The tyre industry is undergoing a profound transformation, driven by sustainability, digitalisation and material innovations. As manufacturers push the boundaries with high-silica compounds, recycled rubber and alternative materials like dandelion rubber, the mixing process faces increasing complexity. Traditional methods struggle to maintain efficiency, necessitating advanced technologies like HF Mixing Group’s Tandem mixing and smart solutions. With automation, and precision engineering, the industry is redefining efficiency and sustainability.

Tyres are a sheer example of impeccable chemical engineering. From passenger car radials (PCR) to off-the-road (OTR), these technical marvels can carry loads weighing tonnes even in the deadliest of roads. For centuries, they have been the backbone of logistics, transportation and more.

But making a tyre is not an easy task. It involves a tremendously meticulous process ranging from raw material selection to mixing compounds for deriving the exact formula that gives these rubber casings durability, elasticity and more.

As the global tyre industry undergoes a transition in every critical aspect, it also sees a change in compounds that go into mixtures. This in turn paves the way for upgradation in technologies.

According to HF Mixing Director of Product and Services, Nils Spier, “The growing use of silica in passenger tyres is reshaping the industry with specifications now reaching 100, 130 and even 180 parts per hundred rubber (PHR). Levels above 150 PHR have recently gained traction, particularly in the premium segment, where high-performance tyres demand lower rolling resistance and improved wet grip.”

On the other hand, he revealed to Tyre Trends that increasing silica content presents technical challenges. Standard single-mixer setups face limitations due to the need for adequate silanisation time. When more silica is added, the process becomes more complex and time-consuming. HF Mixing Group’s Tandem mixing technology addresses this by transferring the process from an upper to a lower mixer, preventing capacity losses and optimising mixing efficiency.

“Dispersion is another critical factor as silica’s inherent stickiness complicates processing. The upper mixer completes the dispersing task, utilising a geometry established in the industry for over 20 years. The latest-generation PES7 mixer builds on this, ensuring the same high-quality results. Once the compound moves to the lower mixer, further refinements occur. A specialised bottom mixer rotor TRC, developed to enhance cohesion and compacting, helps mitigate issues where certain components tend to crumble. Without this step, batches risk fragmenting into plates and uneven portions, complicating further processing. The Tandem mixer’s rotor system ensures that the full batch remains intact, facilitating smooth transfer onto a mill or twin-screw extruder,” he added.

In a nutshell, the Tandem mixing technology allows tyre manufacturers to accommodate higher silica content without compromising processing efficiency or final product quality.

HF’s latest advancements in mixing technology are delivering notable efficiency improvements, particularly in intermeshing rotor systems. The PES7 rotor, introduced around two years ago, has now been successfully deployed at multiple customer sites, showing strong results in both new and retrofit applications. The rotor upgrade offers an increased mixer empty volume plus higher possible fill factors, resulting in a 10–15 percent increase in throughput without compromising cycle time or product quality.

UPGRADING MIXING TECHNOLOGY THROUGH SMART DIGITAL SOLUTIONS

According to Spier, “Tandem and the smart digital mixing solutions represent a holistic approach to optimising the mixing process. The smart final mixing solution is a software and service concept developed by HF, designed to work in close collaboration with customers. The process begins with defining the customer’s target recipe and process parameters, followed by calibration tests conducted on-site.”

Calibration tests involve capturing the fingerprint of the mix including rotor speed, drive data, temperature control unit settings and ram seating time. This data is then processed through the company’s proprietary algorithms and material models, which simulate various mixing scenarios to identify optimal process parameters.

The simulation models predict key variables such as batch temperature development at different rotor speeds and the impact of ram lift adjustments to improve compound aeration. This approach eliminates the need for extensive design of experiment, accelerating the optimisation process without compromising on productivity of the production equipment.

The smart mixing solution is specifically designed for HF mixers as the company has precise knowledge of the machine parameters, cooling surfaces and other mixer-specific properties. The validation trials conducted post-simulation have demonstrated cycle time reductions up to 20 percent, translating into significant efficiency gains for manufacturers.

Moreover, the company’s smart mixing approach optimises key parameters to enhance energy efficiency and quality in the mixing process. Cycle time is a primary focus with proprietary algorithms minimising unnecessary processing steps while ensuring uniform distribution and dispersion of the curative package.

Rotor speed plays a crucial role as it must be adjusted at different phases of mixing. A higher speed may be beneficial in the initial dispersion stage, but excessive speed leads to rapid temperature increases, negatively affecting compound properties. The company’s models balance rotor speed, energy efficiency and temperature for optimal results.

Lastly, fill factor is essential for both quality and efficiency. Overfilling can result in uneven mixing and longer processing times, while underfilling reduces throughput and jeopardises batch quality. The company’s Smart Final Solution ensures that the fill factor is set to an ideal level for maximum quality and throughput.

TECHNOLOGICAL INCLUSIVITY

The company’s approach to smart mixing is currently data-driven and reliant on process specialists, but the role of artificial intelligence (AI) in this field is expected to grow. “While AI has the potential to make autonomous decisions and process adjustments in the future, we still integrate human expertise alongside digital tools to ensure process reliability. Factors such as installed downstream equipment, mixer conditions and on-site variations must be considered, which currently require operator input. However, we are already exploring AI-driven solutions such as predicting batch temperature, optimising carbon black incorporation and refining oil dispersion, which could eventually enhance process automation,” informed Spier.

While digitalisation is a key part of the company’s transformative roadmap, AI’s role is still in development. Instead of full AI automation, it employs advanced models and algorithms that run extensive simulations to optimise mixing conditions without compromising quality. These models provide real-time feedback on the best possible process adjustments, delivering improvements in efficiency, quality and consistency.

Alluding to whether older mixers installed 5 to 10 years ago can be retrofitted with recent upgrades, he noted, “There is a possibility of retrofitting smart solutions to enhance its capabilities. Rather than relying solely on AI, we offer in-line process monitoring, where historical mix data is used to establish a reference baseline with tolerance bands. This allows for real-time adjustments.”

The mixing process is fully automated with step-related control systems defining key parameters such as mixing time, specific energy input and rotor speed per step, batch temperature to ensure precision and consistency. Every mixing step can be supported by HF’s unique intelligent controller technology such as intelligent Ram control iRam, the HF constant temperature controller or iXSeal Dust Stop Lubrication Controller.

PROCESS ADAPTATION

Tyre makers are increasingly experimenting with alternative materials, such as recycled rubber and dandelion-derived compounds, which significantly impact the mixing process. Adjustments are necessary to maintain efficiency and quality, as non-traditional materials alter torque curves and require parameter modifications.

Moreover, different category of tyres requires different mixing processes due to variations in tread compound formulations. Passenger car tread compounds typically differ from OTR formulations, necessitating specific dispersion techniques to achieve the desired performance characteristics.

With that said, it is prudent that companies adapt to changing processes fuelled by market demand. “The company provides a range of rotor solutions to optimise these mixing processes. Tangential rotors are designed to enhance master batch dispersion, especially the NST rotor, ensuring uniformity in the compound. ZZ rotors are mainly used for final batch production, offering precision in mixing the final formulation. In addition, the ZZ rotor geometry has proven strong performance in Master Batch Silica Processing. Additionally, intermeshing rotors are employed to manage specialised compounds, providing better control over the mixing process for unique material requirements,” revealed Spier.

Furthermore, material innovations are significantly impacting the mixing process, requiring process adaptations to maintain efficiency and achieve consistent final results. The use of alternative materials such as recycled rubber or non-traditional sources like dandelion rubber, rCB and other recycled materials alters the torque curves during mixing. These changes necessitate adjustments to mixer parameters, ensuring optimal dispersion and processing without compromising product quality.

To support customers in navigating these challenges, HF’s process experts collaborate closely with them through the technical centre in Germany and worldwide operating process engineers. By testing new processes before full-scale industrialisation, the company helps identify and resolve potential issues in advance.

INDUSTRY SHIFTS

The shift towards premium tyres is shaping the European, Asian and North American markets differently. In Europe, manufacturers are increasingly focusing on premium and OTR tyres while scaling back production of 15–17-inch models and consolidating operations.

This shift is driving higher demand for advanced compounds and increased silica usage. However, capacity expansions remain limited with most investments directed towards equipment upgrades rather than new production facilities.

In Asia, particularly in India and China, greenfield projects are on the rise due to strong automotive demand. This expansion reflects the region’s growing role in the global tyre industry as manufacturers invest in new facilities to meet both domestic and export needs. North America, on the other hand, is seeing a mix of replacement investments and selective large-scale expansions with companies balancing modernisation efforts and strategic growth.

Beyond these key regions, North Africa, specifically Algeria, Morocco and Egypt, is emerging as a new manufacturing hub. This region is gaining traction in the global tyre industry, an area where it previously had little presence. With increasing investment and infrastructure development, North Africa is positioning itself as a competitive player in tyre production.

With many manufacturers shifting to smaller campaign to accommodate different tyre recipe, flexibility in the mixing process has become essential. HF’s automation system is designed to handle these challenges by allowing quick modifications to production plans.

Manufacturers can adjust torque, batch sizes and compound quantities without causing disruptions. Additionally, the manufacturing execution system ensures seamless execution, making even short production runs of 5 to 10 batches efficient and cost-effective.

MARKET EXPANSION

Besides Europe, Asian markets such as China and India remain key growth locations for the company. As manufacturers in these regions adopt new technologies to meet evolving industry standards, the demand for efficient and adaptable mixing solutions continues to rise.

“We continue to invest heavily in innovation and research and development to grow in the Asian market. Allocating three percent of our revenue to innovation and 4.5 percent to development, the company ensures that 35 percent of its projects focus on sustainability. By maintaining technology leadership, we deliver high-quality, high-functionality equipment that supports the growth of new and established manufacturers in the region,” informed Spier.

While HF is known for its high-precision machines used by top-tier tyre manufacturers, it also caters to tier 2 and tier 3 players. The company supplies to many smaller manufacturers.

On the context of sustainability, Spiers noted, “Sustainability is a core focus of our research and development strategy, aligning with the ambitious environmental targets set by tyre manufacturers worldwide. We integrate sustainability by developing energy-optimised mixers with efficient drive setups, introducing new hydraulic power units that significantly reduce power consumption and implementing incremental efficiency improvements such as enhanced heat management to extend machine longevity.”

Lastly, the company provides comprehensive service beyond commissioning, including operator training, process optimisation and trouble-shooting, round-the-clock support via ticket and hotline systems and fast-response local service teams across China, South-East Asia, India, North America, North Africa and Europe.

The 2025 Rally of Poland commenced amid an atmosphere of mourning following the tragic death of Italian motorsport driver Matteo Doretto in a racing accident.

The 81st edition of Europe's second-oldest rally competition, taking place across the challenging gravel roads of the Masurian Lakes region from June 13-15, has been overshadowed by the loss of the rising Italian talent.

"His loss is a tragedy that deeply saddens us," said Terenzio Testoni, Pirelli Rally Activity Manager. "On behalf of Pirelli, I would like to extend our most heartfelt and sincere condolences to his family and friends."

Despite the sombre mood, 63 crews took to the start line for what remains one of the European Rally Championship's most demanding events. Notable competitors include Jon Armstrong driving a Pirelli-equipped Ford Fiesta, alongside Jos Verstappen and Andrea Mabellini, both piloting Skoda Fabias fitted with Pirelli tyres.

The rally features 14 special stages covering 190.40 timed kilometres across terrain known for its technical difficulty. The Masurian Lakes route presents drivers with uneven, often sandy roads where grip proves elusive even for experienced competitors.

"It's a very difficult and high speed rally, where attention to detail is very important," commented Testoni. "With every car passage the terrain gets rougher, forming deep ruts that can challenge even the most experienced drivers."

Weather conditions are forecast to remain dry, though organisers caution that conditions can change rapidly on such challenging terrain.

The rally serves as the third round of this season's ERC Fiesta Rally3 trophy, for which Pirelli provides exclusive tyre supply. Competing crews have access to three variants from Pirelli's Scorpion gravel range: the K4A hard compound, the K6A soft compound designated as the prime choice for this event, and the K8B supersoft option.

Regulations permit each crew to utilise 16 tyres total, including those selected for qualifying sessions. Trophy category vehicles will run on Scorpion 175/70-15 specifications in both K4 hard and K6 soft compounds.

Rally Poland's reputation for difficulty stems from its unique surface characteristics, where the sandy base becomes increasingly rutted as more vehicles traverse each stage. The deteriorating conditions throughout the weekend create an additional strategic element as crews must balance speed with mechanical preservation.

The event's location in the Masurian Lakes region, known for its natural beauty, provides a stark contrast to the intense competition unfolding on its roads. The rally has maintained its position as a crucial championship round despite the technical challenges it presents to both drivers and machinery.

UK-based tyre safety watchdog TyreSafe has welcomed the Society of Motor Manufacturers and Traders (SMMT)’s announcement highlighting Britain’s fast lane position for self-driving vehicles.

While the safety watchdog has acknowledged the potential the technology holds for enhancing road safety and reducing collisions, it maintains a caution towards the effectiveness and safety benefits of Advanced Driver Assistance Systems (ADAS) – and by extension, fully autonomous vehicles. This it shared are intrinsically linked to the fundamental safety and maintenance of a vehicle’s tyres.

Stuart Lovatt, Chair of TyreSafe, said, “We are incredibly optimistic about the future of mobility and the significant strides being made in self-driving technology. Anything that has the potential to save lives and dramatically reduce serious collisions on our roads is something TyreSafe wholeheartedly supports.”

“However, it is crucial to remember that even the most sophisticated ADAS systems rely on optimal vehicle performance, and tyres are the sole point of contact between the vehicle and the road. Without sound tyre safety management – ensuring correct pressure, tread depth, and condition – the integrity and performance of these advanced systems can be severely compromised,” said Lovatt.

He highlighted the persistent issues that is seen among current vehicle owners, when it comes to proper tyre maintenance. 

“For many years, tyres have consistently been identified as the primary cause of MOT failures for vehicles up to seven years old. This underscores a widespread complacency regarding tyre safety that we must collectively address,” he added.

As per the latest statistics, over 35 percent of MOT failures were attributed to previous tyre-related advisories, which translates to 768,410 drivers ignoring warnings and subsequently failed their next MOT due to tyre issues. The trend of vehicles failing MOTs on wheel and tyre-related advisories is unfortunately increasing, indicating a growing disregard for these critical safety components.

“The promise of self-driving vehicles is immense, but their safety cannot be fully realised if the foundational elements are neglected. As we move towards a more autonomous future, the importance of tyres – their condition and correct maintenance – becomes even more paramount. TyreSafe urges all stakeholders, from manufacturers to policymakers and drivers, to recognise that tyre safety is not just an advisory; it is a non-negotiable prerequisite for safe, efficient, and technologically advanced motoring,” concluded Lovatt.

Vaculug has announced the appointment of Darren C. as the company’s Regional Operations Manager for the West, overseeing key areas including Manchester, Birmingham and Wales. Darren brings with him extensive experience, knowledge and skillset and will be a valuable asset to the team, said the company.

Marcus Kirkness, Fleet Operations Manager at Vaculug, said, “These are truly exciting times at Vaculug. We’re incredibly pleased to have Darren join our team. His knowledge of the tyre industry, combined with his experience in managing customer fleets and delivering top-tier customer service, will be instrumental as we continue to expand our customer base. Darren’s expertise ensures we remain agile in addressing challenges and fulfilling our commitments swiftly and effectively."

Former Goodyear executive to lead strategy and sales across Europe, Middle East and Africa

Leading tyre maker Linglong Tire has appointed Jeff Hughes as Regional Director Specialty Tyres for the EMEA region, effective 1June , as the company seeks to establish itself as a leading specialty tyre provider in the market.

Hughes, who brings more than 25 years of industry experience, will be responsible for strategy and sales for the specialty tyres division across Europe, the Middle East and Africa in the newly created role.

Prior to joining Linglong, Hughes served as Sales Director at Maxam Tyres, part of the Sailun Group, where he led the European specialty tyres replacement business. Before that, he spent over two decades in various senior management positions at Goodyear Tyre & Rubber Company worldwide.

"I am very much looking forward to my new role at Linglong Tire and hope to achieve the ambitious goals together with my colleagues in the EMEA region with my more than 25 years of experience in the tire industry," Hughes said.

"Our most important task will be to optimise existing customer contacts and develop new customers and thus further strengthen our company's market position," the new regional director added.

In his new position, Hughes will work closely with product and marketing teams as Linglong seeks to expand its presence in the competitive EMEA specialty tyre market.