Bekaert has achieved a significant sustainability milestone by securing ISCC PLUS certification for its steel tyre reinforcement products. This accomplishment highlights the company's dedication to driving innovation and working closely with tyre manufacturers to promote the widespread use of materials with high recycled content.

Historically, steel used for tyre reinforcement was not covered by ISCC PLUS. However, a partnership between Bekaert, ISCC and the certification body TÜV NORD successfully developed a structured certification path for tyre cord and bead wire with high recycled content. TÜV NORD played a key role by auditing Bekaert’s Burgos facility during a pilot phase, technically validating that the ISCC PLUS framework could be effectively applied to steel-based products. This validation paves the way for its wider acceptance in the tyre sector.

This certification builds upon the foundation laid by Bekaert’s own Recycled Content Standard, which previously set an industry benchmark for traceability and sustainable practices. The earlier standard's success was instrumental in encouraging ISCC to broaden its certification framework to encompass steel products. Although the Bekaert standard will remain valid during the transition, ISCC PLUS now offers a globally acknowledged system that guarantees uniformity and clear traceability throughout the entire supply chain.

This certification positions Bekaert as a leader in advancing certified tyre reinforcement, fostering industry-wide acceptance and generating shared benefits with tyre makers. For manufacturers, utilising ISCC PLUS-certified materials lends credibility to their sustainability assertions, simplifies the certification landscape and aids in meeting regulatory and market demands. Furthermore, their customers continue to gain from Bekaert’s dependable supply chain, which is now enhanced by verified sustainable sourcing.

Annie Xu, President – Rubber Reinforcement, Bekaert, said, "Achieving ISCC PLUS certification demonstrates our leadership in certified steel with high recycled content for tyre reinforcement. We are proud to have worked closely with ISCC and TÜV NORD to shape this framework, which will help our customers stay ahead of sustainability and regulatory expectations."

An ISCC representative said, "We welcome the successful completion of the certification process for steel tyre reinforcement under ISCC PLUS. This demonstrates that the ISCC framework can be applied to additional material categories while maintaining our established requirements for traceability and verification."

Samir Beqqal, Head of Carbon Traceability Business Entity Sustainability, TÜV NORD CERT, said, "Working with Bekaert and ISCC on this pilot certification was an important step towards applying ISCC PLUS principles to new material categories like steel. We are delighted that we were able to contribute our expertise to this process and help ensure that certified traceability and sustainability assurance can also be effectively extended to industrial materials now.”

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Beratex, part of the Bernauer Group alongside Texpak, is positioning itself as a specialist partner to global tyre manufacturers at a time when efficiency demands, sustainability pressures and the technical requirements of electric mobility are reshaping the industry. In a sector often described as mature, the company argues that meaningful gains are still being unlocked – not through disruption but through materials innovation and process optimisation that deliver measurable improvements on the factory floor.

“Beratex and Texpak are both part of the Bernauer Group, which positions itself as a system supplier of specialised auxiliary and raw materials for the tyre and rubber industries. Beratex & Texpak sees itself as a trusted specialist partner to the global tyre industry, with a strong focus on high-performance product solutions. Our products help tyre manufacturers maintain stable, efficient and high-quality production processes across both PCR and TBR applications,” says Hanspeter Bernauer, Owner and CEO. “At the same time, building on our experience since 1972, we continue to expand our footprint in the tyre and rubber sector with complementary products such as low-melting EVA materials for mixing process and embossed PE films for single-use applications, which we distribute through our subsidiary Texpak.”

A key differentiator for Beratex is its vertically integrated production model, spanning from HDPE film supplied by its subsidiary Kunststoffwerk Lahr to in-house yarn production, weaving, heat-setting, hot-calandering, finishing and confectioning, allowing the company to manage the full value chain internally. In addition, its own hydropower generation plays an important role in ensuring supply reliability, efficiency and sustainability.

INCREMENTAL INNOVATION IN A MATURE INDUSTRY

Despite tyre manufacturing’s maturity, Bernauer sees ample scope for innovation – though largely incremental. “Even in a mature industry like tyre manufacturing, there is still considerable room for innovation. In our view, some of the most meaningful progress comes from better materials, more efficient processes and solutions that help customers reduce waste without compromising performance,” he says.

“Innovation does not always have to be disruptive. In many cases, the biggest improvements come from practical developments that make production more stable, cleaner and easier to automate. That is exactly where close cooperation between suppliers and manufacturers can create real value,” he adds.

FACTORY-FLOOR IMPACT AND CONSISTENCY

The operational impact of Bernauer Group’s solutions is most visible in production environments. Liner materials are engineered to stabilise the handling of uncured rubber and reduce variability.

“The most tangible benefits are seen directly on the production floor. Our liner solutions help improve handling reliability, reduce contamination risks and support a smoother, more consistent manufacturing process. As a result, customers benefit from fewer interruptions, lower material waste and more stable output,” Bernauer says.

Texpak’s EVA low-melting bags and films complement this by offering consistent processing behaviour, a defined melting point, consistent thickness, a reliable quality standard and integration into mixing processes.

“For tyre manufacturers, that means better process efficiency, improved product quality and more effective use of materials. In high-volume production, even small improvements in these areas can have a significant operational impact,” Bernauer says.

Consistency remains central to the value proposition. Bernauer notes that Beratex liners are designed to bring consistency and process reliability to high-volume tyre production, with PE and textile liners offering uniform gauges, controlled surface properties and reliable release performance, enabling uncured rubber components to be handled without deformation, contamination or unnecessary variability.

By reducing sticking, tearing and uneven release, these solutions support stable cycle times, smoother automation and lower rejection rates. “Another important advantage is the durability of our liners. Their long service life helps maintain stable conditions over extended production runs, reduces replacement frequency and contributes to overall efficiency on the factory floor,” he adds.

PRODUCTIVITY AND TOTAL VALUE

The company links these performance improvements directly to productivity metrics. “Our solutions can have a very direct impact on factory-floor productivity. When liners perform reliably, manufacturers experience fewer stoppages due to sticking, tearing, misfeeds or contamination. That helps keep line speeds stable and supports better throughput,” Bernauer says.

He explains that by adapting liner solutions to the specific requirements of a process, the company helps customers improve handling, reduce waste  and strengthen production control, contributing, in practice, to better overall equipment effectiveness and a more predictable manufacturing environment.

This underpins a broader emphasis on total value rather than initial price, reflecting the economics of high-volume manufacturing.

EVOLVING EXPECTATIONS: COST, PERFORMANCE AND SUSTAINABILITY

Supplier expectations have shifted materially over the past decade. “Customer expectations have changed significantly over the last 10 years. In the past, the focus was often on price and basic functionality. Today, tyre manufacturers expect much more: reliable performance, process consistency, compatibility with automation and clear added value,” Bernauer says.

Sustainability is now central, with Bernauer noting that customers increasingly look for solutions that support material reduction, recyclability and a lower environmental impact while also expecting closer technical cooperation and more customised support – factors that have made supplier relationships significantly more strategic than before.

“Today, it is clearly a combination of all three,” he says, referring to cost, performance and sustainability. “Cost pressure remains important, but manufacturers also understand that performance and process reliability directly affect efficiency, quality and total production cost. The most attractive solutions are therefore the ones that combine cost efficiency, performance and sustainability rather than treating them as trade-offs.”

REGIONAL SHIFTS AND GLOBAL SUPPLY CHAINS

The tyre industry’s geographic footprint continues to evolve. “Yes, we are seeing clear regional shifts in both demand and manufacturing. Capacity continues to move towards Asia and other cost-competitive regions, driven by local market growth, export opportunities and broader supply chain diversification,” Bernauer says.

At the same time, new regions are emerging. “We are also seeing increasing activity in regions that previously played a smaller role in the global landscape, including parts of Africa,” adds Bernauer.

This creates a dual requirement for suppliers: global consistency and local flexibility.

SUSTAINABILITY IN SOURCING AND PRODUCTION

Sustainability considerations are reshaping procurement decisions, with Bernauer noting that the biggest change is that sourcing decisions are no longer driven by price alone, as tyre manufacturers increasingly assess recyclability, material efficiency, carbon footprint and the overall environmental profile of their suppliers. There is also a growing focus on reducing waste through downgauging and the use of reusable materials.

“Beratex is very well positioned in this respect. We generate 100 percent of our electricity from renewable sources through our own hydropower plants, and we can fully recycle all our production waste and reprocess it into new products,” he says.

EV-DRIVEN REQUIREMENTS

Electric vehicles are tightening manufacturing tolerances. According to Bernauer, the rise of electric vehicles is raising the bar for tyre manufacturers, with EV tyres typically requiring tighter dimensional precision, higher load-bearing performance and very consistent production conditions.

“For us, that means developing liner solutions with even greater surface consistency, controlled release behaviour and clean processing performance,” he says.

DIFFERENTIATION THROUGH DURABILITY

Durability and long-term performance are central to the company’s positioning. “What sets Beratex apart is that we combine proven product performance with a strong understanding of manufacturing realities. Our liner solutions are designed to deliver consistent quality, reliable release performance and exceptional durability, with customer references showing Beratex liners in use for over 15 years when properly handled,” Bernauer says.

Bernauer notes that with more than 135 million square metres of liner solutions supplied, the company’s track record demonstrates both long-term product performance and customer trust, adding that the focus remains on total value rather than just initial price.

REDUCING DEFECTS AND WASTE

At a functional level, the materials are designed to minimise defects. Bernauer explains that, in simple terms, the company’s materials help tyre manufacturers handle uncured rubber components cleanly and consistently. When release performance is stable and the liner behaves predictably, there is less risk of sticking, tearing or surface damage.

“Texpak EVA materials help reduce defects and waste in tyre production by offering consistent melting behaviour, uniform thickness and reliable quality,” Bernauer adds.

CHALLENGES AND OUTLOOK

The operating environment remains pressured. “One of the main challenges is the overall cost pressure in a highly competitive market,” Bernauer says, citing raw material volatility and supply chain disruptions. “Another challenge is meeting rising sustainability expectations while still delivering the functional performance customers require,” he adds.

Looking ahead, he identifies two key opportunity areas. “The first is advanced and more sustainable material solutions,” he says, pointing to the demand for recyclable and environmentally responsible products.

“The second is the ongoing shift towards higher-performance tyres, including EV-related applications, which require greater precision, cleanliness and process stability,” he adds.

For Bernauer Group, the approach remains consistent: deepen process integration, refine materials and deliver incremental improvements that scale across global tyre manufacturing.

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Bansal Wire Industries makes steel wire – bead wire for tyres, springs for suspension systems, cables for automotive assemblies – the sort of components that disappear into finished products and are only noticed when they fail. It is a business built on specification sheets and delivery schedules, not product launches.

Yet the company is in the middle of something that warrants attention. Installed capacity now exceeds 600,000 tonnes. Volumes in the most recent fiscal year grew by over 30 percent. The company is entering the steel tyre cord segment – a product India has never meaningfully manufactured domestically – and is simultaneously pushing into higher-specification wire grades that command better margins and serve more demanding applications.

Pranav Bansal, the Managing Director and Chief Executive Officer, attributes none of this to fortune. The automotive sector is changing, he says – electrification, premiumisation, tighter quality requirements across the supply chain – and the company has been positioning itself for those changes for some time. The conversation that follows is about where that positioning leads.

AUTOMOTIVE TAILWINDS

The automotive sector, he says, is at the centre of everything. Not because car sales are booming – though they are – but because the nature of what a car now demands from its components has changed in ways that reward exactly what his company does.

“Across vehicle segments, there is a clear increase in requirements for reliability and consistency in core components. This directly impacts demand for steel wire products used in applications such as tyre bead wire, steel tyre cord, springs, auto cables and other critical automotive components where performance and durability are essential, “he says.

The shift towards electric vehicles has sharpened that dynamic considerably. EVs are heavier than their internal combustion equivalents. That additional weight increases mechanical stress on every load-bearing component, including tyres. Premium tyre grades – already in growing demand as Indian consumers trade up – require reinforcement materials built to tighter tolerances. The thread running through all of it is quality: the ability to hold a specification, batch after batch, without drift. That is, in Bansal’s telling, precisely what the company has spent years building the capacity to deliver. “While infrastructure and engineering continue to support overall demand, the automotive sector remains a key driver, both in terms of scale and the evolution of product requirements,” Bansal says.

THE CORD BET

The more immediately consequential wager, however, is steel tyre cord – the high-tensile reinforcing material woven into a tyre’s carcass and belt structure. It is a product that India has, for the most part, not made. The domestic tyre industry has historically imported it, primarily from a small number of established global producers. Bansal Wire intends to change that.

"India currently relies on imports of steel tyre cord, creating a strong opportunity for domestic manufacturing. Our entry into this segment is a focused step towards building this capability in India," Bansal says.

He is careful about how he frames the competitive case. Steel tyre cord is not a market one enters by undercutting on price. Global tyre OEMs run structured, multi-stage validation processes before approving a new supplier, and those processes are neither quick nor forgiving. Bansal does not try to compress that timeline rhetorically. “Approvals from global OEMs follow a structured and time-intensive process, involving multiple validation stages. Our approach is to build capability, demonstrate consistency over time and then scale relationships once approvals are in place,” he explains.

What he is offering, in the near term, is not a displacement of established players but a domestic alternative for a supply chain that has good reason to want one. The argument intersects neatly with national industrial policy – Make in India, Atmanirbhar Bharat – without depending on it. The structural case stands independently: a reliable domestic source of a critical input, available without the freight, lead time and currency exposure that imports carry. The company is simultaneously working towards pairing steel tyre cord with bead wire, which it already produces. For a tyre manufacturer, sourcing from a single domestic supplier simplifies procurement considerably and improves supply assurance. That integration is central to the pitch.

MOVING UP

Alongside the tyre cord push, Bansal Wire has launched in-house-treated, oil-hardened and tempered wires – products used in high-performance automotive applications such as valve springs and suspension components. These are not commodity lines. They require tighter dimensional tolerances, more demanding heat-treatment processes and more rigorous quality documentation than standard wire grades. They also command better margins.

“Unlike standard wires, these applications require tighter specifications and greater reliability, which allows for better realisation and more stable margins over time,” Bansal says.

The logic of the portfolio shift is deliberate. Moving into higher-specification products does not require abandoning the volume business – the two coexist within the same manufacturing footprint – but it gradually shifts the revenue mix. As speciality products take a larger share of output, the company becomes less exposed to commodity price cycles and more valuable to customers with fewer alternative suppliers. “This allows us to move higher up the value chain while maintaining a balanced portfolio and positions us well to support future requirements of the automotive industry,” Bansal says. It is a repositioning years in the making, and he shows no impatience with its pace.

PLI AND CAPITAL

Bankrolling part of that transition is a commitment of INR 700 million under the Production-Linked Incentive Scheme for speciality steel, which will fund approximately 90,000 tonnes of new capacity at the company’s Sanand facility. The PLI incentive improves the investment’s return profile; the speciality focus means the new capacity generates better margins per tonne than an equivalent expansion of a commodity would. “This investment is therefore aimed at strengthening our product mix and supporting long-term growth,” Bansal says.

Expansions are also underway at the Dadri facility. Bansal’s framework for thinking about capital allocation across sites is deliberately non-ideological. He does not treat brownfield and greenfield as competing philosophies, or as choices that require one to be favoured over the other. “We look at brownfield and greenfield not as separate choices but as complementary approaches depending on the requirement,” he says. Brownfield works where existing infrastructure can be leveraged and operational continuity matters; greenfield is necessary when new technical capabilities need to be built without the constraints of a legacy layout. Steel tyre cord, given its technical specificity, falls clearly into the latter category.

In both cases, investment decisions are anchored in demand visibility, not just growth goals. “We focus on measured capital deployment, emphasising efficiency, consistency and long-term value over scale for its own sake,” he says. Industry overcapacity can erode returns, so maintaining this restraint is vital.

MARGIN ARCHITECTURE

That instinct for discipline extends to how the company manages its cost structure day to day. Bansal Wire operates on a cost-plus basis, which provides a degree of insulation from raw material price volatility that purely market-priced competitors lack. The model means that swings in wire rod costs – the primary input – do not automatically compress margins as they might for a company selling at fixed market prices.

Combined with rising asset utilisation – which distributes fixed costs across higher volumes as the capacity base fills – the model has allowed the company to grow margins alongside revenue. “As utilisation increases, fixed costs are distributed across higher volumes, which supports margins,” Bansal explains. The simplicity of the statement belies the operational consistency required actually to deliver it.

Customer retention has also played a role that Bansal is reluctant to understate. The company’s key customer relationships have proved durable over time, and Bansal notes that retention among its most important accounts has remained strong. That durability provides demand visibility – a meaningful advantage when planning capacity additions – and reduces the kind of revenue volatility that can destabilise an investment cycle.

EXPORT AMBITIONS

Bansal Wire currently serves customers in more than 50 countries. The geopolitical turbulence of recent years has not prompted a strategic retreat from export markets, though it has reinforced the value of running a diversified book. Global supply chain disruptions have increased international buyers’ appetite for suppliers who can demonstrate reliability and financial stability. “Demand across markets has remained stable, and global customers continue to look for reliable suppliers,” Bansal says.

The company intends to maintain a balanced split between domestic and international revenue, expanding both in parallel rather than trading one off against the other. India’s domestic demand base – across automotive, infrastructure and industrial sectors – provides the stability and visibility that allows the export business to be pursued opportunistically rather than defensively. Bansal says, “Going forward, we will continue to strengthen both domestic and export markets. The focus will be on maintaining a balanced mix while expanding our presence in key international markets.”

TECHNOLOGY’S ROLE

Underlying all of it is a sustained wager on technology – specifically, on the role of automation and in-house research and development in sustaining quality at scale. In the speciality segments Bansal Wire is moving into, process control is not incidental to the value proposition. It is the value proposition. Steel tyre cord that varies from one coil to the next is not the steel tyre cord that a global OEM will put through qualification. The margins that speciality products command exist precisely because producing them consistently is difficult.

“We are investing in advanced machinery, automation and in-house R&D to strengthen these capabilities. Automation and process improvements help us maintain consistent quality while operating at higher volume,” Bansal says. The investment extends beyond equipment to the quality systems, testing infrastructure and technical personnel needed to operate at the standards global customers require.

Industry trends, he argues, only reinforce the case for continued investment. Demand for high-performance wire products across automotive and industrial applications is rising, driven by the same forces – electrification, premiumisation and tighter safety standards – that are reshaping the broader materials landscape. In that context, technology is not a discretionary spend. It is the price of remaining relevant.

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As the tyre industry confronts electrification, sustainability mandates and shifting supply chains, Milliken Textiles is focusing on specialised textile reinforcements rather than volume tyre cord. The strategy reflects a deliberate choice to concentrate on high-value niches where engineering expertise, rather than scale, defines competitiveness. Products such as Beadwrap and Millicap highlight how materials hidden inside tyres can influence safety, rolling resistance and rubber consumption.

The global tyre industry is approaching a structural turning point, driven by electrification, sustainability targets and changes in manufacturing footprints. For Milliken, this transition is creating opportunities for specialised textile reinforcements that improve tyre performance while reducing material usage.

Speaking about the company’s strategy, Lieven Keymeulen, Marketing Director at Milliken Textiles, explained that the US-based materials science company has deliberately avoided competing in the high-volume tyre cord market dominated by large suppliers.

“We are more of a speciality textile reinforcement supplier,” Keymeulen said. “We are not looking at mainstream tyre cord applications. We are focused on specialised solutions.”

Instead of commodity tyre cord production, the company positions itself as a development partner to tyre manufacturers seeking customised solutions for specific applications.

“As a textile company, we are active in many different markets, so we can take knowledge from other applications and bring that into tyres,” Keymeulen explained. “That allows us to develop products that are much more specific than standard tyre cord.”

Over time, the company has also developed strong application knowledge, investing significant effort in understanding how its materials behave inside tyres. This helps refine its textile solutions further.

OCTAGONAL STEELCORD SOLUTIONS

One example of this approach is Beadwrap, a reinforcement designed as a safety component within tyres. It is particularly relevant for larger tyres, where it helps maintain structural integrity, and for passenger car radial tyres with orthogonal design solutions, where it secures the structure and stabilises the tyre. Another established offering is Millicap, which supports tyre performance improvements linked to sustainability. With the rise of electric vehicles, rolling resistance has become a critical parameter because it directly affects battery range. Tyres that reduce rolling resistance can also reduce rubber consumption, resulting in cost savings and lower carbon emissions.

Although around 90 percent of the tyre market consists of mass-market tyres, the company has deliberately chosen not to focus on that segment.

“The mass market is highly crowded, with many companies offering similar products and limited opportunities for differentiation,” Keymeulen said. “Our strategy is to remain innovation- and technology-driven, concentrating on specialised applications where we can offer unique, customised solutions.”

HIDDEN VALUE IN NICHE COMPONENTS

The tyre industry is vast, meaning even niche components can generate significant volumes. Products like Beadwrap may represent only a small portion of a tyre, but when each tyre uses several centimetres of material across millions of tyres, volumes quickly become substantial.

Although such components remain hidden inside the tyre, the company’s primary focus is not end consumers but tyre manufacturers and their engineering teams.

“A key part of our role is educating engineers within tyre companies about the capabilities of textile reinforcements and how they can improve tyre performance,” Keymeulen explained. “Manufacturers typically approach us with specific technical challenges, and we work together on customised solutions.”

Global supply-chain diversification and geopolitical concerns are also influencing partnerships, as tyre makers increasingly prefer suppliers with a balanced global presence. With operations in United States, Europe and India, Milliken offers a more resilient supply base.

“Collaboration often begins in the early stages of tyre development, focusing first on understanding the application and the problem,” he noted. “Over time, this builds strong trust with tyre manufacturers.”

The company also collaborates with machine suppliers, enabling it to present tyre makers with semi-finished integrated solutions that combine materials with compatible processing equipment. This ensures alignment between materials, machinery and manufacturing processes.

FOCUS ON INDIA AND EMERGING REGIONS

India is a key market for the company, partly because many Indian tyre manufacturers operate relatively modern equipment, making them competitive and more open to adopting new technologies.

While the company cannot be equally active in every region, such as the Chinese domestic market, it maintains strong engagement with Indian manufacturers as well as Japanese and Korean tyre brands.

“Innovation does not always start with large tyre manufacturers,” Keymeulen said. “Tier-II companies can often be more agile and willing to test new ideas more quickly.”

Regionally, Europe is gradually regaining momentum, Korean tyre manufacturers remain highly innovative, and Southeast Asia continues to drive industry growth.

SUSTAINABILITY AND MATERIAL EFFICIENCY

Looking ahead, tyre companies have ambitious sustainability goals, with many targeting tyres made entirely from renewable or sustainable resources by around 2050. A major contribution to this transition will come from recycled yarns, particularly recycled nylon, which remains one of the best-performing reinforcement materials but is difficult to recycle at scale.

While tyres cannot be produced without rubber, textile solutions can help reduce rubber usage.

One important contribution comes from specialised tackified textile reinforcements, produced using a proprietary dipping process that makes the material naturally adhesive. This eliminates the need for calendaring the textile with an additional rubber layer and enables direct placement within the tyre structure.

“This approach is particularly valuable in space-constrained areas such as the bead,” Keymeulen explained. “By eliminating extra rubber layers, we can reduce thickness and rubber consumption.”

Similar benefits apply to Millicap. According to customer data, rubber savings can reach around around 200 grammes for smaller 15-inches tyres to 500 grammes and more for large size tyres, leading to lower tyre weight and reduced carbon emissions.

Millicap is currently produced mainly using nylon, with a polyester version also available. Over time, the expected transition is towards recycled polyester.

ADAPTING TO INDUSTRY SHIFTS

The industry has faced several structural challenges following the Covid-19 pandemic, while the global tyre manufacturing footprint continues to shift geographically. New capacity is increasingly located in India and Southeast Asia, while European production is moving towards Eastern Europe and parts of Africa.

To remain close to customers, Milliken is reconsidering the traditional model of a few large factories.

“We are exploring smaller, strategically distributed operations,” Keymeulen said. “The idea is to create regional hubs that can source yarns and raw materials locally.”

Currently, the company operates major tyre-related production plants in United States and Europe, along with a processing facility in Bengaluru, India. The Bengaluru plant focuses on slitting and converting master rolls into customised formats closer to customers, with plans to expand its capabilities over time.

NEW AVENUES FOR GROWTH

In terms of tyre segments, the truck and bus radial market remains the largest for the company, while solutions also enable entry into passenger car tyres.

Another growing focus area is bicycle tyres, driven by rising demand for off-road and electric bicycles, which require higher strength and cut resistance.

“In tyre construction, steel cord has historically been dominant,” Keymeulen explained. “Textile reinforcements offer far greater flexibility for innovation. That opens up many more possibilities for optimising performance.”

The company is also exploring new variations of Millicap, including hybrid material concepts and alternative structures aimed at further improving tyre efficiency.

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The tyre industry faces growing pressure to reduce fossil-based inputs, prompting a shift towards bio-based materials as industrial alternatives. Once a niche research area, bio-based solutions are now entering mainstream engineering as manufacturers balance performance and sustainability. This shift is clear in next-generation fillers, with companies like UPM advancing lignin-based solutions from concept to commercial validation.

Florian Diehl, Director of Sales RFF at UPM Biochemicals GmbH, explained that the company positions its BioMotion renewable functional fillers (RFF) as a new material class that addresses sustainability while delivering measurable performance gains.

NEXT-GEN FILLERS

Functional fillers are not peripheral to tyre design; they are central. Typically accounting for nearly 30 percent of a tyre’s composition, materials such as carbon black and precipitated silica have defined performance characteristics for decades. Against this entrenched backdrop, UPM’s innovation is not incremental – it is structural. “This is not a one-to-one drop-in replacement for carbon black, but rather a new material class that sits somewhere between carbon black and silica, with some properties closer to carbon black and others closer to silica,” said Diehl.

This approach is intentional. Instead of matching legacy materials, UPM expands the formulation options for tyre engineers, though this adds complexity. “You cannot just take out carbon black and put in RFF without making adjustments, because while it can replace both carbon black and silica to some extent, it requires changes in the formulation and curing system,” Diehl added.

Adoption will require iterative, collaborative development between material suppliers and tyre manufacturers.

PROOF THROUGH PARTNERSHIP

The collaboration between UPM and Nokian Tyres marks a key milestone in applying material innovation. In June 2024, they introduced the Green Step Ligna concept tyre, the first to use UPM BioMotion RFF, a fully renewable, wood-based lignin material. In this tyre, all fossil-derived carbon black in the sidewalls has been replaced by the lignin-based filler.

The concept tyre demonstrates the practical viability of lignin-based material in tyres and sets a higher benchmark for environmental responsibility in the industry.

For UPM, this collaboration is a strategic turning point. It marks the company’s entry into global tyre markets with renewable functional fillers and supports scaling its biorefinery business through proven application value.

Diehl noted that such collaborations are essential for industrial validation.

“The Nokian Tyres case is the only one we can discuss publicly, but we are working with most major tyre companies behind the scenes, even though we are not allowed to disclose their names,” he said.

PERFORMANCE STILL DOMINATES

Despite the strong sustainability narrative, Diehl was unequivocal that performance remains the primary driver of adoption. “For example, Nokian Tyres reported that when they replaced virgin carbon black in the sidewall, they observed improved rolling resistance, which is a clear performance advantage,” he said. This is consistent with early test findings, which suggest that substituting traditional fillers with RFF can enhance efficiency while reducing environmental impact.

Rolling resistance is particularly critical in electric vehicles, where it directly influences battery range. “In inner liner applications, we have seen that it improves air impermeability, meaning the tyre retains air pressure better, which is another functional benefit,” Diehl noted.

UPM’s data confirms improved air retention and efficiency as key outcomes.

The material’s lower density also reduces weight. “Compared to carbon black and silica, our material has a lower density, so you need less material, which makes the final product lighter and further supports improvements in rolling resistance,” Diehl said.

LIGNIN: UNLOCKING AN UNDERUTILISED RESOURCE

The foundation of UPM’s innovation lies in lignin, a natural polymer that has historically been undervalued. “Lignin is the second most abundant natural polymer and is present in all plants, but in the paper industry, it is typically separated and burned as an energy source rather than being used as a material,” Diehl explained.

For UPM, this represented a strategic opportunity. “As a company with deep expertise in wood handling and wood chemistry, we decided to move from fibre-based applications to the molecular level and develop biochemicals,” he said.

Through proprietary processing, lignin is transformed into a rigid particulate filler with controlled surface properties. “We developed a process that converts lignin into a particulate material that behaves like a filler, with tunable surface area and without the typical polymer characteristics,” Diehl added.

This transition – from waste stream to high-performance material – illustrates the broader industrial shift towards biomass valorisation.

SCALING FROM CONCEPT TO INDUSTRY

While the concept tyre proves technical feasibility, scaling is the next critical step. “The material is just becoming commercially available, and manufacturers prefer to test it from the final production site rather than pilot batches, so the current limitation is availability while our Leuna Biorefinery is in its start-up phase,” Diehl explained.

UPM’s Leuna biorefinery is central to addressing this. “At our biorefinery in Leuna, we will produce a total of 220,000 tonnes of biochemicals, with renewable functional fillers representing a significant share,” he said.

The facility itself represents a substantial industrial commitment, with investment exceeding EUR 1 billion and designed to convert sustainably sourced hardwood into next-generation biochemicals.

Crucially, scalability is underpinned by feedstock availability. “Lignin is already available at industrial scale in pulp and paper mills, so if the market adopts our solution, we can scale production significantly,” Diehl added.

COMPLEMENTARY MATERIAL STRATEGY

The rise of recovered carbon black (rCB) adds complexity to sustainability efforts. UPM positions its material as complementary rather than competitive. “We see our solution as complementary, meaning tyre manufacturers can use recovered carbon black alongside our renewable functional fillers to replace fossil-based carbon black,” Diehl said.

He also challenged assumptions around cost. “There is a perception that recovered carbon black is cheaper, but in some European markets, we hear that it can even be more expensive than virgin carbon black,” he noted. This suggests future tyre compounds will likely blend recycled and renewable inputs, rather than rely on a single alternative.

MARKET STRATEGY: PREMIUM FIRST

UPM’s commercial approach follows a well-established pathway for advanced materials. “As with most new materials, we expect initial adoption in premium segments before it gradually expands into the mass market, although this transition will take time,” Diehl said.

Premium manufacturers are expected to lead this transition, with emerging global players likely to follow as they move up the value chain.

ELECTRIFICATION DRIVES CHANGE

The rise of electric vehicles introduces new performance constraints. “Electrification will have a clear impact on tyre design because vehicles are becoming heavier and have higher torque, which makes wear resistance more critical,” Diehl said.

UPM is already adapting. “With our current solutions, we would not yet fully meet all requirements in such applications, which is why we are already working on a second generation that can compete more effectively,” he added.

SUSTAINABILITY

UPM’s RFF is positioned as a 100 percent renewable, CO₂-negative solution (from cradle to gate, considering the biogenic carbon and purchasing 100 percent green electricity), contributing to reduced reliance on fossil-based materials. However, Diehl is candid about market realities. “A few years ago, sustainability was the dominant driver, but today the focus has shifted towards combining sustainability with performance,” he said. “The willingness to pay higher prices is currently limited, which is a challenge, even though we believe our material delivers additional value,” he added.

REGULATION NOT ENOUGH

“There are discussions around end-of-life tyre regulations that could include bio-based quotas, which would support solutions like ours,” Diehl said. Yet he remains cautious. “Ultimately, the product must deliver performance, because regulations can change and cannot be relied upon as the only factor,” he added.

“We designed our processes so that the material can be handled and dispersed in a similar way to traditional carbon black and silica,” Diehl said. “When tyres containing our material are recycled, the filler will end up in pyrolysis oil, similar to natural rubber,” he added.

MEASURED TRANSFORMATION

UPM’s strategy focuses on systematic integration: introducing a new material class, validating it through partnerships and scaling it through industrial infrastructure. The Nokian Tyres concept tyre offers a tangible glimpse of what that future may look like: a tyre in which fossil-derived fillers are partially or fully replaced by renewable alternatives, without compromising performance. As Diehl concluded, “we are convinced the product delivers the performance and provides additional value, and will succeed in the market.”

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