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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Epsilon Carbon has significantly expanded its manufacturing footprint with the formal activation of a new 300,000-tonne-per-annum speciality carbon plant in Vijayanagar, Karnataka. This latest addition brings the company’s aggregate production capacity in this segment to 600,000 tonnes annually, a development that elevates the firm to a leading position among domestic producers and reinforces India’s broader influence in the international speciality carbon market.

The new installation operates on a fully digitised manufacturing architecture, incorporating real-time process monitoring, automated quality controls and interconnected production systems. Such technological integration is intended to minimise operational variability, maximise throughput and provide overseas buyers with a stable and predictable supply base across multiple product categories.

Output from the Vijayanagar complex will encompass a wide array of coal-tar derivatives, including binder and impregnated pitches, refined naphthalene, anthracene and creosote oils and wash oil. These intermediates find application across a spectrum of heavy and light industries, ranging from primary aluminium and graphite electrode production to tyre compounding, pigment formulation, pharmaceutical synthesis and speciality construction materials.

Looking ahead, the company has outlined a trajectory towards further capacity enhancement, with a proposed integrated facility in Jharsuguda, Odisha, expected to push total speciality carbon output to one million tonnes per annum by the end of the decade. Meanwhile, the Karnataka plant has been configured with closed-loop water management, recycling all treated effluent internally, and derives its entire power requirement from a 17‑megawatt captive unit running on recycled process off-gases. Certifications such as Responsible Care, EcoVadis Silver and SA8000 attest to the company’s adherence to stringent safety, environmental and labour standards.

Gaurav Mathur, Chief Executive Officer, Epsilon Carbon, said, "This expansion reflects India's growing capability to become a global supplier of speciality carbon materials. With 600,000 TPA of Speciality Carbon capacity, we are strengthening supply chain resilience for both domestic industries and international customers, particularly the global aluminium sector. As the world looks to diversify supply chains, Epsilon Carbon is proud to contribute to India's emergence as a reliable, sustainable and globally competitive manufacturing hub."

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HS HYOSUNG ADVANCED MATERIALS participated in the China Composite Expo 2026 (CCE 2026), held at the National Exhibition and Convention Center in Shanghai from 1 to 3 September. This annual event stands as Asia’s largest specialised exhibition for composite materials, drawing a significant global audience.

The company has been a consistent participant in CCE since 2013, leveraging the expo to progressively reinforce its foothold in the Asian market. At this year’s showcase, the strategic focus was on its portfolio of high-performance carbon fibre products, which are increasingly recognised as essential materials for advanced sectors including energy, mobility and aerospace due to their superior tensile strength and modulus.

Central to the presentation were actual samples of TANSOME, the company’s proprietary carbon fibre brand developed through in-house technologies. The exhibit featured a diverse range of applications, from mobility components like automotive wheels, hoods and brake discs to sporting goods such as hockey sticks and pickleball rackets, as well as high-pressure vessels for hydrogen and oxygen, drones and wire cores.

In parallel, HS HYOSUNG ADVANCED MATERIALS emphasised its robust manufacturing capabilities and stable supply chain, supported by production bases in Korea, China and Vietnam. This strategy reinforces its standing as a leading global carbon fibre manufacturer. Notably, the company achieved a milestone in 2011 as the first in Korea to independently develop TANSOME, a material 4 times lighter and 10 times stronger than steel. This was followed by the 2022 launch of H3065, a T-1000-grade fibre with strength exceeding steel by over 14 times, designed for demanding aerospace applications.

Jin Dal Lim, CEO, HS HYOSUNG ADVANCED MATERIALS, said, “This exhibition is an important opportunity to further strengthen strategic partnerships with global customers and demonstrate the outstanding technological capabilities of HS HYOSUNG’s carbon fibre. We will continue to build deeper trust in the global market based on world-class product quality and stable supply capabilities.”

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Bekaert has taken a decisive step towards reshaping its operational footprint in Sardinia by securing a preliminary deal with Nuova Icom, a local engineering entity. The arrangement paves the way for the handover of the Macchiareddu premises and guarantees job continuity for the existing staff stationed there, subject to the final stipulations of the contract.

The decision stems from long-term turbulence in the tyre sector, which has steadily undermined the commercial viability of the plant's primary output. With tyre cord manufacturing struggling to remain profitable amidst evolving industry dynamics, the company concluded that a fundamental operational shift was unavoidable.

This initiative follows an extensive search for sustainable alternatives, emphasising regional employment preservation. Bekaert remains attuned to the social ramifications of the transition and pledges to engage transparently with all affected parties. The prospective ownership change is scheduled for completion by October 2026, pending regulatory clearances and the finalisation of employee consultations.

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Every day, tyre recyclers face the same challenge: processing more tyres while maintaining sorting quality, protecting equipment and meeting increasing traceability requirements. Every misidentified tyre represents lost value. Every hidden contaminant can lead to costly downtime. Every manual operation limits productivity.

As tyre volumes continue to grow worldwide, the question is no longer whether tyre sorting should be automated. It is how quickly operators can adopt technologies that make their facilities more efficient, more reliable and more profitable.

As a specialist in intelligent tyre identification, sorting and traceability solutions, REGOM is actively contributing to this transformation through technologies designed to help recyclers process more tyres, improve sorting quality and gain better visibility over their operations.

Through artificial intelligence, advanced inspection technologies and digital traceability, the company is helping transform end-of-life tyres from a waste stream into a valuable resource.

SMARTER TYRE SORTING THROUGH ARTIFICIAL INTELLIGENCE

For decades, tyre sorting relied heavily on manual inspections performed by experienced operators. While this approach remains valuable, it can be time-consuming and difficult to scale as tyre volumes continue to increase.

To address these challenges, REGOM has developed intelligent tyre identification technologies capable of automatically reading and analysing tyres in just a few seconds. Powered by artificial intelligence and advanced image recognition, these systems capture and process tyre information in real time, generating reliable data that can immediately be used by operators.

The benefits are significant. Automated identification increases processing capacity through a continuous production flow and automatic evacuation rates of up to 25 percent. It improves sorting consistency, with customers reporting grading quality improvements of up to 3 percent while reducing the risk of human error. By automating repetitive identification and sorting tasks, operators can focus on higher-value activities. Every tyre is identified in just 2.5 seconds and enriched with detailed product data, creating a fully traceable digital record from collection to grading and reporting. This structured database supports regulatory compliance, operational monitoring and data-driven decision-making while preparing facilities for future traceability requirements.

Importantly, artificial intelligence is not designed to replace operators. Instead, it helps redefine their role by automating repetitive tasks and enabling them to focus on activities that require experience, expertise and decision-making. This shift supports higher productivity while creating greater value from human involvement throughout the sorting process.

As the industry continues to evolve, AI-driven sorting is becoming an essential component of modern tyre recycling facilities.

While artificial intelligence enables faster and more reliable identification, another challenge remains: Detecting contaminants hidden in whole tyre or shreds flows.

Some metallic objects or other contaminants not visible during standard inspections may end up in the flow of shreds or whole end-of-life tyres. Once these contaminants enter shredders, pyrolysis units or downstream processing equipment, they can cause costly damage, unplanned maintenance and production downtime.

To address this issue, REGOM has been investing for several years in the development of innovative X-Ray inspection technologies. This new machine aims to detect hidden contaminants before tyres enter critical processing stages. By identifying potential risks at an early stage, operators can better protect their equipment and avoid costly interruptions.

If your shredder or downstream equipment has already suffered unexpected downtime due to hidden contaminants, you already know the consequences: production stops, maintenance costs increase and valuable processing time is lost.

The challenge is that many contaminants remain invisible during traditional inspections and are only discovered once they have reached critical equipment.

This is where X-Ray technology can make a significant difference. By detecting hidden metallic objects and other contaminants before tyres enter shredders, pyrolysis units or other processing equipment, operators can reduce risks, protect critical assets and maintain smoother operations.

The benefits extend throughout the entire recycling process: lower maintenance costs, improved equipment availability, increased operational reliability and ultimately higher productivity.

“The X-Ray solution we are developing directly addresses our customers’ need to automate their operations, making them more reliable and consistent in an increasingly challenging labour market.

The X-Ray solution we are developing directly addresses our customers’ need to automate their operations, making them more reliable and consistent in an increasingly challenging labour market. This inspection system also helps mitigate a growing risk: fires caused by the increasing number of batteries found in end-of-life tyres. By reducing operational costs while ensuring consistent production, this solution delivers significant operational benefits and enhances overall efficiency,” says Arthur Wagner – CEO, REGOM.

TURNING DATA INTO OPERATIONAL EXCELLENCE

One of the most significant transformations occurring within the tyre recycling industry is the growing importance of data.

Historically, large quantities of operational information remained unavailable or underutilised. Today, advanced sorting technologies generate valuable data that can be used to improve decision-making across the entire facility.

By combining artificial intelligence, automated identification and digital traceability, operators gain a clearer understanding of incoming tyre flows and sorting performance. This information supports regulatory compliance, facilitates reporting and provides greater transparency throughout the recycling process.

More importantly, data enables continuous improvement. Facilities can identify trends, optimise workflows and make more informed investment decisions based on objective operational insights.

The result is a more efficient, more transparent and more resilient recycling operation.

SUPPORTING THE DEVELOPMENT OF TYRE RECYCLING IN INDIA

India is one of the world’s most dynamic markets for tyre recycling and resource recovery. As the sector continues to grow, operators face the same challenges seen across the globe: increasing volumes, higher performance expectations and a growing need for traceability.

Recognising this opportunity, REGOM has partnered with PLANNEX to support the deployment of advanced tyre sorting technologies throughout the Indian market.

By combining REGOM’s expertise in intelligent tyre sorting and traceability with PLANNEX’s strong local presence and industry knowledge, the partnership aims to provide Indian recyclers with access to innovative solutions designed to improve productivity, sorting quality and operational performance.

Together, REGOM and PLANNEX share a common vision: helping recyclers unlock greater value from every tyre while supporting the transition towards a more efficient and sustainable circular economy.

THE FUTURE OF TYRE RECYCLING

The future of tyre recycling is not simply about processing larger quantities of tyres. It is about understanding each tyre better, managing resources more effectively and extracting maximum value from every material entering the recycling stream.

Through artificial intelligence, advanced inspection technologies and data-driven decision-making, REGOM is contributing to this transformation by helping operators build safer, smarter and more efficient recycling facilities.

The challenge is no longer simply to process more tyres. The challenge is to extract more value from every tyre entering the recycling stream.

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