BKT has announced that with its enhancement at Bhuj, it is aiming for an annual tyre production of 600,000 metric tonnes (MT). The company also envisages the achievement of two billion dollars in turnover in three years.

Bhuj from 201 to 2023
When the first tyre rolled off the Bhuj production line in 2012, the plant was located on an area of 123 hectares. Then it was a $500 million investment. Before starting the works, the desert landscape was completely arid. There was neither water nor electricity. But after the laying of many kilometres of drinking water pipes and power lines, the site grew with 126 hectares in 2016, 131 in 2019, 137 in 2021 and 258 in 2022. By the end of 2023, the forecast is to reach a total surface area of 323 hectares, of which 283 have already been acquired.

Better production and safety
BKT claims that Bhuj today sees more efficient machinery installed, with features that make it possible to work faster and more precisely. This increases the quantity of production and the quality of the finished product. This means, for example, that the amount of product discarded is reduced, increasing the sustainability of the manufacturing process and consequently reducing production costs. Occupational risks are also reduced and worker comfort improved.

Self-produced carbon black
A further strategic choice by BKT to enhance the Bhuj site was to invest in its own carbon black plant. The plant came into operation in 2017, when the first 65,000 MT/PA of hard grade carbon black was produced, the type of carbon black used specifically in tyre tread.  The following year, production increased from 65,000 to 110,000 MT and saw the addition of production of soft grade carbon black. This carbon black is used in the casing compound to improve its strength and durability, generating less heat. In 2021, total production of the two types of carbon black reached 138,000 MT per annum, while last year it rose to 165,600 MT per annum.

The goal for 2023 is 198,600 MT. In addition to this, the R&D department plans to add a third type of carbon black, the ‘specialty carbon black’. It is a type of carbon black with unique properties compared to that used in rubber compounds, such as high resistance to colouring, a high level of purity, a low ash level and very low level of PAHs, which make it suitable for use in specific applications, such as paints, plastics and inks.

Increasing production capacity
The expansion of the plant means an increase in production capacity. The operational logistics have also improved significantly. This has allowed the introduction of new specialist workers, as well as providing greater flexibility in production and storage flows. Speaking of work, the construction of new facilities also marked an improvement in employees' safety conditions, an aspect which BKT takes very seriously. The community that operates on the Bhuj site today is very large. At the end of December 2022, the number of people working there was 4,776.

The wellbeing of the BKT family
BKT dedicates a significant investment to the wellbeing of its community every year, through the expansion of the area housing the families of employees (now almost 1,000 people live there), in the care of their health and in the education of their children.

A good use of resources
Bhuj is also a model for the good use of resources. In 2013, the internal power plant was created to have a reliable and controlled source of electricity. Today, both solar panels and the cogeneration plant make it possible to self-produce energy. In 2022, the cogeneration plant was expanded from 20 MW to 40 MW. Projects are still underway to increase the power of self-produced renewable resources.

Water is also at the heart of BKT's path towards sustainability. Since 2019, the Zero Liquid Discharge (ZLD) principle has been adopted. This means that no liquid waste is released outside the plant. All water used in the plant is treated, purified and reused. The objective of the ZLD principle is to conserve water resources, reduce the environmental impact of wastewater discharge and improve the overall efficiency and sustainability of the plant.

Carbon black production made more sustainable
The tyre manufacturer has also taken an approach to carbon black production to make the whole process more sustainable. The company has substituted bulk bag containers with mobile silos. This means that the tyre production plant receives the carbon plant with the aid of mobile silos transported pneumatically to the storage. This will make BKT save on packaging, i.e., 100,000 bulk bags in the next few years. The whole transportation system is also designed to reduce energy usage, consumption and quality. Every transfer system is controlled by weight and the energy used. The future goal is challenging – reducing energy consumption up to 70 percent. This translates in saving more than two million kilograms CO₂ emissions per year, which are comparable to 5,000 apartments of 100 square metres each.

At the same time, the gas used to manufacture carbon black is now ending up in a co-generation plant, able to reuse 75,000 cubic metres of gas per year. This means saving 215,000 MT of coal per year. 

Research opens up the future
BKT's R&D division was what allowed the Bhuj site to grow. Established in 2017, this hub develops both products and processes, to ensure the company can maintain its international leadership. Led by a specialist team of researchers and analysts, it remains an important and up-to-date research centre in the tyre sector.

Coming to testing, a special test track was inaugurated in 2017. With six different tracks, this circuit includes tracks for tyre performance tests in dry and wet conditions, an asphalt track and a sloping concrete track. Thanks to a wide variety of tests, many important characteristics such as traction, handling, comfort, soil compaction and more can be measured here because of high precision devices and instruments.

A concrete vision
Rajiv Poddar, Joint Managing Director at BKT, says, "People have asked me if all this was really necessary, so much in such a short time. The goals we set ourselves when we decided to open the Bhuj site were proportional to the financial solidity of the time, but above all, to a vision which is as great as it is concrete.”

He added, “Analysing the market and anticipating it with passion and foresight is what we have done all these years. Growth has always been in step with demand, not without – let me say it – courage and creativity, but never without our objectives and investments having solid foundations. Global tyre demand is growing and we see no signs of it slowing down over the next five years. This is a demand which started to rise during the 2020 pandemic, and which today is above pre-Covid levels. Will it be difficult? Will it be a challenge? Our vision is simple, which is why it is very concrete. The journey we started out on at Bhuj in 2012 was never a return journey, but one to prepare ourselves to discover the future."

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Dunlop Tires North America (DTNA), a Sumitomo Rubber Industries, Ltd. subsidiary, has appointed Robert Liu as Assistant Vice President of Product Management. Liu brings more than three decades of varied experience in the tyre and automotive sectors to guide the Dunlop and Falken brands through their next stage of product innovation and expansion.

Liu started his career as a simulation engineer at General Motors before spending 27 years at Continental Tire, where he held positions in Product R&D, Sales and Product Management. He also completed a five-year expatriate assignment in Shanghai, leading Product Management and R&D for Asia-Pacific, and most recently directed R&D for the American region with a focus on replacement Passenger Light Truck tyres. In his new role, Liu will lead product development, overseeing PLT and Truck & Bus Radial products with a skilled Product Management team.

Ken Hsu, Vice President – Marketing, DTNA, said, “We are excited to welcome Robert to our team. His extensive experience and proven leadership in the tyre industry align perfectly with our goals for innovation and growth. We believe his insights will greatly benefit our product strategies as we move forward.”

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Portugal’s retreading industry is caught between its established technical capabilities and a market increasingly shaped by low-cost new tyres, regulatory shifts and price-driven purchasing. Associaçao de Recauchutagem de Pneus (ARP) President David Laureano speaks to Tyre Trends about the necessary changes, current state of the industry and how to rebuild confidence and create conditions for investment.

Are policy changes necessary to create a level playing field for retreaders?

I consider policy changes a priority for boosting Portugal’s retreading sector and plan work on four fronts. The first is to review the environmental and economic treatment of retreading so that charges and incentives acknowledge the extension of tyre service life.

The second is to strengthen enforcement of compliance obligations for all operators placing tyres on the market. The third is to introduce criteria regarding lifecycle costs, performance and circularity in public procurement, enabling the participation of technically suitable retreaded solutions.

The last is to facilitate company access to instruments for industrial modernisation, energy efficiency, training and innovation. These measures should be developed in collaboration with public entities and other sector stakeholders. Policy quality improves when those who manufacture, use and manage tyres participate in their formulation.

What are the ARP’s priorities under your leadership?

My priority is to strengthen a unified voice for the sector while respecting the diversity of the companies that comprise it. Building trust among users by demonstrating the quality of domestic retreaders. I want to contribute to an association that stays close to its members and is capable of gathering reliable data, fostering knowledge sharing and presenting well-founded proposals to public authorities.

I also view it as essential to bring the fleet industry, educational institutions and technology partners closer together. We can collaborate on training, research and the dissemination of best practices, thereby strengthening the sector’s collective capacity. The change I would like to see in the market is a more informed purchasing decision, one that recognises tyre performance and the value of extending its service life.

What role can retreading play in reducing raw material consumption and waste?

Retreading preserves a significant portion of the tyre structure by utilising a technically sound casing and enables a new cycle of use. This reduces the need for materials required to manufacture an entirely new structure and postpones the casing’s end-of-life.

Realising this potential requires effective management across the entire value chain including initial selection, maintenance, timely tyre removal and casing inspection. Benefits must be measured rigorously. Savings depend on the tyre type, process and usage conditions; therefore, we must communicate substantiated results rather than applying a single percentage figure to every situation.

What hinders greater acceptance by fleets and consumers?

Doubts regarding quality and safety persist, alongside insufficient information about the industrial process. The perception of poor quality was already among the obstacles identified in the sector characterisation study conducted by Valorpneu in 2019. Trust is built through transparency that requires explaining casing selection, production controls, traceability and the tyre’s suitability for its intended use.

There are specific United Nations regulations for retreading, namely Regulations No. 108 and No. 109. Under these regulations, all operators are required to conduct tests on the tyres they produce, and the tests are identical to those performed on new tyres. The sector also needs to make results more visible through fleet monitoring and comparable usage data.

We cannot focus solely on sales as after-sales service is crucial for building trust and ensuring continuity with the end customer, whether they are transport companies or private individuals.

How can retreading be better integrated into circular economy and sustainability policies?

Retreading should be considered right from the initial tyre selection. This entails prioritising casings designed for extended use, ensuring proper maintenance and establishing systems to evaluate their utilisation. Valorpneu specifically identifies extending service life, the potential for reconstruction and the segregation of tyres with retreading potential as preventive measures.

We would like to see this logic translated into specific objectives and indicators such as how many casings are utilised, how many usage cycles are achieved and how much resources are preserved. These results would help guide incentives and purchasing decisions.

What is the current state of the tyre retreading industry in Portugal?

Portugal possesses a retreading industry with experience, technical expertise and close ties to its customers. Its presence is particularly significant in the heavy-vehicle tyre market. However, it is a sector that needs to strengthen its position.

Commercial pressure challenges companies to demonstrate the product’s value over its lifespan, particularly in a market where the purchase price is a decisive factor. Our ambition is to unite the sector to transform existing industrial capacity into a stronger market presence driven by quality, information and constructive institutional representation.

What is the impact of low-cost imported tyres on retreaders?

Pressure from low-cost tyres is a key concern, one that has also been highlighted in ARP’s public communications. When the decision focuses solely on the initial price, it becomes harder to highlight the value of durability, technical support and the potential to reuse the casing for further service cycles.

Geographic origin alone does not determine a tyre’s quality. We advocate for competition based on verifiable criteria regarding safety, performance, compliance with environmental obligations and lifecycle costs. There is also the issue of continuity as retreading relies on the availability of suitable casings. Therefore, the choice of a new tyre should also take into account its retreadability potential.

Which segments show the highest demand?

Heavy vehicles form the sector’s core base. Road freight transport is therefore a central market, and we see opportunities to strengthen our presence among passenger transport and service fleets, tailored to the specific demands of each operation. There are also specialised applications.

Retreading data for 2024 covers commercial, agricultural, industrial and civil engineering tyres, among other categories. While these figures characterise the activity, they should not be confused with domestic market demand shares. Our goal is to work with each segment to identify where retreading offers a technically sound and economically advantageous solution.

How do regulatory uncertainty and capacity expansion affect investment?

An industrial facility invests with a multi-year horizon. Equipment, training and process improvements require confidence in future operating conditions. When rules or charges change, projects tend to be re-evaluated, complicating investment and expansion decisions.

A concrete example of a shift in the economic landscape is the Ecovalor (environmental fee). In 2025, the Valorpneu schedule indicated a zero Ecovalor for domestically retreaded tyres placed on the market. In 2026, it introduced a specific schedule with a 10 percent bonus, and for the heavy-duty category, the indicated rate is EUR 8.07 per tyre, plus VAT.

We believe that changes of this nature must be accompanied by dialogue with the sector, an assessment of their impact and predictability. Companies need to understand how their environmental contribution will be valued before committing to new investments.

How important is the total cost of ownership regarding demand?

It is fundamental. For a fleet, the purchase price is just one part of the equation. The assessment must include mileage, fuel consumption, maintenance, downtime and casing utilisation. Comparisons must be made under similar conditions regarding load, route, axle position and usage.

Retreading must demonstrate its value in this context through concrete results. I would like to see more long-term relationships between fleets and retreaders with records that allow for tracking cost-per-kilometre and improving decision-making over time. This benefits both parties.

Should retreading be recognised as a strategic industrial and environmental activity?

Yes. That is the vision I want to help affirm. It is an activity that brings together industrial production, technical expertise, transport services and resource preservation. This recognition must be reflected in industrial policies, investment instruments and purchasing decisions.

It must also be accompanied by the sector’s own commitment to quality, innovation and demonstrating its results. ARP aims to contribute to this effort alongside companies, fleets and public entities. We share a common interest in maintaining an industry capable of generating value in Portugal and making better use of the resources on which we all depend.

What is the outlook for the next three to five years?

I see growth potential, but that growth will depend on the conditions we are able to create. Increased fleet focus on operating costs, the need for efficient resource utilisation and industrial modernisation could create opportunities. To capitalise on them, we need suitable casings, customer trust and economic stability.

I would not venture a specific growth rate without a sufficiently solid statistical basis. Ambition must translate into concrete objectives by winning over users, increasing casing utilisation and strengthening corporate competitiveness.

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India’s tyre recycling industry discussed regulation, technology and material recovery at RE-GO 2026, a three-day conclave held in South Goa from 10 to 12 September. Organised by the Tyre & Rubber Recyclers Association of India (TRRAI), the event brought together more than 250 delegates, representatives from more than 200 companies and participants from more than 20 states.

The third annual conclave, hosted at Novotel Goa Dona Sylvia, included more than 20 speakers and experts, three panel discussions and more than 20 exhibitors and sponsors. The conference programme ran on 10 and 11 September , followed by a departure programme on September 12.

Regulation and technology dominate discussions

Held under the theme of policy, compliance and circularity, the conclave brought together recyclers, technology providers, tyre industry representatives, policymakers, regulators, standards professionals, consultants and business leaders.

Discussions covered regulation and standards, extended producer responsibility (EPR), traceability, automation, environmental performance, digitalisation, artificial intelligence, material recovery and circularity.

The technical programme examined automated pyrolysis, co-processing, national standards for tyre pyrolysis oil (TPO) and recovered carbon black (rCB), fleet management, EPR policy and compliance, and the Common EPR Portal. Other topics included life-cycle assessment (LCA), greenhouse gas emissions accounting, digital transformation and technical innovation.

Industry and regulatory representatives attend opening session

The inaugural session featured Satish Goyal, President of TRRAI, and Jairaj Zarekar, its Secretary. Other participants included Anand Kumar, Former Director and Scientist ‘F’ at the Central Pollution Control Board; H. M. Meena, Scientist ‘D’ and Joint Director at the Bureau of Indian Standards; and Sanjeev Sharma, Senior Vice-President And Business Head For Mobility Solutions And Fleet Management at JK Tyre & Industries.

Arup Kumar Misra, Chairman of the Assam Pollution Control Board, was the chief guest and delivered the keynote address, “Tyre Recycling: From Liability to Asset”. The address focused on turning end-of-life tyres into recoverable resources and sources of economic value.

Three panels examine the sector’s priorities

The conclave featured three high-level panel discussions on sustainable recycling policy, recycling technology and the development of a circular tyre economy.

The first examined policy, standards, EPR, compliance and sustainable development. The second focused on shredding, granulation, automation and continuous pyrolysis. The third considered how collection, technology, markets and manufacturing could be connected to support a circular tyre economy.

The panels were moderated by Tushar Suhalka, Varun Manjunath and Jayant Vaidya, respectively.

The event also included an exhibition featuring more than 20 exhibitors and sponsors, networking sessions and an awards and recognition ceremony.

TRRAI highlights collaboration and standards

TRRAI said it had more than 500 members, representing approximately 75 percent of the tyre recycling market. The association works on standardisation, professionalisation, technical advancement, regulatory dialogue and collaboration across the sector.

The conclave highlighted the role of co-operation among industry participants, government bodies, regulators, standards organisations, technology providers and technical experts. Its discussions reflected a focus on stronger standards, improved traceability, environmental accountability, digitalisation and circularity.

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Metso has named Renaud Lapointe as President of its Aggregates business area and a member of the Metso Leadership Team, with the appointment taking effect on 15 November 2026. He takes over from Markku Simula, whose departure from the company was announced on 11 August 2026.

Lapointe has been with Metso since 2005 and has served as President of the Europe and Central Asia market area since December 2024. Before that, he led the Metso Products business line within the Aggregates business area from 2018 to 2024, and between 2014 and 2017 he was Vice President of the Crusher Systems business line in the same segment. Earlier in his tenure, from 2005 to 2014, he held several leadership positions at Metso in France. Lapointe holds a degree in mechanical engineering from ISTIL in Lyon, France.

Lapointe said, "I am excited to return to the Aggregates business and lead such a highly respected global organisation. With its strong customer relationships, industry-leading solutions and talented team, the business is well positioned for continued success and growth.”

Sami Takaluoma, President and CEO, Metso, said, “Renaud brings experience from both our Aggregates business and our market area organisation. This combination will support the continued development of our offering and close cooperation with customers. I look forward to welcoming him to the Metso Leadership Team.”

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