The integration of Radio Frequency Identification (RFID) technology into the tyre industry is gaining momentum, offering solutions for traceability, sustainability and lifecycle management. Beontag, in collaboration with Michelin, is spearheading this innovation by jointly designing specialised RFID tags that can withstand the harsh conditions tyres face, such as extreme heat and pressure. The tags store crucial data, enabling efficient recycling, retreading and warranty management. As the tyre industry evolves, RFID adoption is seen as essential for ensuring authenticity, improving asset management and supporting regulatory frameworks. However, challenges remain in scaling production and increasing industry awareness.

Punch card systems, barcodes, dog tags, biometric scanners etc. are all instruments that offer basic information about humans and commodities for identification, authentication, traceability and retrospection.

The tyre industry is similarly standing at a crossroad where the demand for traceability and retrospection is growing. Tyre manufacturers, retailers, retreaders and recyclers are showing a growing exuberance for digital footprints that can record, summarise and authenticate information related to each existing and new tyres throughout the commodities lifecycle.

And the simple solution catering to such demands is a radio frequency identification (RFID) tags. While the use of RFID tags is new within the global tyre market, these have found a stronghold across retail, logistics, manufacturing, healthcare etc.

The tag is changing the game of traceability within tyre markets as the adoption grows. Technological companies are collaborating with tyre manufacturers to develop tailor-made RFIDs.

International RFID and IoT expert Beontag is one such company that has developed RFID tags for the tyre industry. Divulging deep into the engineering mechanics of the tag, APAC Senior Sales Manager Evelyn Ong told Tyre Trends, “RFID technology used in tyres is significantly different from conventional RFID applications due to the harsh conditions tyres endure, such as high temperature, pressure and wear and tear. Unlike RFID tags used in retail or medical settings, tyre RFID tags must be engineered to survive extreme conditions. As a result, traditional RFID designs, which use PET labels and conductive paste for chip attachment, are unsuitable. Instead, tyre RFID tags rely on a mechanically robust and inductively coupled antenna structure.”

“Designing RFID for tyres required a completely new approach, and the current version (generation four) is believed to be durable enough to last the entire lifecycle of a tyre. This innovation aligns with initiatives like the European Digital Product Passport (DPP), which mandates that products must be identifiable throughout their life cycle. Although RFID chips themselves only store a unique identifier (similar to a FASTag or car license plate), all detailed data such as manufacturing date, plant origin, distribution history, usage, retreading details and material composition is stored in backend software systems. As the tyre moves through the supply chain, each stakeholder adds relevant data to the software based on the RFID, creating a comprehensive database that supports traceability and lifecycle management including recycling or retreading,” she added.

The company’s main RFID tag for the tyre industry includes a chip with memory, enabling it to store data and serve as a digital identifier for the physical tyre using radio waves. This transforms a traditional tyre into a digitally traceable product.

Beontag jointly designed this RFID tag with Michelin, exploring the benefits of embedding a chip in tyres for purposes like asset management and product authentication and was instrumental in driving standardisation across the industry. While Michelin is the first tyre manufacturer to roll out the new ‘smart tyres’ with Beontag technology, the manufacturer recently announced a partnership with Kumho Tire and aims to go into partnership with other brands in the near future.

DEMAND AND SUPPLY

The company recently participated in a global tyre exhibition and rationalised its participation with significant long-term potential of the tyre RFID market. “With over 30 billion tyres in circulation globally, the scale of the opportunity is enormous. Having worked in RFID for over 20 years, the technology excels in applications involving products that are physically similar and difficult to differentiate visually like tyres. This makes tyres an ideal use case for RFID,” said the official.

Ong explained that beyond the European Digital Product Passport regulation, a key driver for embedding RFID in tyres is the fundamental need for every product to have a unique identity, whether through a barcode, QR code or digital tag. In the tyre industry, this need has been especially pressing due to the limitations of traditional identification methods like hot stamping, which often wear off over time and result in a loss of traceability.

She noted that the absence of a durable, readable ID creates challenges in verifying authenticity, determining warranty status and tracing the tyre’s origin. For instance, without a reliable identifier, it becomes difficult to confirm whether a tyre is genuinely from Michelin or to retrieve key manufacturing details such as plant location, batch number or intended distribution path.

By embedding RFID tags with unique digital identities, the industry gains the ability to link every part of the tyre’s lifecycle across the value chain. This ensures consistent traceability, facilitates better inventory and warranty management and combats counterfeiting.

“We are actively engaging with the top 10 global tyre manufacturers in the transition towards RFID-enabled tyres. While the European market is leading adoption driven largely by regulatory frameworks, we are also working with tyres manufacturers across the Asia-Pacific region and beyond.

“Although OEMs like Michelin are beginning to integrate RFID tags, starting with high-end passenger tyres, there is a growing and immediate demand from the aftermarket. This secondary market includes fleet operators, leasing companies and pay-per-use models, where the need for tyre tracking is urgent. These businesses want to monitor retreading cycles, ensure asset recovery and verify ownership, especially to prevent tyre theft or unauthorised replacements,” she added.

According to Ong, some aftermarket players are even looking to embed RFID tags independently rather than waiting for OEMs to standardise the process, underscoring strong demand outside the traditional supply chain.

When asked about growth potential between the passenger and commercial segments, she indicated that although current OEM efforts are focused on high-end passenger tyres, interest from the commercial and aftermarket sectors is strong and could drive faster adoption due to practical and financial incentives.

Furthermore, RFID tags play a key role in sustainability by enabling traceability throughout a tyre’s lifecycle. It allows manufacturers to capture crucial data at the point of manufacture, which is essential for tracking and recycling. With RFID, recycling processes become more efficient because tyres can be easily sorted based on type, size and materials. This minimises waste, reduces sorting time and improves the overall effectiveness of recycling efforts.

HURDLES IN ADOPTION

The executive noted that there are unique challenges of designing an RFID tag for tyres given the nature of its operations. To address these hurdles, the company and Michelin jointly designed and extensively validated a specialised RFID tag consisting of a chip and an antenna, which is fully embedded within the tyre.

This tag is designed to be invisible from the outside and integrated into the tyre structure in a way that ensures durability without compromising performance. The antenna’s spring-like structure allows it to expand and contract along with the tyre’s movement without affecting its function.

Crucially, the connection between the chip module and spring antenna is linkless, using inductive coupling instead of mechanical connection. This inductive mechanism ensures reliability even under extreme conditions like high temperature, pressure and physical deformation.

Although the tag is not constantly read during vehicle operation, it must remain functional and readable during inspections or servicing.

Alluding to broader industry challenges towards adoption, Ong said, “Current challenges centre primarily around a lack of awareness and industrialisation of the production process in existing tyre production lines and factories. Unlike retail, where RFID is well-established, the tyre sector is still in the early stages of adoption. Because of this, there is a need to educate the market, build trust and demonstrate real-world use cases. Potential customers are hesitant to act as first movers and prefer to see proven implementations to reduce perceived risk. A hopeful future challenge would be demand outpacing production capacity. However, a more realistic and significant long-term challenge lies in technological evolution, particularly around IC size, performance development and adding more functionality through sensor information.”

INTEGRATING RFIDS

The RFID chip used in tyres stores a minimum of 96 bits of data, which aligns with the standard size modelled after barcodes. This size is sufficient to encode essential identifying information including a serialised number.

While barcodes only identify products at the SKU level, RFID allows each item to have a unique identifier, making it far more powerful for inventory management. At every stage in the tyre’s lifecycle, it is the responsibility of the user or stakeholder to read the RFID tag and input relevant data into the software system, linking it to the tag’s unique identifier.

One of the most compelling applications of tyre RFID is during the tyre’s second life – especially in retreading. In this stage, the retreader can embed a new RFID tag and effectively reset the tyre’s lifecycle. This allows the retreading company to claim and track the work they’ve done including how many times the tyre has been retreaded and when.

Fleet operators or regulators can use this data to verify authenticity, ensure compliance and manage safety.

At the end of the tyre’s life, especially during the recycling stage, RFID continues to offer value by recording the tyre’s complete journey. Recyclers can access a tyre’s full history by ensuring proper handling and reporting.

The key challenge in placing the RFID tag is ensuring its proper location and integration into the tyre’s structure. This process must be carefully controlled as the tag must not only be positioned in the optimal spot but also withstand the stresses and heat of the curing process. If the tag was placed improperly, it could potentially cause issues with its performance, especially in terms of readability after the tyre is fully cured and ready for use.

COMPETITION AND EVOLUTION

Besides Beontag, there are other companies operating within the tyre RFID space. Alluding to the distinction between them, Ong explained, “The main difference of our product lies in the patented POD design (POD = IC module/package). Our product utilises a special alloy for the antenna, which prevents deformation and ensures consistent diameter and gap size. Additionally, the chip packaging has been specifically designed to offer better protection, reducing the risk of damage and ensuring reliable readings.”

She explained that the company’s business case for RFID technology in the tyre industry is clear and it believes strongly in its potential. She emphasised the importance of spreading awareness about the technology, as Europe will be implementing the technology first, but other regions including APAC and the Americas will be catching up as the technology is proven in the coming years.

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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.”

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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.

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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."

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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.

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