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.

Bridgestone India announced the winners of the 5th Edition of its Mobility Social Impact Awards (MSIA) 2025 in Pune, celebrating organisations that use mobility for social good.

The top honour in the Road Safety Innovation and Excellence category went to ALERT (Amenity Lifeline Emergency Response Team) from Chennai for empowering over 450,000 citizens with emergency response skills. Safety Research Foundation (SRF), based in Pune, received a Jury Commendation for its BRACE Project, which transforms school zones with safety audits and infrastructure upgrades.

In the Empowerment of Vulnerable Communities category, The Association of People with Disability (APD), Bengaluru, won the top honour for its Rehab on Wheels initiative, which provides last-mile rehabilitation services.

The winners were presented with their awards by social worker Dr. Girish Kulkarni, founder of Snehalaya.

Hiroshi Yoshizane, Group President, Bridgestone Asia Pacific and Managing Director, Bridgestone India, said: “It is a privilege to honour these changemakers who are redefining mobility for social good. Their work reflects our shared commitment to building inclusive, safe, and empowered communities.”

Jeya Padmanaban, Founding Trustee, Safety Research Foundation (SRF), said, “We are truly honoured to receive the Jury Commendation at the Bridgestone Mobility Social Impact Awards 2025. The BRACE Project reflects our belief that road safety must begin at the community level, where awareness and infrastructure meet action. This recognition strengthens our resolve to continue building safer environments for children and fostering a culture of responsibility and care on our roads.”

Category	Winner / Commendation	Organisation (Location)	Initiative Focus
Road Safety Innovation and Excellence	Winner	ALERT (Chennai)	Empowering citizens with emergency response skills
	1st Runner-up	SAFE India (Bhubaneshwar)	Improving safety through #ZoneZero Safe School Zone and Driver Training programs
	Jury Commendation	Safety Research Foundation (SRF) (Pune)	Transforming school zones via the BRACE Project
Empowerment of Vulnerable Communities	Winner	The Association of People with Disability (APD) (Bengaluru)	Providing last-mile rehabilitation services via Rehab on Wheels
	1st Runner-up	Impact Guru Foundation (IGF-India) (Delhi)	Initiatives like Empower Her and Mission I-M-Possible, focusing on healthcare, education, and skilling
	Jury Commendation	Jharkhand Vikas Parishad (JVP) (Jharkhand)	Community-led programs promoting sustainable livelihoods and women’s empowerment

Linglong Tire has announced the promotion of Alessio Iacovelli to Deputy Director of Replacement Sales for Western Europe, effective 1 September 2025. In this elevated role, Iacovelli will take on leadership of the regional sales team with a mandate to accelerate business development. His key objectives will include forging strategic alliances and implementing programmes to strengthen customer loyalty. Iacovelli will report directly to Lisa Zhao, the Director of Replacement Sales for Western Europe, and will collaborate with her to manage key markets, including Germany, the UK, Italy and Spain.

Iacovelli, who began his career with Goodyear and Nexen, first joined Linglong Tire at the end of 2022 as a Sales Manager. In that capacity, he demonstrated significant success in developing the Southern European aftermarket, where he expanded the brand's footprint, defined effective growth strategies and secured robust partnerships with distributors. This strategic appointment and the restructuring of the sales leadership underscore Linglong Tire's intensified focus on achieving its ambitious growth targets across the European continent.

Iacovelli said, "I am very pleased to have been promoted to Deputy Director Replacement Sales West Europe at Linglong Tire. We have fantastic products such as the Sport Master 4S and the Sport Master Winter, both successfully tested in the recently published tyre tests. We have a state-of-the-art development centre in Germany and a new tyre plant in Europe and are successful in original equipment – ideal conditions for achieving our ambitious goals together with my team and the colleagues in Hannover and continuing to grow, especially in Europe."

German synthetic rubber maker ARLANXEO has launched consultations with worker representatives over the potential closure of its Port Jerome facility in France, citing persistent weak demand and declining competitiveness in the European chemicals industry.

The company, which is majority-owned by Saudi Aramco, had begun an information and consultation period with the Works Council at the site, located in northern France. A final decision on the closure will be taken after the mandatory consultation process concludes and approval is obtained from the French labour authorities, DREETS.

“The European chemical industry continues to face persistent weak demand and declining competitiveness driven by rising costs, unbalanced global markets, and increased regulatory pressure,” said Stephan van Santbrink, ARLANXEO chief executive.

“These conditions have generated a significant burden on the sector across the regional value chain. ARLANXEO has not been an exception to these challenges. The Port Jerome site has remained in a structurally loss-making position. Despite numerous improvement efforts, we do not foresee a viable path to a sustained structural improvement.”

The company did not disclose how many jobs would be affected by a potential closure, nor did it provide details on the facility’s production capacity or annual output.

Van Santbrink acknowledged the impact on workers, saying: “We recognise the impact a potential closure may have on our employees, and we regret the need to consider these steps. We will continue to treat all employees with respect. If we decide to cease operations at the site, we will do our utmost to assist in finding alternative solutions for all impacted employees. In addition, we intend to provide impacted employees with a social plan which reflects their valued contribution to ARLANXEO.”

The announcement adds to a growing list of European chemical producers struggling with high energy costs, sluggish demand and competition from lower-cost producers in Asia and the United States.

ARLANXEO said it would work closely with all affected internal and external stakeholders to minimise the impact of the intended closure.

Continental's Tires group sector has strengthened its leadership team with two key internal appointments, effective 1 September 2025. Jana Striezel has been named the new head of global purchasing for Continental Tires, while Dennis Bellmund has assumed leadership of the global original equipment business for both passenger and commercial vehicles. Both executives will report directly to Christian Kötz, the member of Continental AG's Executive Board who leads the Tires group sector.

In her new capacity, Striezel will oversee worldwide strategic and operational purchasing. She brings extensive experience from the automotive industry, having previously held several procurement management roles at Renault, where she led purchasing for the Renault brand and its alliance with Nissan and Mitsubishi in Europe. Her career began at Volkswagen in 2014.

Bellmund, who has a 25-year tenure with Continental, steps into his role following the departure of his predecessor, Manja Greimeier, to the ContiTech sector. His extensive background within the company includes recent responsibility for Continental’s tyre retail operations, alongside prior leadership roles in EMEA supply chain management and sales direction for the European replacement tyre business. These appointments signal a strategic reinforcement of Continental's tyre division leadership.

Kötz said, “We’re delighted to welcome Jana Striezel, a highly skilled manager, to our team. She brings extensive expertise in international procurement and will focus on driving forward our purchasing strategy. In Dennis Bellmund, our global original equipment business has gained a highly experienced leader. Thanks to his many years at Continental, he is familiar with our company and our customers’ needs from many different angles. On behalf of the entire management team, I wish both of them every success in their new roles and look forward to working together.”

“On behalf of the entire team, I would like to thank Manja Greimeier for her successful leadership of our original equipment business and wish her all the best and continued success,” added Kötz.