 

Energy-intensive industries are increasingly prioritising renewable electricity to manage power costs and reduce operational emissions. Manufacturing sectors with continuous loads are particularly suited to long-term renewable procurement models such as group captive and open-access PPAs, which provide cost stability while supporting decarbonisation goals,” Jain says.

That demand is already translating into project pipelines. CleanMax’s collaboration with CEAT involves developing 59 MW of hybrid wind-solar capacity to supply renewable power to its Halol and Kanchipuram plants. Similarly, its engagement with Michelin includes an open-access solar power purchase agreement supporting operations at the company’s Chennai facility.

“These projects illustrate how large industrial consumers are integrating renewables into their long-term energy strategy. For instance, globally, the International Energy Agency has already noted that industrial electrification and renewable procurement will drive the next phase of the energy transition. Tyres are firmly in that wave,” Jain notes.

FROM INTERMITTENT SUPPLY TO ENGINEERED RELIABILITY

Tyre manufacturing presents a distinctive challenge for renewable integration. Plants operate continuous processes – mixing, curing and vulcanisation – that require stable baseload electricity and thermal energy. Traditional solar PPAs, while cost-effective, are inherently intermittent, limiting their suitability for such operations.

The industry is therefore evolving towards hybrid models that combine multiple renewable sources. “Hybrid projects are gaining traction because they smooth generation across the day, improving plant load factors,” Jain says. According to the International Renewable Energy Agency, such hybrid systems are among the fastest-scaling formats for industrial decarbonisation.

“As a result, the industry is moving beyond single-source solar PPAs towards wind-solar hybrid projects and open-access group captive models that provide higher plant load factors and more balanced generation profiles across the day. Wind-solar hybrid is increasingly seen as the most practical and efficient pathway to scale renewable penetration in continuous manufacturing environments,” Jain explains.

This shift reflects a broader reframing of renewables – not as intermittent substitutes for fossil fuel power but as engineered systems tailored to industrial demand curves. The emphasis is on aligning generation profiles with consumption patterns, rather than expecting operations to adapt to variable supply.

SECTOR-SPECIFIC DECARBONISATION PATHWAYS

Not all heavy industries decarbonise along the same trajectory. Jain draws a clear distinction between tyre manufacturing and sectors such as cement or steel, where process emissions form a significant share of the carbon footprint.

“If you step back, industries don’t decarbonise in the same way because they don’t consume energy in the same way. A tyre plant is largely powered by electricity. So if you clean up the electricity, you’ve already addressed a meaningful part of its emissions,” he says.

However, the challenge lies in reliability. “These are continuous operations. They don’t switch off when the sun sets or the wind drops. That’s why hybrid becomes important, as a way of shaping energy to demand,” Jain adds.

“In case of cement or steel, a significant portion of emissions comes from how the product itself is made. So the shift we’re seeing is subtle but important. It’s about redesigning the energy profile itself so that clean energy isn’t intermittent in theory but dependable in practice,” he continues.

The implication is that electrification-driven sectors such as tyre manufacturing can achieve faster decarbonisation gains through renewable procurement, provided supply reliability is addressed through hybridisation and system design.

ESG, PRODUCT STRATEGY AND COMPETITIVE POSITIONING

Renewable energy is also assuming a more strategic role within tyre companies’ ESG frameworks. What began as a cost-management exercise is increasingly tied to product innovation, sustainability reporting and global competitiveness.

“The conversation around renewable energy in the tyre industry has clearly evolved beyond cost optimisation. Many manufacturers are increasingly integrating renewable power into their broader ESG strategies and supply-chain decarbonisation commitments, particularly as global automotive OEMs push for lower-carbon sourcing across the value chain,” Jain says.

This transition is evident at the product level. CEAT’s launch of its SecuraDrive CIRCL tyre – produced with up to 90 percent sustainable materials – signals how manufacturers are aligning product design with sustainability objectives.

“Renewable electricity procurement helps reduce Scope 2 emissions and supports the development of lower-carbon products, which is becoming an important factor in both sustainability reporting and global competitiveness. As a result, renewable energy is now seen not only as a cost-management tool but also as a strategic lever for product decarbonisation and ESG positioning,” Jain explains.

TECHNOLOGY MIX AND OPERATIONAL ALIGNMENT

From a systems perspective, no single technology provides a complete solution. CleanMax advocates a portfolio approach that combines generation assets with digital tools and flexible contracting structures.

“A portfolio approach works best. For manufacturing operations with steady electricity demand, hybrid renewable systems combining solar and wind have proven effective, as the complementary generation profiles improve overall availability and plant load factors,” Jain says.

Digital energy management platforms play a supporting role by optimising dispatch and aligning supply with consumption patterns. Flexible procurement structures, including open-access and group captive models, further enhance adaptability across sites and regulatory regimes.

“In practice, hybrid setups combining solar and wind have proven effective because they smooth generation across the day and improve overall availability. That’s what makes renewable power usable at scale,” Jain adds.

The CEAT and Michelin projects exemplify this approach, integrating multiple procurement pathways – onsite solar, offsite generation and open-access PPAs – to increase renewable penetration without compromising operational stability.

POLICY VARIABILITY AND MULTI-LOCATION STRATEGIES

India’s regulatory landscape remains heterogeneous, with state-level policies shaping the feasibility and economics of renewable procurement. For tyre manufacturers operating across multiple locations, this creates both complexity and opportunity.

“Overall, the ecosystem is steadily evolving to support higher renewable penetration practically. Open-access mechanisms are becoming more aligned with industrial needs. Renewable procurement is naturally becoming more location-specific,” Jain says.

Different state frameworks enable companies to tailor their energy mix – combining onsite solar with offsite wind or solar depending on regional resource availability and regulatory incentives.

“In practice, this leads to more balanced and resilient energy portfolios. This is also where developers with experience across markets can add value by structuring solutions that are aligned to each site’s load profile, regulatory context and long-term cost objectives, rather than taking a one-size-fits-all approach,” Jain explains.

GLOBAL SUPPLY CHAINS AND RISING EXPECTATIONS

Pressure from global automotive OEMs is accelerating the adoption of renewable energy in India’s tyre sector. As manufacturers integrate more deeply into international supply chains, emissions performance is becoming a criterion for sourcing decisions.

“As tyre manufacturers become more integrated with global OEM supply chains, expectations around emissions are becoming more defined. Renewable electricity is one of the more immediate ways to address this, especially for Scope 2 emissions,” Jain says.

“What we’re seeing is more about alignment – companies are adapting their energy mix to stay relevant in global markets, where sustainability is increasingly part of how sourcing decisions are made,” Jain says.

This dynamic is likely to intensify as OEMs tighten decarbonisation targets and extend accountability across their value chains, reinforcing the role of renewable energy in industrial competitiveness.

THE NEXT FRONTIER: TRACEABILITY AND CARBON MARKETS

As companies move towards net-zero targets, the focus is broadening beyond direct emissions to include value-chain impacts and verification mechanisms.

“Instruments such as renewable energy certificates and carbon markets help companies transparently account for the renewable electricity they procure. At the same time, there is growing focus on Scope 3 reporting as manufacturers work to address emissions across their broader value chains and align with global supply-chain decarbonisation expectations,” Jain says.

Traceability – ensuring that renewable energy claims are verifiable and auditable – is expected to become increasingly important, particularly for export-oriented manufacturers facing stringent disclosure requirements.

A DECADE OUTLOOK: ACHIEVABLE, BUT CONDITIONAL

Looking ahead, Jain is cautiously optimistic about the pace of renewable adoption in India’s tyre manufacturing sector. The fundamentals – declining costs, expanding capacity and supportive policy evolution – are largely in place.

“Over the next decade, higher renewable penetration in tyre manufacturing is well within reach, especially as clean power availability continues to expand. For electricity-led operations, increasing the share of renewable energy is already a practical pathway, not a distant target,” he says.

However, execution will hinge on system-level factors. “What will make the difference is how reliably this power can be integrated at scale – through consistent open-access frameworks, stronger grid alignment, and wider use of hybrid solutions that better match continuous industrial demand,” Jain says.

The trajectory is clear: renewable energy in tyre manufacturing is transitioning from opportunistic adoption to structural integration. For developers such as CleanMax, the challenge – and opportunity – lies in engineering solutions that convert intermittent resources into dependable industrial infrastructure.

Wallace Instruments, a globally recognised leader in rubber testing equipment, has expanded its United Kingdom-manufactured specimen preparation lineup with the launch of the WAS3 Pneumatic Cutting Press. The new device joins the company’s range of rubber testing equipment.

Unlike manual cutting methods, pneumatic systems apply consistent force on every cycle, eliminating operator fatigue and variability. Poorly prepared specimens with uneven edges or internal stress can compromise test accuracy, while the pneumatic approach also reduces repetitive physical strain, supporting technician wellbeing during long production runs.

The WAS3 prioritises safe single-operator use through a two-button activation system requiring both buttons to be pressed within half a second, preventing any hand contact with the cutting area. Additional three-sided protective guards further enhance operational safety.

Delivering 15 kN of cutting force, the press easily cuts through 10-mm thick, 95 Shore A rubber sheet using five bar of filtered air pressure. It works with existing Wallace cutting dies, so laboratories can integrate the unit without replacing current tooling, and its compact footprint suits both lab and production environments.

Chris Norval, Managing Director, Wallace Instruments, said, "Specimen preparation is the foundation of accurate rubber testing. With the WAS3, we focused on practical safety, dependable cutting performance and drop-in compatibility. Labs get a compact pneumatic press that fits the air lines already in place, uses their current Wallace dies and delivers consistent results for every operator – because when specimen quality is controlled, you can have confidence in the results that follow."

DUNLOP (company name: Sumitomo Rubber Industries, Ltd.) has teamed up with Fujitsu Limited to create an artificial intelligence (AI) surrogate model that predicts tyre performance rapidly and with high precision. The breakthrough was validated in a proof of concept tied to DUNLOP’s digital transformation strategy. When applied to tyre deformation upon road contact, the technology slashed analysis time by 90 percent, from 45 minutes to just 5 minutes while processing nearly 600,000 mesh elements.

Based on these results, both firms will build a design support tool, aiming for deployment at DUNLOP by April 2027. The system runs on FUJITSU MONAKA, a next-generation energy efficient Arm-based CPU.

Tyre design typically relies on finite element method (FEM) analysis, where finer mesh grids boost accuracy but increase calculation time and costs. To tackle this, the partners developed an AI surrogate model that solves FEM equations using past data. The model, based on the Graph Neural Network algorithm, predicted contact shape with 87.7 percent accuracy, enabling faster decisions and lower costs.

Select findings will be shared at the 31st Computational Engineering Conference starting 3 June 2026. By December 2026, both companies will test the model on a FUJITSU MONAKA prototype to refine speed and power use.

Under its long-term strategy R.I.S.E. 2035, DUNLOP seeks to provide new experiential value from rubber. Through this co creation, the tyre maker will enhance its analytical technologies and strengthen innovation. Fujitsu will promote this approach across large scale FEM analysis in automotive and other manufacturing sectors, contributing to carbon neutrality via an AI platform combining FUJITSU MONAKA and GNN.