Continental is increasing its use of recycled materials in tyre manufacturing, with more facilities now using polyester fabric made from recycled polyethylene terephthalate (PET) bottles. This initiative has raised the recycled content in several tyre lines by an average of thee percent. Depending on the tyre size, up to 15 PET bottles can be used in a single tyre, conserving valuable resources.

“Reduce, reuse, recycle – this trio is key to more sustainable tyres “, says Jorge Almeida, Head of Sustainability at Continental Tires.

“Reduce, reuse, recycle – this trio is key to more sustainable tyres. Wherever possible, we use recycled materials while maintaining our highest quality standards,” says Jorge Almeida, Head of Sustainability at Continental Tires. “Our polyester yarn made from recycled PET bottles is just as strong as conventional polyester yarn. This shows that sustainability, performance, and safety go hand in hand at Continental.

The company’s ContiRe.Tex technology, unveiled in late 2021, processes PET bottles that would otherwise go unrecycled. These bottles are spun into high-performance polyester yarn without intermediate chemical treatments, producing materials robust enough to meet the demands of tyre manufacturing.

Since 2022, this technology has been used on a limited scale at Continental’s tyre plants in Lousado, Portugal, and Otrokovice, Czech Republic. Recently, facilities in Korbach, Germany, and Sarreguemines, France, have also adopted recycled PET in series production.

Ambitious sustainability goals

The transition to sustainable materials aligns with Continental’s broader sustainability strategy. The company aims to increase the proportion of renewable and recycled materials in its tyres to over 40% by 2030. By then, all new car and light truck tyres are expected to feature high-performance polyester fibres made entirely from sustainable PET.

At present, an average passenger tyre contains 15–20 percent recycled and renewable materials. By 2050, Continental plans for all its new tyres to be made from 100 percent sustainable materials.

Turning waste into high-quality materials

Continental’s use of recycled PET is part of a broader effort to replace raw materials with sustainable alternatives. Textile fabrics made from recycled polyester enhance the strength, flexibility, and durability of tyres, with performance matching that of materials derived from crude oil.

In addition to recycled PET, Continental is exploring other sustainable materials, including bio-based and chemically recycled PET. Agricultural by-products, such as rice husk ash, rubber from dandelions and recycled rubber, are also being tested for future use.

Bridgestone Retail Operations, the service and retail arm of Bridgestone Americas, has named Zachary Borden as its 2025 Automotive Service Excellence (ASE) Master Technician of the Year, recognising his performance across technical skills, productivity and customer service.

Borden received the award at a ceremony hosted by the National Institute for Automotive Service Excellence, which oversees certification standards for vehicle repair and maintenance technicians in the US.

Borden joined the company’s Firestone Complete Auto Care network in Virginia Beach, Virginia, in 2016 after completing an associate degree in automotive technology at Tidewater Community College. He holds nine ASE certifications and has exceeded his service productivity rate by nearly 300 per cent for the past two years, according to the company.

Marko Ibrahim, president of Bridgestone Retail Operations, said: “Zach exemplifies the spirit of this award through his commitment to efficiency, clear and productive communication, and fostering a collaborative work environment. He is a standout technician and a trusted advisor for our customers, and it is an honour to recognise his servant leadership.”

Borden said: “Being named ASE Master Technician of the Year is truly an honour, and I’m grateful to be recognised for the quality of my work. What means the most to me is the opportunity to grow alongside a team that supports, challenges, and learns from one another every day.”

ASE Technician of the Year nominations are determined by employers based on test scores, on-the-job performance and community involvement. Bridgestone Retail Operations selects candidates from its network of more than 2,200 outlets across the US operating under the Firestone Complete Auto Care, Tires Plus, Hibdon Tires Plus and Wheel Works brands.

The award follows the accreditation of Bridgestone Retail Operations’ technician-training curriculum by ASE in October. Accreditation is granted to institutions that meet established standards for technical education and is intended to support technicians in gaining ASE certifications throughout their careers.

India’s tyre industry is accelerating at an unprecedented pace with a turnover of INR 900 billion and production exceeding 217 million units in FY23. Amid this dynamic growth, JK Tyre has emerged as a front-runner, combining manufacturing excellence with sustainability-focused practices. From advanced automation to energy-efficient operations and innovative product development, the company is re-defining tyre production standards. Its Chennai plant with premium and export-oriented capabilities exemplifies this transformation, positioning it at the forefront of next-generation tyres both domestically and globally.

A turnover of INR 900 billion and a production strength of 217.352 million units was the key figures of India’s tyre industry in FY23, according to statistics by the Automotive Tyre Manufacturers’ Association.

Unequivocally, the third-largest automobile market’s tyre sector is expanding by leaps and bounds. From passenger car to OTR tyres, Indian tyre makers are making a name for themselves not only in the homeland but internationally too.

With individual leaders in every segment of tyres, the industry as a whole is also changing its approach towards the different aspects of the supply chain.

One of the leaders, JK Tyre, is banking on its manufacturing excellence and sustainable methodology for paving the road for the next generation of tyres.

The statement is further reinforced during Tyre Trends’ tour of JK Tyre’s Chennai facility, which is spearheading this transformative movement. Commissioned in 2012 with investments exceeding INR 26 billion, the plant is one of the company’s most advanced facilities and is strategically located near Tamil Nadu’s automotive hub and major ports for exports.

It produces passenger car radial (PCR) and truck and bus radial (TBR) tyres including premium and export-oriented ranges. The plant has received International Sustainability and Carbon Certification Plus (ISCC Plus) certification for using bio-based, renewable and recycled raw materials and has been a consistent award-winner for energy and water efficiency, operating as a zero-liquid discharge facility while sourcing over half its power from renewables.

JK Tyre’s recent INR 14.3 billion expansion plans will increase TBR capacity by 800,000 tyres and PCR capacity by two million tyres annually, enabling JK Tyre to roll out next-generation sustainable products like the UX Royale Green.

“We save around 56 percent of our energy through renewable sources and significantly reduce coal consumption. On sustainability, we have several products that can be commercialised through back-end raw material suppliers, although global adoption is still evolving due to cost and scale feasibility. Every energy efficiency initiative involves upfront investment with payback realised over time. Our company vision emphasises green and sustainable mobility, evident even in the plant environment as our facilities are designed with greenery and environmental considerations in mind,” said Managing Director Anshuman Singhania.

Automation is another defining feature of the plants. Very few people are directly involved in machinery operation as most processes have been automated to minimise or eliminate manual intervention. In tyre building, for example, green tyres move seamlessly via conveyor systems through painting units, curing and finally to inspection, mostly without human handling.

Across facilities, processes are fundamentally auto-controlled. Manpower is primarily assigned to oversight roles such as conducting checks or managing specific material movements that cannot be automated.

Otherwise, each stage is tracked through sensors, cameras and online data capture. The high level of automation is evident throughout operations from AGVs transporting tyres to robotic handling systems.

TECHNOLOGICAL PROWESS

A tyre’s birth involves many stages starting from the raw materials that go into a gigantic mixture. According to the company’s Technical Director V K Misra, a PCR tyre needs 8-10 raw materials, while a TBR tyre needs 16.

Once the raw materials are intricately mixed, the mixer sends it to an extruder machine to shape raw rubber compounds into continuous strips or profiles that form different tyre components.

The third step involves the extruder passing on the strips to an auto booking machine, which automatically measures, stacks and aligns these sheets for easy handling. The following step uses a leaf truck machine that carries and transports the stacked sheets or semi-finished materials to the calender machine.

The calender then coats the rubber sheets and sends them to the steel wire room, where the tyre gets its much-favoured durability. The next steps involve assembly, testing and the final roll out.

Across the entire manufacturing unit, a key metric is traceability ranging from individual components to final rollout and even through the operational life of the tyre – every stage leaves a footprint.

The company primarily uses German and Chinese machinery at its Chennai facility and is exploring the integration of Radio Frequency Identification (RFID) chips in tyres for enhanced traceability, while currently, tyre life is monitored through embedded sensors.

The plant takes around 15 minutes to produce a PCR tyre and 50-55 minutes for a TBR tyre.

“We collaborate closely with equipment suppliers to implement automation, robotics and conveyor systems. Some proprietary solutions are exclusive to our plants, though specific details remain confidential. Many robotics systems were developed in-house, integrating artificial intelligence and machine learning to optimise productivity, quality and minimise wastage,” explained Singhania.

He added, “We benchmark ourselves against global standards across productivity, scrap, energy efficiency and water conservation. In water management, we are global leaders. For instance, innovations implemented at our first plant in Kanpur have set industry standards for water conservation.”

Furthermore, the company’s in-house research indicates that nearly 70 percent of low-inflation tyres, especially on highways and city roads, contribute to accidents or injuries. To mitigate this risk, it is deploying tyre pressure monitoring systems and advanced sensor technologies that alert consumers via smartphones.

Efforts are also underway to integrate these alerts directly into OEM dashboards across trucks, buses, passenger cars, two- wheelers and three-wheelers and even farm or off-the-road (OTR) applications.

“The next generation of tyres will incorporate embedded sensors directly within the tyre, eliminating the need for external kits. This approach not only improves consumer safety but also generates valuable research and development insights in a large and diverse market like India. Adoption has been particularly strong among younger consumers,” contended a confident Singhania.

SUSTAINABILITY

JK Tyre developed the UX Royale Green with 80 percent sustainable, recycled and renewable materials. The tyre was produced at its Chennai facility. The development of this line was a result of over a decade of research at JK Tyre’s Global Tech Centre.

The tyre incorporates bio-attributed polymers, recycled rubber powder, recovered carbon black, renewable oils, sustainable steel wire and recycled polyester. Despite its sustainable composition, the UX Royale Green delivers performance comparable to standard tyres and has a lower carbon footprint.

Moreover, the ISCC Plus certificate serves as a testament towards the company’s relentless efforts towards sustainability. “When we talk about sustainability, it encompasses the circular economy by using recycled materials where feasible, incorporating natural raw materials and minimising fossil-based chemicals. For example, recycled polyester, steel and natural rubber may be used without compromising performance,” averred Singhania.

He added, “We are committed to sustainability and green practices. While investments are necessary, balancing productivity, quality and cost control ensures profitability in cost-sensitive markets like India. Measures such as process optimisation, quality control and energy efficiency help us reconcile green mandates with financial goals.”

Commenting on the same lines, Misra stated, “Extensive testing ensures that recycled or sustainable materials do not reduce tyre performance metrics and mileage, ride comfort and handling remain consistent. The use of recycled rubber from cured tyres is minimal and does not impact the product beyond a small percentage. End-of-life tyre recycling is a separate initiative and does not feed directly into new tyre production at significant levels.”

MARKET OUTLOOK

Singhania affirmed that the company is anticipating 8–9 percent growth in the tyre industry this year. While commercial vehicle tyre demand remains subdued, passenger vehicles are stable and two-wheelers are expected to perform well post-monsoon.

“This growth is supported not only by GST sentiment but also by overall economic activity, government infrastructure pushes and strong rural demand. We are targeting white spaces in India, especially in towns with populations under 100,000, where demand for tyres is rising and our presence is limited,” noted Singhania.

The tyre maker is also confident of a significant growth opportunity in the off-road segment with GST reducing the rate to five percent for farm tyres. “We have re-positioned our product line and introduced a premium offering with enhanced performance. Activities were initiated well before the season began and our OEM footprint has already shown positive signs. With improving monsoon conditions, rising rural demand and GST benefits, the outlook for this segment looks very bright,” explained Chief Financial Officer Sanjeev Aggarwal.

He added, “The commercial vehicle industry, where we are primarily present, stands to benefit the most from GST. Increased consumption of goods and white goods will raise total freight availability. Alongside reduced interest rates, capacity utilisation in CVs is expected to increase, further supporting demand for new tyres.”

Radialisation in the TBR segment has reached around 68–70 percent of the market. JK Tyre continues to lead this segment, supplying directly to 85–90 percent of fleet operators and maintaining a strong market presence.

Innovative products such as the XF tyre provide fuel-saving benefits, a critical factor for transporters focused on cost per kilometre. These tyres are supplied entirely to OEMs while also being available in the replacement market.

The company serves approximately 1,800 fleets directly or through dealer networks. Its tiered fleet management programmes include a per-kilometre model, where transporters pay only for the distance covered with tyre performance guaranteed for that usage. This hands-off, mobility-based solution is unique in the industry, creating a clear differentiation from competitors, including international players.

Moreover, the company has strategically diversified its exports across multiple international markets to mitigate risk. Its key export products include TBR tyres, covering heavy trucks from SDM to HD, passenger vehicle radial tyres, truck bias and radial tyres, light commercial vehicle tyres in both radial and bias formats, farm tyres in limited quantities, industrial tyres and tyres for two-wheeler and three-wheelers.

Truck bias tyres are primarily exported to Brazil, parts of Latin America and select African countries, while PCR tyres are directed mainly to the European Union and the UK, particularly for heavy trucks.

OUTPACING HURDLES

About half of the company’s rubber requirements are met through imports. However, it doesn’t see tyre imports currently a threat to domestic manufacturing, and the market remains balanced.

Imports, particularly from China and Southeast Asia, including Vietnam, are carefully managed through a license-based restricted system. For very small tyre sizes, limited imports, typically around 100 units annually for applications such as passenger cars, are allowed in close coordination with government authorities and ATMA, ensuring domestic production is not adversely impacted. Broader policy continues to encourage capacity creation within India to meet local demand, noted Singhania.

On the exports front, approximately 12–15 percent of JK Tyre’s total revenue comes from international markets, with around three percent previously destined for the US. Some of this volume has been redirected to other countries with key markets including Southeast Asia and the Middle East.

Europe is identified as a growth opportunity with significant product launches planned for the start of the next financial year. Latin America and Brazil are also showing promising demand following previous disruptions. Overall, the company anticipates mid-to-high single-digit growth in exports.

Another major industry challenge is sourcing skilled talent. Commenting on this, Singhania mentioned that JK Tyre addresses this through comprehensive internal training programmes, upskilling initiatives and structured human resource interventions ensuring a consistent pipeline of capable personnel.

The Chennai plant contributes approximately 26 percent of the company’s total revenue and plays a critical role in its portfolio. Continuous upgrades and investment in advanced equipment is on the books to allow the plant to continue producing high-quality TBR and PCR) tyres.

JK Tyre’s approach underscores the convergence of technology, sustainability and market foresight. By integrating automation, embedded sensor technologies and energy-efficient processes, the company ensures quality, safety and environmental responsibility.

Its diversified product portfolio, ranging from passenger car radials to truck and bus tyres, coupled with a robust aftermarket and export strategy, strengthens its competitive edge.

Strategic investments in talent, research and development and sustainable materials position JK Tyre to meet evolving industry demands while addressing global challenges.

As domestic growth aligns with international opportunities, the company is set to become a pioneer in an innovation-driven future.

Tolins Tyres will open a distribution depot in Gujarat recently, extending its national network into one of India’s fastest-growing tyre markets. The move is intended to shorten delivery times, deepen customer access and support the company’s push to strengthen its presence across western India.

The Kerala-based manufacturer said the new facility would allow it to “penetrate deeper into untapped territories, acquire new customers, and substantially reduce lead times”. Gujarat, a major hub for logistics and commercial vehicle activity, has until now been a limited-reach region for Tolins.

The depot will supply both retread products and new tyres, aiming to provide faster turnaround and improved availability for dealers and fleet operators. Tolins added that the investment aligns with rising demand for retreading solutions, which are increasingly adopted by transport companies seeking cost efficiency.

Dr K V Tolin, promoter of Tolins Tyres, said: “This depot is an important step in our growth strategy for western India. It reinforces our commitment to delivering value and expanding our footprint in key growth markets, and we are confident it will strengthen customer relationships and fuel our long-term growth.”

The company said the site complements its existing manufacturing and distribution footprint. Tolins operates two plants in Kalady, Kerala, close to natural rubber resources, and runs a subsidiary in Ras Al Khaimah in the UAE. Its domestic network spans eight depots and 3,737 dealers, according to the release.

JK Tyre & Industries Ltd. has reinforced its commitment to the construction and mining sectors with the launch of four new off-the-road (OTR) tyres at the CII EXCON 2025 trade fair in Bangalore. The products, unveiled by Dr R Mukhopadhyay, Director of R&D, expand the company’s specialised portfolio, focusing on application-specific performance for demanding environments.

A key introduction is the all-new SKY GRIP tyre, designed for Aerial Work Platforms and Boom Lifts. The size 355/55D625 tyre aims to provide enhanced stability and superior traction for equipment operating at elevated heights, ensuring safer mobility for articulated and telescopic boom lifts across diverse terrains in construction and industrial settings.

The launch also includes three critical variants for heavy machinery. For backhoe loaders, the 14.00-25 GTL PLUS promises durability and stability during excavation. The 23.5-25 GTL PLUS variant is engineered for wheel loaders, offering improved traction on demanding surfaces. Addressing the extreme conditions of underground mining, the 14.00-20 VEM AS-UG features a reinforced casing and a specialised compound to withstand abrasive environments and the rigorous duty cycles of shuttle cars.

From pioneering India's largest OTR tyres to developing advanced technologies, JK Tyre continues to strengthen its portfolio, providing reliable and high-performance solutions tailored to support diverse industrial operations.

Srinivasu Allaphan, Director – Sales & Marketing, JK Tyre & Industries, said, “India is witnessing a transformative phase in infrastructure development, and JK Tyre remains committed to support this journey. With the launch of our new OTR range at EXCON, we are strengthening our support for equipment that powers critical infrastructure, enabling greater productivity, durability and operational safety across the country’s construction, mining and industrial projects.”