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.  

Comments (0)

ADD COMMENT

Link Copied!

Continental has secured a global original equipment supply agreement for the new all-electric Renault Twingo. The latest generation of the compact vehicle is now being produced exclusively with the 18-inch Continental EcoContact 7 tyre as standard across all worldwide markets.

The selection of this specific tyre is underpinned by its superior performance on the EU tyre label, particularly regarding energy efficiency and rolling noise. These attributes are critical for electric vehicle applications, as low rolling resistance directly contributes to maximising the driving range per charge, while reduced noise emission ensures a more serene cabin environment.

The tyre’s exceptional energy efficiency stems from a novel rubber compound and the advanced Smart Energy Casing technology, which incorporates new materials to minimise internal friction. Efficiency is further amplified by an aerodynamically optimised sidewall, featuring a golf-ball-inspired ‘Aerodimple’ structure that reduces air turbulence and the energy required to maintain motion.

Furthermore, Continental has engineered the Silent Pattern tread design to specifically mitigate rolling noise. By meticulously calibrating the tread block spacing and angles to counteract low-speed urban frequencies, the tyre delivers a quieter experience for both passengers and surrounding communities. This tyre variant, size 205/45 R18 90H XL FR, has been homologated for the Twingo in numerous countries.

Comments (0)

ADD COMMENT

Link Copied!

Bridgestone UK has been named Tyre Manufacturer of the Year at the 2026 TyreSafe Awards, recognising its sustained efforts to improve road safety and influence driver behaviour across the country. The honour specifically highlights the effectiveness of the company’s 'Be a Road Safety Hero' initiative.

Since its inception, that campaign has reached over 24 million individuals, combining public education, retailer participation and direct engagement to translate awareness into practical action. More than 25 nationwide events have been held at venues ranging from supermarkets to tyre retail sites, resulting in over 10,500 complimentary safety inspections. Those checks uncovered more than 1,200 separate issues, including roughly 200 tyres deemed illegal for road use.

Beyond these hands-on clinics, the programme has distributed extensive educational resources and maintained visibility through digital media and targeted public relations. Partnerships with groups like Sporting Bears have helped convey safety messages to enthusiast communities, while Bridgestone staff have collectively logged over 10,000 volunteer hours in support of the campaign’s objectives.

Helen Roe, Senior Manager – Brand, Events, Product & Digital Marketing, said, "While we're naturally delighted to receive this recognition, what matters most to us is the impact the campaign is having beyond the award itself. Our 'Be a Bridgestone Road Safety Hero' campaign was designed to encourage drivers to take simple steps that can make a big difference, and we're proud that the campaign is helping to identify potentially dangerous tyres and prompting drivers to take action. Tyre safety isn’t something any one organisation can tackle alone. That’s why we’ve worked closely with our retailers and partners to take this message directly to motorists in ways that are practical, visible and engaging. To have carried out over 10,500 tyre checks over the last couple of years, demonstrates the scale of the challenge but also the power of education and collaboration. We see this award not as the finish line, but as motivation to continue championing safer roads for everyone.

“We’d also like to recognise and congratulate TyreSafe, on their 20th year anniversary, for bringing together so many to collaborate on raising tyre safety awareness in the UK and for their continued work with government, police and emergency services to raise the profile of tyre safety nationwide. Ultimately, tyres carry lives. With an estimated 6.1 million illegal tyres still on UK roads, raising awareness remains critical. Regular tyre checks are a simple step that can make a real difference – for drivers and for everyone around them.”

Comments (0)

ADD COMMENT

Link Copied!

Toyo Tires secured a dominant performance at the 58th SCORE Baja 500, with drivers Trey Gibbs and Gustavo Vildósola Sr. claiming victories in the Trophy Truck Spec and Legends classes, respectively. The championship-winning Open Country M/T-R tyres were instrumental in the success, particularly in the highly competitive Spec class, which boasted the largest field among the top five categories. Brent Fox added to the brand's success by finishing second in the Spec class, delivering a third podium finish for Team Toyo over the race weekend.

The second round of the 2026 SCORE World Desert Championship unfolded on a demanding 468.70-mile circuit through the northern Baja California peninsula. Driving the #215 Mason Motorsports / Toyo Tires / Ford Raptor, Gibbs achieved his maiden SCORE race victory with a winning time of 9 hours, 46 minutes and 7.59 seconds. This triumph extended Team Toyo’s remarkable winning streak in the Spec class to four consecutive years, a reign that began at the 2023 Baja 500. Fox secured the runner-up position in his #282 1Nine Industries / Ford Raptor, clocking in at 9 hours and 55 minutes to complete a one-two finish for the team.

In the Legends category, Vildósola Sr. returned to the top step of the podium behind the wheel of his #1L Mason Motorsports / Toyo Tires / Vildosola Racing / Ford Raptor. His winning effort, completed in 9 hours, 47 minutes and 56.17 seconds, marked his first victory of the season and extended his personal winning streak at the Baja 500 to five consecutive races, a run that started in 2022.

Looking ahead, Team Toyo aims to build on this momentum as the series progresses towards the Baja 400 in September. The brand’s legacy in the SCORE World Desert Championship remains extensive, with multiple victories across all major events. Notable wins include the San Felipe 250 on four occasions, the Baja 500 six times, the Baja 400 five times and the prestigious Baja 1000 six times, with a roster of accomplished drivers contributing to this storied record.

Gibbs said, “Winning the Baja 500 is something I’ve always dreamed of, and it still hasn’t fully hit me what my team and I accomplished over the weekend. Honestly, I don’t have the words to describe what this win feels like.”

Fox said, “Taking home second place in the Trophy Truck Spec class and completing the Baja 500 is something we’re really proud of. Thanks to Toyo Tires, we ran the entire race with no flats and zero issues.”

Stan Chen, Deputy Director – Consumer Marketing, Toyo Tire U.S.A. Corp, said, “Congratulations to Trey Gibbs on earning his first SCORE race victory this weekend, and to Gustavo Vildósola Sr. on adding another win to his accomplished career. Our drivers have continued to set the standard in the Spec and Legends classes at the Baja 500, and we’re proud of this past weekend’s continued success.”

Comments (0)

ADD COMMENT

Link Copied!

Tyres Europe has joined a broad coalition of industrial sectors calling on the European Union to adopt a more dynamic and forceful trade policy amid deliberations by the European Council on economic security, competitiveness and EU-China relations. The tyre industry contends that current frameworks are increasingly mismatched with the realities of a fast-moving global economy, where distortions rapidly transcend borders and sectors.

The sector underpins approximately 500,000 jobs across the Union and supplies essential products for passenger mobility, freight, agriculture and defence. Its viability depends on fair competition within deeply interconnected value chains, yet structural overcapacity, state-induced market distortions and unfair trading practices are simultaneously affecting multiple industries. These pressures cascade across supply networks, weaken investment incentives and progressively hollow out Europe's industrial base. Tyres Europe argues that only a coherent policy combining robust trade defence instruments with broader industrial resilience measures can effectively counter this erosion.

A critical challenge lies in the temporal disconnect between agile global supply chains and the slower pace of EU investigations and duty implementation. Tyre manufacturing routes can be reconfigured within months, allowing exporters to front-load shipments during probes and redirect production to alternative locations once tariffs are imposed. This leaves European manufacturers under sustained competitive pressure even after investigations conclude. Tyres Europe has therefore endorsed the Joint Industry Statement, which urges a more ambitious application of trade policy that reflects the fundamentally altered contours of global commerce.

The organisation supports enhanced resources for investigations, a more proactive deployment of existing instruments aligned with industrial objectives and exploration of additional WTO-compatible tools to tackle systemic state-induced distortions. It also advocates for strategic use of the Foreign Subsidies Regulation to address recurrent distortive patterns beyond isolated case assessments. Given that tyre manufacturing involves long-term, capital-intensive decisions with near-irreversible capacity loss, preserving a competitive domestic base is framed as both an industrial goal and a matter of strategic autonomy. As European leaders shape their response to a volatile trading environment, Tyres Europe urges them to ensure that trade defence evolves to safeguard fairness and the industrial capabilities underpinning prosperity and innovation.

Comments (0)

ADD COMMENT

Link Copied!