The global tyre industry’s top manufacturers and technology suppliers met at the Tire Technology Expo 2025 in Hannover on 4-6 March to unveil technologies focused on driving sustainability, digitalisation and road safety. At the Deutsche Messe, the exhibition featured advances in tyre engineering, materials science and manufacturing technologies that will define mobility in the future.

In opening the event, expo founder Tony Robinson called on manufacturers to close the knowledge gap with consumers, highlighting how most drivers undervalue the importance of tyres in ensuring a vehicle’s safety. He mentioned that safety rests on the four small ‘footprints’ of rubber linking a car to the road, which tends to be undervalued by the general driver.

Looking to the future, Robinson saw a day when tyres contain sensors that share real-time information with other cars and roadside infrastructure. These sensors could warn drivers of dangerous road conditions like flooding or new potholes, making roads safer and avoiding crashes. He predicted that information from tyres could also feed into weather forecasting services, providing useful real-time information on road conditions.

The exhibition floor showcased innovation and high-performance solutions from more than 240 exhibitors, with Bekaert, Rockwell Automation, VMI Group, HF Group, ARP Technologies, Synthos, Nynas, Schill+Seilacher “Struktol” GmbH, Kordsa, Black Donuts and others.

SUSTAINABILITY AND MATERIAL INNOVATION TAKE CENTRE STAGE

The expo also reflected the tyre industry’s growing focus on sustainability, with manufacturers launching new materials and processes to lower environmental impact. Bekaert launched its Mega Tensile reinforcement technology, a major innovation in its Elyta range. The technology enables tyre manufacturers to produce up to 20 percent less steel and 10 percent less rubber compound in belt plies, achieving a 2-4 percent drop in rolling resistance and a huge 15-20 percent reduction in CO₂ emissions per tyre.

Kordsa introduced its REV Technologies, which are specifically tailored to electric vehicle tyres. The company’s innovations include recycled PET (rPET) cord fabric and RFID tyre tags, enabling improved lifecycle monitoring and data collection. Kordsa expects to enhance sustainability and recycling practices by combining digital identification with tyre production.

Teijin Aramid featured its Twaron para-aramid reinforcement, a material that can manufacture lighter tyres with reduced rolling resistance and eventually lower emissions.

EV AND DIGITAL INNOVATION LEAD DISCUSSIONS

As the electric vehicle (EV) market grows, tyre makers focus on creating solutions specific to the special needs of EVs and autonomous vehicles. Continental Tires unveiled an overall sustainability strategy, emphasising the environmental impact of tyres throughout their life cycle. The firm detailed plans to incorporate more sustainable raw materials, minimise waste during production and enhance tyre durability.

Michelin’s Director of Standards and Regulations for Connected Mobility, Claire Fioretti, outlined the company’s efforts around Digital Product Passports (DPP), a major initiative within the (ESPR). The regulation, enacted in 2024, aims to increase supply chain transparency by mandating that products carry a permanent, readable identifier usable throughout their life cycle. Michelin is already testing the programme in various industries, such as textiles, electronics and automotive components, with the cooperation of French, German and Swedish stakeholders.

The ESPR system, Fioretti characterised as an ‘ambitious information system’, will enable the maker, the recycler and the buyer to make environmentally informed decisions. She stressed that the movement is not so much about compliance as a transition towards the principles of the circular economy. By 2027, by the time broad adoption of the ESPR sets in, product design may improve, recycling efficiency will be elevated and buyers’ confidence will be boosted in second-hand markets.

MANUFACTURING INNOVATION AND AI TECHNOLOGY

The event showcased the latest digital manufacturing solutions to enhance efficiency, lower waste and better quality control. Rockwell Automation launched AI-driven tools to optimise tyre production, including digital thread technologies for tracking data without interruption through various manufacturing processes.

Black Donuts launched its Digital Twin Tyre Plant Simulation, a cutting-edge real-time virtual modelling tool that aids manufacturers in minimising downtime and optimising production. The company’s methodology involves end-to-end finite element analysis, enabling accurate tyre performance simulations before production.

HF dominated the manufacturing technology market with its state-of-the-art electric tyre curing presses. The company illustrated how its new electric curing technology could be applied to new and retrofit installations to minimise energy consumption and enhance process efficiency. Fischer TireTech exhibited computerised cord-cutting lines and premium extrusion technologies aimed at increasing accuracy in tyre production.

Uzer Makina launched a high-end electric tyre curing press focused on energy efficiency and precision production. ARP Technologies showcased its Electromagnetic Heating (EMH) curing system, a more energy-efficient curing process, alongside an artificial intelligence-based inspection machine that can spot tiny defects with great accuracy.

KraussMaffei featured its multiplex extrusion technology, which enhances first-time production quality and eliminates material bleeding during tyre formation. The company showed a new head clamping technology that maximises channel cleaning effectiveness, further expanding the limits of green manufacturing.

REGULATORY DEVELOPMENTS AND ENVIRONMENTAL CONSIDERATIONS

Regulatory matters were on the agenda at the expo, with leading experts discussing the changing scene for tyre production and green compliance. Adam McCarthy, Secretary General of the European Tyre and Rubber Manufacturers’ Association (ETRMA), gave a definitive overview of recent European Commission regulatory interventions impacting the sector.

A specific session on Tyre and Road Wear Particles (TRWP) collaborated with industry experts from Bridgestone, Continental and Michelin, as well as leading research institutions, to address the implications of future Euro 7 regulations. It was centred around reducing tyre wear’s environmental footprint without compromising performance levels.

FUTURE OUTLOOK AND INDUSTRY COLLABORATION

During the three-day conference, experts worldwide exchanged information, delved into future technologies and worked on crafting the mobility of the future. The event highlighted reducing carbon footprint, improving safety and customising solutions for future electric and self-driving cars.

The next edition will be held on 3 and 4 March 2026.

TIRE TECHNOLOGY INTERNATIONAL AWARDS FOR INNOVATION AND EXCELLENCE

A key highlight of the event was the prestigious Tire Technology International Awards for Innovation and Excellence 2025. Recognising achievements across 12 categories, the awards celebrate the latest advancements in tyre technology, progress towards a more sustainable industry and the outstanding contributions of individuals driving innovation. This year’s winners are as follows:

Goodyear bagged Environmental Achievement of the Year – Tire Design for its ElectricDrive Sustainable- Material (EDS) tyre.

Continental was awarded the Environmental Achievement of the Year – Manufacturing award for its CO2-neutral tyre production at the Lousado plant in Portugal.

Nokian Tyres won the Environmental Achievement – Industry Contribution award for its inauguration of the world’s first full-scale tyre factory with zero CO₂ emissions in Oradea, Romania.

Bekaert received the Materials Innovation of the Year award for its next-generation reinforcement solution, Mega Tensile.

Sumitomo Rubber Industries won the R&D Breakthrough of the Year award for its Active Tread technology.

VMI was awarded for Tire Manufacturing Innovation of the Year award for its integrated quality monitoring for the MAXX and MILEXX platforms.

ARP Technologies was selected as Industry Supplier of the Year for its many innovations in the tyre curing sector.

Bridgestone bagged Tire Concept of the Year for its Lunar concept tyre.

Michelin was awarded Tire of the Year for its Primacy 5 tyre.

Continental won the Tire Manufacturer of the Year award for the fourth time, acknowledging the scale and breadth of the company’s achievements over the last year.

Two further awards were also given for individual achievements in the industry:

Katerina Filzer, a PhD student at Twente University in the Netherlands, was awarded the 2025 Young Scientist Award for her presentation, ‘An Innovative  Method to Incorporate a Devulcanization Aid into Rubber’.

Anke Blume, head of elastomer technology and engineering at the University of Twente, received the Lifetime Achievement Award for her outstanding contributions to the tyre industry.

production defects in the final product and increase productivity with AI based scanning, inspection, real-time decision-making processes.

Digitalisation in the tyre industry is a gradual process that will improve performance, quality and profitability being on the way of real Industry 4.0 applications in tyre manufacturing. It continually opens up new opportunities to leverage data for better decision-making. Overall, digitalisation in tyre manufacturing is a powerful tool that unlocks the full potential of production. However, after implementation, continuous investment, as well as internal research and improvements, are required.

The tyre manufacturing industry is constantly evolving. Machines are becoming increasingly automated, more precise and data-driven. Recent advances based on the principles of Industry 4.0 include the aforementioned IoT, AI (artificial intelligence), robotics and sustainability.

Industry 4.0-driven digitalisation is based on the concept of the ‘digital twin’, meaning every machine is a data node. Data from every step (compound parameters, component dimensions, curing profiles) is collected for each tyre. This creates a virtual replica of the physical tyre, which is a ‘digital twin’ that enables complete traceability and data-driven process optimisation.

The role of humans is evolving from simple manual tasks to monitoring, diagnostics and data analysis. Robots, especially collaborative robots or cobots,

are taking over tasks such as final inspection and material handling. These revolutionary steps and concepts are having a major impact on manufacturing, optimising quality, performance, customer satisfaction and contributing to business success.

Modern mixing systems are increasingly replacing conventional tangential mixers. The intermeshing of the two rotors ensures more efficient and homogeneous mixing with better temperature control. This leads to higher mixing quality and consistency.

New mixing technologies, on the other hand, utilise ‘continuous mixing systems’, i.e. the continuous and simultaneous supply of all raw materials in precisely controlled quantities. The materials are continuously mixed in a series of specialised extruders and mixing units. At the end, a continuous stream of a perfectly homogeneous mixture emerges. This represents a revolution compared to conventional batch mixing. It improves energy efficiency, reduces the carbon footprint and enables unprecedented consistency and traceability.

Highly automated ‘multi-calender systems’ are equipped with multiple rollers that can simultaneously produce multiple layers (e.g. carcass ply, squeegee layer or inner liner) with extreme precision in thickness and width. Similar to extrusion lines with laser thickness control, these systems ensure 100 percent control and transmit data immediately to the extrusion head and calender roll clearances for automatic adjustment and maintenance of tolerances down to a fraction of a millimetre.

Thanks to the ‘multi-stage transfer’, the tyre casing is transferred between drums for the various production steps automatically and without human intervention, automatic cutting and splicing prevent deviations in quality. RFID technology integrated fully assures correct recipe and security in component application.

The robotic application and component preparation, such as with 6-axis robots, is now widely used for the fast and precise gripping and placement of complex components such as bead and apex assemblies.

Electric vulcanising presses are equipped with intelligent mould controls, whose integrated sensors monitor temperature and pressure in real time across multiple zones. The AI system dynamically adjusts the vulcanisation cycle (time, temperature, steam pressure) to ensure perfect curing of each tyre and compensate for any mould or material deviations.

Furthermore, predictive maintenance is now essential to avoid unplanned production downtime. Vibration, temperature and pressure sensors installed on manufacturing machines monitor all machine functions and alert when maintenance is required. High-precision servomotors, replacing pneumatic or hydraulic systems, work with servo-electric robots and are used in various production phases with submillimetre precision, reducing energy consumption and maintenance requirements.

The most visible technological advances in finishing and inspection lines today are fully automated with full sensitive cameras, AI-integrated and non-destructive testing (NDT) machines. Automated high-resolution X-ray machines scan each tyre to detect hidden defects such as trapped air, steel cord separation, or bead wire issues. Shearography and holography – being traditional but now equipped with intuitive, incredibly fast and precise modes – use lasers and intelligence to detect underlying defects or separations by measuring stress-induced deformations.

Uniformity and force variation measurement systems utilise AI algorithms to not only identify a tyre as ‘good’ or ‘bad’ but also diagnose the root cause of the deviation. Robotic trimming and polishing machines automatically locate and remove burrs (excess rubber) from the tyre using precise grinding tools – a traditionally manual and laborious task.

Of course, the future of tyre manufacturing, driven by advanced digitalisation, IoT and robotics, is rapidly evolving into a model for a smart, autonomous and sustainable industry, often referred to as ‘Tyre Industry 4.0’.

This transformation isn’t just about doing the same things faster; it will fundamentally change tyre design, production, sales and even performance. Tyre production facilities will become more autonomous, adaptable, efficient, predictive, personalised and, as expected, more sustainable.

Industry 4.0 and AI-powered digitalisation will accelerate sustainability. Precision manufacturing minimises material waste through the use of high-precision components. AI can easily manage energy consumption throughout the factory. IoT sensors monitor the overall condition of tyres, ensuring fast tyre changes, safety and performance.

This transformation will lead to safer, more efficient and more environmentally friendly tyres.

Balkrishna Industries Ltd (BKT), a global leader in Off-Highway tyre manufacturing, has received the British Safety Council’s 2025 ‘Sword of Honour’ for exemplary workplace health and safety management. The honour was presented during a ceremony at London’s Drapers’ Hall.

BKT earned this distinction after its flagship Bhuj production facility in India attained a flawless Five-Star Audit Report, the highest possible rating within the Council’s audit framework. The award acknowledges the plant’s exceptional dedication, rigorous efforts and sustained commitment to managing occupational risks. BKT was among only 70 organisations worldwide to qualify for the 2025 Sword of Honour. As a recipient, the company has been presented with a custom-made stainless-steel ceremonial sword. This achievement underscores BKT’s ongoing organisational priority to foster and maintain industry-leading safety standards across its operations.

Peter McGettrick, Chairman of British Safety Council, said, “On behalf of the Board of Trustees and all staff of the British Safety Council, I would like to congratulate BKT on achieving the highest standards within its health and safety management. Achieving recognition of this kind involves full dedication and utmost professionalism. We are proud to support you in your achievements and are delighted that we can contribute to your ongoing success.”

Mike Robinson, Chief Executive of British Safety Council, said, “I would like to congratulate BKT and its staff on this award, in tribute to their commitment to keeping their workplace safe and healthy.”

Anil Kumar Sharma, Corporate Head of Quality Assurance and Sustainability, BKT, said, “The recognition of the British Safety Council rewards the great perseverance of BKT’s employees in putting in place a high-level and high-quality workplace for all, and I personally wish to congratulate all of them to promote the company’s highest standard in every operation.”

In a discussion with Tyre Trends, Chief of the United Nations Economic Commission for Europe (UNECE) Information Unit Jean Rodriguez detailed how the Working Party on Noise and Tyres (GRBP) is driving international regulations on tyre safety, noise and sustainability. From pioneering micro-plastic emission measurement to strengthening wet-grip requirements and updating studded and retreaded tyre rules, Rodriguez emphasised UNECE’s role in shaping a harmonised global framework that balances consumer safety with environmental protection.

What is the role of the Working Party on Noise and Tyres (GRBP) within UNECE?

As one of the six subsidiary bodies of the World Forum for Harmonisation of Vehicle Regulations, hosted by UNECE, the Working Party on Noise and Tyres continues to spearhead globally harmonised standards through UN Regulation No. 117, covering tyre rolling resistance, noise, wet grip and, with recent developments, abrasion measures. These UN Regulations form the backbone of safety and environmental tyre specifications adopted by numerous countries and a substantial share of tyre producers globally.

What were the key regulatory changes between 2022 and 2025?

In early 2024, the Working Party adopted the first-ever methodology to measure particle emissions from tyres, critical for tracking micro-plastic emissions via two protocols including real-world 8,000 kilometres convoy tests and 5,000 kilometres rolling-drum lab tests. These are slated for integration into a new UN Regulation by September 2025 for passenger tyres, expanding into heavier vehicle categories (C2, C3) into 2026 and 2027.

Once in force, these regulations will contribute to significantly reducing micro-plastic pollution. In 2016, tyre abrasion was estimated to represent 78 percent of the 1.3 million metric tonnes of microplastics entering the ocean.

The UNECE methodology to measure particle emissions from tyres will become the reference methodology of the Euro 7 proposal of the European Union. Moreover, EU tyre regulation and labelling covering noise, wet grip, rolling resistance and environmental transparency build directly on UNECE’s standards.

How has UNECE addressed tyre safety at legal minimum tread depth?

GRBP introduced requirements ensuring that tyres at the legal minimum tread depth (1.6 millimetres) retain a minimum wet-grip level relative to new tyres. This is a shift towards safety and sustainability by permitting consumers to drive worn tyres safely, potentially reducing waste. It obliges manufacturers to design tread compounds and patterns that preserve wet performance over the tyre’s life, not just when new.

What regulations were introduced for studded tyres in 2022?

In September 2022, a new UN Regulation to cover performance requirements and marking of studded tyres entered into force to increase road safety by introducing harmonised snow grip requirements for studded tyres. It simplified the legislative situation in several countries that allowed the usage of studded tyres on public roads, introduced strict requirements and procedures for testing their snow grip and allowed consumers to benefit from more coherent winter tyre markings.

What additional areas has UNECE been working on to align safety and environmental goals?

By refining noise standards, updating testing protocols and promoting tyre lifecycle efficiency, UNECE is steadily shaping regulations to match environmental and safety objectives. This includes work on enhanced noise testing for tyres (UN Regulation No. 117) and motorcycles (UN Regulation No. 41) and vehicle alert systems (UN Regulation No. 138/51)

How does UNECE ensure global relevance, transparency and participation in its work?

All this work in setting technical specifications testifies to UNECE’s high relevance in providing a global harmonisation framework. Its expanding scope, especially in environmental dimensions such as micro-plastic emissions, is helping it maintain policy leadership and normative force, shaping tyre safety, noise and environmental performance worldwide.

A very important aspect of UNECE work is that it prevents fragmentation of the tyre regulatory landscape. GRBP is open to governmental experts from any member country of the United Nations and to any regional economic integration organisation set up by member countries of the United Nations including experts of governmental organisations and non-governmental organisations (NGOs).

UNECE provides secretarial support to WP.29 and its working parties, facilitating negotiations between contracting parties to the 1958, 1997 and 1998 agreements. More than 100 experts participate in the sessions of GRBP and all documents considered by GRBP are available in the public domain.

What are UNECE’s priorities going forward to support safety and the circular economy?

Leveraging its technical authority and norm-setting capacities, UNECE is uniquely positioned to foster a globally harmonised tyre labelling framework that covers rolling resistance, wet grip and, for the first time, tyre abrasion. This framework promotes consistency, environmental protection, consumer transparency and ultimately supports worldwide regulatory alignment.

At its session in September 2025, GRBP will consider the proposal for a new UN Regulation on the uniform provisions concerning the approval of tyres with regard to abrasion performance.

UNECE is also updating UN Regulations no. 108 (passenger car/towed vehicle Retreaded tyres), 109 (commercial vehicle retreaded tyres) and 172 (snow performance of retreaded tyres) to ensure retreaded tyres meet the same safety standards as new tyres, even in challenging winter conditions but in a way that makes regulatory processes smoother and more conducive to circular economy practices.

For the second consecutive year, Trelleborg Tires has earned the prestigious title of Best Agriculture Tyre at the 22^nd Visão Agro Brazil Awards. This 2025 accolade, presented during a ceremony in Ribeirão Preto, highlights the company’s dedicated role in advancing Brazilian agribusiness through technological leadership and a commitment to sustainable practices. The award was received on behalf of the company by Fábio Metidieri, Agri Sales Director for Yokohama TWS Brasil.

Central to this achievement is Trelleborg’s ongoing innovation, particularly the expansion of its ProgressiveTraction technology within the TM tyre series. This engineering, featured in models from the row-crop TM600 to the high-horsepower TM1000, utilises a dual-edge lug design. The tread operates progressively on the soil to enhance traction, promote self-cleaning and minimise vibration. The resulting benefits include improved operational efficiency, increased tyre durability and superior soil protection, directly supporting farmers’ goals for greater productivity and environmental stewardship.

The company’s deep roots in Brazil, supported by a specialised local team, rigorous field testing and strong manufacturer partnerships, ensure its solutions are finely tuned to regional demands. This local infrastructure allows for responsive technical service and keeps product development closely connected to the practical challenges faced by the agricultural sector. The Visão Agro Brazil Awards, judged by a panel of industry executives and researchers, serve as a recognised benchmark for innovation and performance, making this recognition a significant testament to Trelleborg Tires’ impact on the country’s farming landscape.

Metidieri said, “Receiving this award at such a prestigious event once again reinforces our commitment to Brazilian agriculture. Our goal is to keep advancing in technology and field performance, ensuring that every Trelleborg tyre delivers real value – helping farmers operate more efficiently, sustainably and profitably. This award reflects the trust placed in our team and our products by professionals throughout the sector. It strengthens our commitment to delivering technologies that address local challenges and help shape the future of Brazilian farming.”