Like many other sectors, India’s tyre industry is undergoing a massive digital transformation. Companies like CEAT have been at the forefront of this shift, adopting state-of-the-art technology.

The company was recently included in the World Economic Forum’s Global Lighthouse Network due to its impactful digital transformation using Fourth Industrial Revolution (4IR) technology.

The leading tyre manufacturer has also planned to extend its technological advancements to its Nagpur plant. “CEAT’s vision for a smart factory dates back to 2015, when it commissioned its Nagpur plant. The groundwork, however, was laid earlier at Halol, where barcode tagging was introduced for traceability and error-proofing. While Nagpur became the first facility to implement a manufacturing execution system (MES), deeper analytics and machine learning capabilities were not yet in focus between 2015 and 2020,” revealed Jayasankar Kuruppal, Sr Vice President –Manufacturing, during an exclusive interview with Tyre Trends.

As Halol expanded and exports to Europe surged by the early 2020s, CEAT had to rethink its manufacturing strategy, shifting from a high-volume, low-variant model to a high-variant, low-volume approach. Once limited to 60-70 stock-keeping units (SKUs), the company's passenger car segment expanded nearly fivefold to meet European demand, requiring a complete overhaul of production workflows. 

At the same time, the adoption of silica-based compounds, which is critical for wet grip and rolling resistance, posed new challenges. These materials inherently increased cycle times, impacting capacity utilisation. While Halol was not initially designed for high-silica production, the company’s Chennai plant incorporated necessary corrections. However, tighter OEM specifications and European market requirements led to higher scrap and yield losses. 

Recognising the limitations of conventional manufacturing, CEAT turned to 4IR technology to optimise its processes. The 4IR technology refers to the advanced digital and automation-driven technologies transforming industries today. It builds on the Third Industrial Revolution by integrating AI, IoT, big data and robotics to enhance efficiency and decision-making.

“The digital transformation began at the Halol plant, expanded to Chennai and is now planned for Nagpur. Between 2020 and 2022, CEAT developed and deployed over 80 digital use cases, earning its first Lighthouse Factory designation. This data-driven manufacturing approach is now being systematically rolled out across its entire production network,” added Kuruppal.

Intelligent factories

4IR plays a crucial role in tyre manufacturing and recycling by enhancing predictive maintenance through IoT sensors, increasing energy efficiency via AI, production optimisations and advancing smart tyres with real-time monitoring.

On the other hand, an intelligent or smart factory in tyre manufacturing is defined by two core pillars, namely automation and digital intelligence. Traditionally, the tyre industry has been labour-intensive, but the shift towards smart factories is transforming operations through seamless machine-to-machine communication, real-time data sharing and AI-driven decision-making. 

The first layer of an intelligent factory is pure automation. This includes automated machines for tyre handling, programmable logic controllers for managing machine operations and automated warehousing systems to ensure smooth flow.

“For a plant to be truly smart, data must move seamlessly across all these systems, creating a connected ecosystem. This integration extends to ERP systems and advanced AI/ML-powered analytics, optimising throughput and efficiency,” said Kuruppal.   

The next stage is where operations run end-to-end with minimal human intervention. CEAT has already implemented elements of this, particularly through curing-to-dispatch automation, where tyres move untouched from uniformity testing to segregation, grading, storage, retrieval and final dispatch. It also has AI-driven IoT integrations that enhance energy efficiency, yield optimisation and first-time-right accuracy across all processes.

“The fusion of AI, IoT and automation is enabling tyre manufacturers to move from traditional manual-heavy processes to a digitally orchestrated, high-efficiency production model,” quipped Kuruppal.

CEAT’s production capacity spans multiple plants, each specialising in different tyre categories. The Chennai and Halol plants both produce 20,000 passenger car tyres daily. The Nagpur plant, India’s largest two-wheeler tyre manufacturing facility under one roof, with a capacity of close to 78,000 two-wheeler tyres daily.

Digital implementation

Curing operations in CEAT’s passenger car and truck tyre segments are almost entirely automated. While the curing medium remains unchanged, continuing with a combination of steam and nitrogen across Halol, Chennai and other facilities, the company is also exploring radical new processes, though still in the proof-of-concept stage. 

One key digital use case implemented in Chennai focused on reducing steam consumption through real-time process monitoring. Traditionally, mould heating followed fixed time cycles (e.g. 120 or 150 minutes). CEAT optimised heating based on actual temperature data, cutting steam consumption by almost 30 percent by integrating sensors and applying a machine-learning model.

The manufacturer has invested approximately INR 450-500 million in capital expenditure across its three factories to implement automation and digital transformation initiatives. On the operational expenditure side, CEAT spends INR 60-70 million annually on software licenses, infrastructure upgrades, sensors and scanners to sustain these smart factory systems.

Adopting smart manufacturing technologies has led to significant cost reductions for CEAT. Factory conversion costs at Chennai and Halol have decreased by 20-30 percent, driven by lower energy consumption, improved yield, higher manpower productivity and throughput enhancements.

Lead times from order placement to tyre dispatch have been cut by 50-55 percent, significantly improving supply chain efficiency. Additionally, material wastage has been reduced with process scrap, both component-level and finished product waste, dropping by 25-30 percent, resulting in substantial raw material savings.

Alluding to how difficult was it to implement such extensive digital changes, the executive explained, “From an infrastructure standpoint, Chennai had a clear advantage over Halol since the latter was commissioned in 2010 and 2015, when network and digital infrastructure were not as advanced. Unlike Chennai, Halol still does not have a fully integrated MES, making digital transformation more complex.”

“However, the approach to smart manufacturing differed at both plants. At Halol, the primary focus was on efficiency improvements. In contrast, Chennai underwent a more comprehensive transformation, covering the entire manufacturing chain from design and production to dispatch and supply chain optimisation. The goal at Chennai was to reduce overall turnaround time, significantly cutting the cycle from customer order receipt to final dispatch,” he added.

While Chennai benefited from a stronger digital foundation, CEAT did not merely replicate Halol’s use cases but developed new ones tailored to Chennai’s specific needs, further driving end-to-end operational efficiency.

Commenting on the challenges surrounding this paradigm shift, the executive noted, “Integrating legacy systems with Industry 4.0 technologies posed a significant challenge as ensuring compatibility between older manufacturing infrastructure and new automation, IoT and AI-driven solutions required meticulous planning and phased implementation.”

“Another critical hurdle was maintaining data quality and governance, necessitating robust validation processes, data lineage tracking and an accountability framework to enhance data integrity and reliability,” he added.

Answering whether such transformation is possible on OTR production lines, he said, “Unlike passenger or two-wheeler tyres, OTR tyres have a longer cycle time and high levels of customisation, making digital automation less complex but highly specific. While digital transformation is feasible, CEAT plans to prioritise full automation at Nagpur in the next 18–24 months, before shifting focus to digitalisation in OTR production.”

Workforce re-alignment

CEAT is reshaping its workforce strategy to align with its digital transformation, ensuring that shop floor employees are equipped and actively involved in adopting new technologies. 

It has digitised over 100 operator touchpoints to secure operator buy-in. The programme simplifies shop floor tasks through digital tools, MES integration and real-time dashboards, allowing operators to make decisions independently and reducing reliance on supervisors. Every operator has undergone basic digital awareness training to facilitate this transition. 

A key move was the introduction of business translators, who are frontline supervisors with strong technical acumen. They bridge shop floor pain points with digital solutions. Working alongside data engineers and scientists, these individuals co-develop AI-driven use cases, such as reducing setup time in mixing processes to improve efficiency. 

The company also strengthened its talent pipeline, hiring computer science graduates, a rarity in the tyre sector just a few years ago.  It has pioneered hiring female operators in the tyre industry, beginning in Halol in 2009.

“Today, 24–30 percent of shop floor employees in Chennai and Nagpur are women. While digitalisation isn’t the primary driver of this shift, automation has made traditionally labour-intensive jobs more accessible. The company also enforces pro-women policies, including home pick-ups and drop-offs, designated rest areas, female security and an internal support forum (V Power) to address workplace concerns,” informed Kuruppal.   

When asked whether digitisation will lead to a cut in vacancies, Kuruppal stated, “Contrary to fears that digitalisation reduces shop floor jobs, we find ourselves grappling with the bigger challenge of talent attraction. Post-pandemic, fewer young workers are willing to pursue manufacturing roles, with many opting for finance, retail and IT-driven careers instead. This trend is evident across major tyre-producing states like Tamil Nadu, Maharashtra and Gujarat.” 

“While automation and AI reduce physical strain and deskill certain operations, a fully manless tyre plant remains economically impractical in the near term. However, with rising labour costs and shrinking workforce interest, a fully automated future – perhaps within 15–20 years – isn’t off the table,” he added.

Sustainability through digitisation

CEAT is driving sustainability through digital transformation, reducing energy and water consumption while lowering its carbon footprint. Energy efficiency measures have led to a 15 percent reduction in power consumption at Halol and 25 percent at Chennai.

Renewable energy accounts for 40 percent of the company’s power mix, cutting Scope 1 and Scope 2 carbon emissions by nearly 30 percent. Water usage has been reduced by 30-35 percent over the past three years through steam optimisation, with future plans to eliminate steam in curing.

In green material adoption, integrating silica-based compounds in tyre manufacturing has required process adjustments as it increases cycle time. CEAT collaborates with equipment manufacturers to enhance efficiency. It has upgraded mixers to improve silica processing and support its shift towards sustainable materials.

Commenting on future plans to implement digital solutions, Kuruppal said, “We plan to integrate virtual and mixed reality into the manufacturing processes to enhance equipment maintenance and reduce mean time to service. We are also exploring AI-driven process optimisation, as these models will auto-correct processes in real-time, enhancing product consistency and accelerating decision-making. These technologies will also help identify and eliminate bottlenecks in manufacturing and planning, ensuring a more agile and efficient production flow.”

“The company is looking into GenAI to address complex operational challenges. AI-driven predictive maintenance will improve equipment reliability by forecasting potential failures before they occur. Additionally, GenAI will optimise supply chain and production planning, ensuring better resource allocation and efficiency,” he added.  

Professor James Busfield of Queen Mary University of London has been awarded the prestigious IRCO Medal by the International Rubber Conference Organisation (IRCO) in recognition of his longstanding contribution to international rubber conferences. The honour was presented by IRCO Executive Chairman Michael Clayton at IRC 2026 in Aichi, Japan, immediately before Busfield delivered his plenary lecture. The IRCO Committee unanimously approved the award at its meeting in Bangkok on 2 December 2025.

His involvement with the organisation spans more than a decade, having represented the United Kingdom on the IRCO Committee since 2013. He chaired and organised IRC 2019 in London, attracting 550 delegates, and led the organisation of RubberCon events in Manchester in 2014 and Edinburgh in 2023, the latter welcoming over 310 participants from 26 countries. A frequent plenary and keynote speaker, he also regularly involves postgraduate students in these international gatherings, providing opportunities to showcase their research and build professional connections.

Left to right: Michael Clayton, Executive Chairman of IRCO; Professor James Busfield, Queen Mary University of London; and Professor Mikihito Takenaka, Congress Chair of IRC2026 AICHI and Professor at the Institute for Chemical Research, Kyoto University.

Beyond his international conference work, Busfield has headed the Elastomer Group at the Institute of Materials, Minerals and Mining (IOM3) since 1995. Under his leadership, the group has delivered more than 100 meetings and conferences for the rubber sector while introducing hybrid events to expand global accessibility. At Queen Mary, he serves as Professor of Materials, National Teaching Fellow, Deputy Head of School and Head of the UK's largest soft matter research group. His career began in automotive suspension engineering before he completed his doctorate under Professor Alan Thomas.

Busfield's research encompasses rubber friction, fatigue, fracture, recycling and smart materials, supported by more than 190 peer-reviewed publications and industrial collaborations with Bridgestone, Continental, Aston Martin F1 and Schlumberger. Elected a Fellow of the Royal Academy of Engineering in 2020, he has also received the Colwyn Medal (2009), the American Chemical Society Rubber Division's George Stafford Whitby Award (2021) and the IOM3 T B Marsden Medal (2024).

Michael Clayton, Executive Chairman of IRCO, said, “James never travels alone. At every conference he brings his students, and gives them the chance to present, to meet people and to begin their careers in our industry. He is incredibly generous with his time, and one of our industry's most engaging speakers. Professor Busfield is an incredibly worthy recipient of the IRCO Medal.”

Professor James Busfield said, “It is a great honour to receive the IRCO Medal. IRCO has coordinated the International Rubber Conference and RubberCon events for about 60 years, and I have been fortunate to have been a part of that community for about half of that time. I enjoy greatly participating in these conferences and value the opportunity to meet the global rubber experts, discuss with them new innovations and together help to move the discipline and our industry forward. My thanks are extended to all of those from the global rubber community who have worked to make our IRCO events so successful.”

Hankook Tire is set to exhibit at the 2026 SEMA Show, the leading annual gathering for aftermarket automotive manufacturers, scheduled for 3–6 November at the Las Vegas Convention Center. The company’s display at Booth #80021 in the Silver Lot will feature a broad selection from its Dynapro line, a brand focused on SUVs and light trucks, alongside a rally car from the FIA World Rally Championship.

The Dynapro showcase will include four products: the mud-terrain Dynapro MT2, the rugged-terrain Dynapro XT, the all-terrain Dynapro AT2 Xtreme and the highway-terrain Dynapro HT2. These will be presented together with customised off-road vehicles and the WRC rally car, underscoring the company’s engineering capabilities across varied driving conditions.

Two customised vehicles will demonstrate the lineup’s versatility: the TRAILFINDER Nissan Xterra, previously called Project X, fitted with Dynapro AT2 Xtreme tyres, and the Donut Media Baja Bug equipped with Dynapro MT2 tyres. These builds illustrate Dynapro’s performance across different off-road environments while reinforcing Hankook’s ties to SUV and off-road communities in North America. Donut Media hosts Justin Freeman and Adam Knapik will appear at the booth on 4 November from 11 AM to 4 PM to meet visitors and discuss the Baja Bug build and the NORA 500 event.

A WRC rally car equipped with Dynapro R213 competition tyres will also be on display. Engineered for gravel rally conditions, the R213 offers grip, handling stability, and durability on unpaved surfaces, highlighting Hankook’s specialised tyre development in high-performance motorsports. The company continues to build its premium presence in North America through events such as SEMA and Overland Expo, and aims to strengthen its position in the global SUV and light truck tyre market by leveraging technologies and expertise gained from motorsports and demanding driving environments.

Aaron Hong, Vice President – Marketing, Hankook Tire America Corp, said, "SEMA continues to provide an important opportunity for Hankook to connect with the automotive aftermarket and demonstrate our commitment to innovation and performance. From the technical demands of WRC competition to the diverse needs of SUV and light truck drivers, our Dynapro portfolio reflects the depth of our tyre engineering expertise. We're excited to showcase our products alongside an impressive collection of vehicles that highlight our continued focus on performance, versatility and engagement with the enthusiast community."

Nokian Tyres has launched its 2026 Virtual Green Tire Giveaway, an annual campaign tied to the company's partnerships with leading mountain resorts across US and Canada. The programme, which debuted in 2023, continues to connect drivers with winter destinations, resort partners and the Nokian Tyres brand through an interactive digital scavenger hunt offering weekly tyre prizes and a grand-prize mountain getaway.

Running through 22 November, the campaign invites participants to follow clues posted on Nokian Tyres' social media channels and those of participating mountain resorts to find a virtual green tyre hidden on an interactive map. A new resort destination and fresh set of clues are unveiled each week, with weekly winners earning a free set of tyres and runners-up receiving resort lift ticket vouchers.

On 23 November, one grand prize winner will be randomly selected to receive a three-night mountain getaway. Further information on featured resorts and clues is available through Nokian Tyres' North America Facebook and Instagram channels, while complete details and participation options can be found online, with a dedicated page offered for French-speaking Canadians.

Hans Dyhrman, Director of Marketing, Nokian Tyres, said, "Our resort partnerships help us connect with consumers who embrace winter and seek adventure. The Virtual Green Tire Giveaway is an engaging way for Nokian Tyres to reach drivers as they prepare for the winter season while highlighting the confidence and peace of mind our tyres provide."

Pirelli's medium and soft compounds shaped the Mexico City Grand Prix, where Max Verstappen took victory for Red Bull and Kimi Antonelli secured the Formula 1 World Championship with a third-place finish. Lewis Hamilton completed the podium in second for Ferrari at the circuit named after the Rodríguez brothers.

Verstappen triumphed through a two-stop strategy, beginning on mediums before switching to softs on lap 27. After 18 laps on the C5 compound, a red flag stopped the race, and the Dutchman used the pause to fit another set of softs, then resisted Hamilton's challenge to the finish. Hamilton had started on softs, moved to mediums and took another set of softs during the Safety Car that preceded the red flag, later choosing a previously run soft set at the restart while setting fastest laps on both compounds.

Antonelli, at 20, becomes Formula 1's youngest World Champion, breaking Sebastian Vettel's record of 23. The Italian started on softs, switched to mediums on lap 43 and used the red flag to fit another used set of softs, a strategy that delivered third place and the title. The podium contained only World Champions, with Verstappen on four titles, Hamilton on seven and Antonelli on his first.

Antonelli is the third Italian driver to claim the championship. His predecessors also won exclusively on Pirelli tyres, with Giuseppe Farina taking the inaugural 1950 title across six races and Alberto Ascari securing his second consecutive crown in 1953 by winning all eight Grands Prix he entered.

Dario Marrafuschi, Pirelli Motorsport Director, said, “Congratulations to Kimi Antonelli on winning the World Championship. It is a thoroughly deserved success, built on the consistency he has demonstrated throughout the season and sealed today with another outstanding performance, culminating in a podium finish in a race packed with drama alongside two World Champions. Without the neutralisations, a one-stop strategy would have been the most competitive option for this Grand Prix. Both the Soft and Medium compounds proved capable of covering around half the race distance, making it possible to complete the event with a single tyre change. The C5 once again confirmed itself as the benchmark compound in terms of grip and driver confidence, although the performance gap to the C4 was very small, with both compounds showing similar levels of degradation. It was therefore no surprise that every driver chose the Soft for the final stint after the Safety Car, despite also having the Hard compound available.

“From a technical perspective, tyre behaviour was very positive. We recorded no significant graining, and degradation remained within expected levels, proving lower than what had been observed on Friday. A lock-up by Leclerc at the restart following the red flag also provided further evidence of the robustness of Formula 1 tyres. The tyre sliding across the asphalt caused particularly severe localised wear on the front-left tyre, bringing it very close to the internal structural layers. This is certainly not a routine occurrence, but it is one that is consistently taken into account throughout Pirelli’s development and validation processes, including through rigorous indoor testing programmes. The ultimate objective is to ensure that the tyre maintains an appropriate level of integrity even under extreme conditions, allowing drivers to continue racing in complete safety.

“The performance of the Soft compound was particularly interesting, as demonstrated by Antonelli’s lengthy stint. He completed 43 laps while maintaining very limited degradation and a competitive pace right through to the closing stages of the race. The C3, meanwhile, was not considered by the teams because, under race conditions, it did not offer any performance advantage over the two softer compounds. Overall, the data collected confirmed a very clear picture, fully consistent with the simulations carried out before the event, both in terms of degradation and the competitiveness of the various strategic options.”