Turkey’s first producer of fully bio-based process oils is challenging industry conventions with a zero-waste approach and performance-driven sustainability. Müge Metinöz, R&D Director, Skyhem, explains how a young Turkish chemicals company is transforming an industry long dominated by petroleum derivatives.

When Müge Metinöz joined Skyhem Kimya at a very early stage of its journey, she brought eight years of experience developing more sustainable tyres, focusing on alternative and non-conventional materials and innovative approaches. Throughout that period, one recurring challenge had become very clear to her: the gap between sustainability ambitions and industrial reality.

“What made Skyhem particularly distinctive and exciting for me was its clear recognition of this gap and its decision to address it not by slightly improving existing systems but by rethinking bio-based process oils from the ground up. The objective was never to offer a ‘greener version’ of petroleum-based products but to develop an alternative that is non-food-chain-based, fully bio-based and capable of performing under real production conditions,” Metinöz says.

That approach was both technically bold and foundational for long-term transformation, she reflects. In the global tyre and rubber raw materials market, Skyhem identified strong demand for solutions that transcend sustainability claims – solutions that are scalable, performance-driven and fully compliant with regulatory requirements.

“Being part of the development journey of Ecosky process oils represents, for me, an opportunity to contribute to a transformation that delivers real and measurable impact. The strong interest and positive feedback we are receiving today from markets around the world clearly confirm the tangible nature of this need. With Ecosky-3103, my belief continues to grow that we are not simply introducing a new product but actively contributing to a lasting and meaningful shift in the tyre industry’s sustainability transition,” Metinöz explains.

GREEN CHEMISTRY AS FOUNDING PRINCIPLE

From the very beginning, Skyhem was a company with a clearly defined vision. The company was founded in 2023 with a strong emphasis on green chemistry, but for Skyhem, this has never been merely a marketing label.

“For us, green chemistry has never been a marketing label but rather the starting point of all decision-making processes. Already at the foundation stage, key questions – such as which raw materials to work with, which markets to address and which regulations to be prepared for – were shaped in line with this vision,” Metinöz says.

At the same time, having a clear vision does not mean remaining static, she notes. As Skyhem has grown, the company’s vision has evolved into something more tangible, more measurable and more industrially grounded. In the initial phase, the primary focus was to demonstrate that a fully bio-based, non-food-chain process oil was technically feasible.

“Today, that vision has progressed to delivering solutions that are tested on a global scale, compliant with regulatory frameworks and applicable at an industrial scale,” Metinöz says. One of the most important lessons Skyhem has learned throughout this journey is that sustainability only creates real value when it is addressed alongside performance, process compatibility and scalability.

“As a result, Skyhem’s vision has become even more focused with growth: not simply to develop sustainable products but to contribute to the transformation of the tyre and rubber industry through practical, reliable and performance-driven solutions,” Metinöz says.

TURNING GEOGRAPHY INTO ADVANTAGE

Turkey is not traditionally viewed as a centre for bio-based process oil innovation, yet Skyhem has successfully turned this into a strategic advantage rather than a limitation. Although Turkey has a strong chemical engineering infrastructure and technological capability, process oils used in the tyre industry have historically been fully imported.

Through its green journey, Skyhem has successfully changed this landscape, establishing itself as Turkey’s first domestic producer in this field. The company’s process oils are 100 percent bio-based, outside the scope of the EU Deforestation Regulation and strictly non-food-chain.

“Our process oils, which are 100 percent bio-based, outside the scope of EUDR and strictly non-food-chain, represent a milestone not only for Turkey but also at a global level. This achievement clearly demonstrates that Turkish engineering can compete internationally in the fields of sustainability and advanced materials technology,” Metinöz says.

Turkey’s strategic geographic position, connecting Europe, Asia and Middle East, provides Skyhem with a significant advantage in accessing global markets efficiently and reliably. Today, with its current production capacity, Skyhem has the potential to meet approximately 41 percent of Turkey’s total process oil demand.

“Taken together, these elements show how Skyhem has reshaped perceptions in this field by transforming Turkey’s geography and engineering strength into a strategic competitive advantage,” Metinöz says.

THE CONSCIOUS CHOICE OF BIO-BASED MATERIALS

Skyhem claims to be Turkey’s first producer of fully bio-based process oils. The decision to move away entirely from petroleum-derived oils was not a necessity for the company but rather a conscious identity choice.

“The decision to move away from petroleum-derived process oils was not a necessity for Skyhem but a conscious identity choice. From the very beginning, Skyhem positioned itself not simply as an alternative to existing systems but as a pioneer of more nature-friendly, greener and long-term sustainable solutions,” Metinöz explains.

This mindset allowed the company to place environmental impact and responsibility at the core of its product development process. From a technical perspective, the main challenge was to achieve critical performance parameters – such as process compatibility, viscosity control, ageing behaviour and compound stability – using bio-based raw materials in tyre and rubber manufacturing.

Ensuring that Ecosky-3103 could be used alongside petroleum-based reference oils without creating compatibility issues on existing production lines was one of Skyhem’s key priorities. In this context, the hybrid use flexibility of Ecosky-3103 has proven to be a significant advantage.

“When required, Ecosky-3103 can be integrated into formulations together with petroleum-based process oils, offering manufacturers a gradual and controlled transition path. This approach makes the sustainability transition more manageable and lower-risk while fully preserving production continuity,” Metinöz says.

From a business perspective, the main challenge was earning market trust in a sector that has historically viewed process oils as an immutable component. Thus, highlighting environmental advantages alone was insufficient.

“It was essential to demonstrate – under real production conditions – that Ecosky-3103 is a scalable, consistent and reliable long-term solution. Today, the fact that leading global tyre and rubber manufacturers have begun to adopt Ecosky-3103 in their production clearly validates this approach. The ability of our products to remain fully compatible with petroleum-based systems while delivering sustainability without compromising performance has positioned Skyhem as a trusted solution partner in the market,” Metinöz says.

RECOGNITION AND DIFFERENTIATION

Ecosky-3103 has been shortlisted for the 2026 TTI Awards for Materials Innovation. In Metinöz’s view, what makes this product stand out in an increasingly crowded sustainability-driven market is not only its bio-based nature.

“What differentiates Ecosky-3103 is not only that it is bio-based but also that it is a non-food-chain, EUDR-exempt process oil produced at an industrial scale under a zero-waste principle. It can be directly integrated into existing production lines or applied through partial substitution, and its consistency has been proven under real production conditions. Skyhem’s approach has been to position sustainability not as a statement but as an industrially applicable reality,” Metinöz explains.

PERFORMANCE AGAINST ESTABLISHED OILS

From a tyre manufacturer’s perspective, the critical question is how Ecosky performs compared with established low-PAH and TDAE oils across filler dispersion, rolling resistance, durability and ageing behaviour. In studies conducted by Skyhem, Ecosky-3103, compared with TDAE reference oils, demonstrates predictable, consistent behaviour in terms of filler dispersion and compound homogeneity.

“In both tread and non-tread applications, mechanical properties are fully maintained; parameters such as elongation at break and tensile strength show equivalent and, in some cases, improved values. From a dynamic performance perspective, tan δ and E* measurements indicate that Ecosky-3103 offers controllable effects on rolling resistance and low-temperature performance, depending on formulation design,” Metinöz says.

With regard to ageing behaviour and process stability, Skyhem’s evaluations show that the glass transition temperature (approximately -65°C) remains stable, viscosity levels are consistent across production batches and the flash point lies within a highly acceptable range for industrial use.

“Overall, Ecosky-3103 can be considered an alternative that preserves the performance framework manufacturers are accustomed to when compared with TDAE and low-PAH oils while offering additional functional potential in certain applications. This positions Ecosky-3103 as a technically reliable process oil capable of supporting sustainability objectives without compromising performance,” Metinöz explains.

ZERO-WASTE PRODUCTION IN PRACTICE

Zero-waste production is central to Skyhem’s positioning. At Skyhem, the zero-waste approach is embedded as a core design criterion of the production system. From the product development stage onwards, all input raw materials are selected and used to minimise by-product formation and to allow materials to be recovered and reutilised within the process.

“As our facility is designed according to a closed-loop principle, potential side streams are systematically reintegrated into the production process,” Metinöz says. On the supply side, Skyhem exclusively sources non-food-chain raw materials from ISCC-certified sustainable sources, ensuring environmental impact and traceability remain fully under control.

From an energy perspective, the on-site solar power plant at Skyhem’s chemical facility plays a key role in operations. This system enables the company to cover a significant portion of its energy demand for production from renewable sources. In parallel, all production processes are continuously optimised with a strong focus on energy and resource efficiency.

“Through this integrated approach, the zero-waste principle at Skyhem goes beyond an environmental commitment and becomes a measurable and operational system, directly linked to product consistency, process efficiency and industrial sustainability. Looking ahead, we aim to convert 100 percent of our production energy demand to green energy via solar systems by 2030,” Metinöz says.

THE IMPORTANCE OF THIRD-PARTY VALIDATION

Skyhem has achieved REACH registration and received an EcoVadis Bronze Medal. For global OEMs and Tier-1 suppliers, such third-party validations have become fundamental trust-building elements rather than mere requirements.

“For global OEMs and Tier-1 suppliers, sustainability is no longer based on declarations but on verifiable and auditable systems. For this reason, third-party validations such as REACH registration and EcoVadis assessments have become fundamental trust-building elements rather than mere requirements,” Metinöz says.

EUDR COMPLIANCE AND NON-FOOD-CHAIN MATERIALS

Compliance outside the EU Deforestation Regulation and the use of non-food-chain raw materials are factors that Skyhem often highlights. These factors are becoming decisive for customers today for specific reasons.

With the introduction of EUDR, it is no longer sufficient for raw materials to be sustainable; their origin must also be traceable, verifiable and free from regulatory risk. For this reason, solutions that fall outside the scope of EUDR offer a significant advantage, particularly for manufacturers operating on a global scale, by reducing both operational and commercial risks.

“Raw materials that do not interact with the food chain have likewise become an increasingly important ethical and structural criterion in sustainability discussions. Solutions that do not compete with food resources are preferred due to their higher social acceptance and long-term supply security,” Metinöz says.

When these two aspects are combined, customer sustainability is no longer only about environmental benefits but also about regulatory compliance, supply continuity and forward-looking risk management.

“Skyhem’s approach is built precisely on this understanding – treating sustainability not as a short-term advantage but as a long-term, secure and industrially viable solution,” Metinöz explains.

THE ELECTRIC VEHICLE TRANSFORMATION

Demand for sustainable materials is accelerating, particularly with the rise of electric vehicles. The shift towards EV tyres is reshaping requirements for process oils in fundamental ways.

Metinöz believes that the transition to electric vehicles has already begun to gradually and fundamentally reshape tyre performance expectations. EV tyres operate under much tighter tolerances due to higher torque, increased vehicle weight and stricter noise requirements. As a result, parameters such as rolling resistance, wear resistance and compound stability have become even more critical.

“This shift means that process oils can no longer function merely as softeners; they must act as components that precisely tune the dynamic behaviour of the compound. Consequently, these new requirements place greater emphasis on controlled rheological behaviour, the retention of properties after ageing and predictability across formulations,” Metinöz says.

At the same time, EV manufacturers’ sustainability targets require greater transparency and measurability of the environmental impact of all raw materials used. Within this context, process oils for EV tyres are now expected to meet not only technical performance criteria but also low environmental impact, regulatory compliance and long-term supply security.

“At Skyhem, our approach is built on addressing these multi-dimensional requirements simultaneously, developing solutions that are well aligned with the needs of next-generation tyre applications,” Metinöz says.

GLOBAL VISIBILITY AND COLLABORATION

Skyhem has been highly visible at global tyre industry events. Beyond branding, these platforms contribute significantly to collaboration and product development. At Skyhem, the primary focus is to represent the country in the best possible way within the industry.

“For us, global industry events are not merely platforms to increase brand visibility but environments where technical feedback, mutual learning and collaborative development actively take place. Through these events, we have the opportunity to directly understand the real expectations, technical challenges and regulatory priorities of manufacturers across different regions,” Metinöz explains.

At the same time, such platforms enable potential collaborations to take shape early. From Skyhem’s perspective, the real value lies not in promotion but in fostering a constructive dialogue where the right technical questions are asked and common solution areas are clearly identified.

“This approach supports our products in reaching the market more efficiently and in a more robust manner,” Metinöz says.

CO-DEVELOPMENT WITH MANUFACTURERS

Skyhem’s approach to innovation is highly collaborative. At Skyhem, innovation is not an R&D activity carried out independently of customers but a development process that progresses alongside manufacturers.

“Our work with tyre and rubber producers is based on evaluating products under real formulations and actual processing conditions. All technical feedback we receive is directly incorporated into product improvement. Through this approach, Skyhem’s R&D is positioned not merely as a raw material supplier but as a technical partner delivering practical, reliable solutions aligned with real production requirements,” Metinöz says.

BALANCING GROWTH WITH CULTURE

As a young company scaling internationally, Skyhem faces the challenge of balancing rapid growth with maintaining a strong sustainability-led culture internally. At Skyhem, growth has never been treated as a goal in itself; how the company grows has always been more important than how fast it grows.

“Our sustainability approach is not a policy added later on but a culture that has been embedded into our decision-making processes since the company’s foundation. To be candid, this mindset and philosophy have played a key role in keeping our direction clear throughout our growth journey,” Metinöz says.

As Skyhem grows, the primary focus is to avoid compromising technical discipline and sustainability standards. The company applies the same principles consistently across product development, sourcing and production and approaches new markets and partnerships within this framework.

Metinöz explains, “As a result, growth does not put pressure on our system; instead, it becomes a controlled process that strengthens our existing structure. For us at Skyhem, maintaining a strong sustainability culture depends on having teams that fully understand the processes and on clearly questioning the technical and environmental implications of every decision. This approach ensures that, as the company grows, the culture does not weaken but rather becomes more structured and institutionalised.”

FUTURE GROWTH OPPORTUNITIES

Looking ahead, where does Metinöz see the strongest growth opportunities for Skyhem – in terms of markets, applications or next-generation materials?

“I see the strongest growth opportunities for Skyhem in application areas where sustainability is no longer a choice but a mandatory technical requirement,” Metinöz says. “In the tyre and rubber industry in particular, markets where regulatory pressure and performance expectations are increasing simultaneously show a natural alignment with Skyhem’s solution approach.”

From an application perspective, high-performance tyres, electric vehicle applications and speciality rubber compounds are among the company’s key focus areas. In these segments, process oils are no longer merely auxiliary components; they have become elements that precisely control compound behaviour, further increasing demand for technically robust and sustainable solutions.

“With regard to next-generation materials, Skyhem’s growth strategy is based not on a single product but on a modular and evolvable technology platform. This approach allows us to develop solutions that can be adapted to different markets and applications,” Metinöz explains.

Geographically, Skyhem sees controlled, high-quality growth opportunities particularly in Europe, where regulations are clearly defined and sustainability targets are firmly established.

“In short, for Skyhem, growth is not about volume expansion but about progressing with the right technical value in the right applications,” Metinöz says.

DEFINING SUCCESS

Finally, how would Metinöz define success for Skyhem Kimya over the next five to 10 years, both as a business and as a contributor to the tyre industry’s transition towards more sustainable materials?

“For Skyhem, I define success not solely by growth figures but by the lasting impact we create within the industry. Today, Skyhem has reached a position as a company delivering technically reliable solutions with measurable sustainability and proven industrial applicability,” Metinöz says.

Within the next five years, Skyhem aims to establish strong R&D centres in four different regions. Through these centres, the company plans to provide more effective technical support to Ecosky-3103 users while also developing its own compounds at laboratory scale to evaluate product performance directly at the application level.

At present, Skyhem serves four industries and is actively advancing sustainable, bio-based product development across multiple sectors. Looking further ahead, over the next 10 years, the company aims to evolve into an integrated chemical manufacturing structure and reach a broader customer base through new product classes.

“As a business, we measure success through consistent growth, stable product quality and the ability to build long-term partnerships,” Metinöz says. “In this context, positioning Skyhem not merely as a raw material supplier but as a strategic technical partner for our customers is a critical benchmark for us.”

From an industry perspective, Skyhem sees true success in enabling sustainable materials to move beyond niche applications and become a natural part of mainstream production processes.

“At Skyhem, our objective is to demonstrate – on a lasting basis – that sustainability does not conflict with performance but rather, when addressed through the right engineering approach, becomes a driver that moves the industry forward,” Metinöz concludes.

AMETEK recently completed its USD 5- billion all-cash acquisition of a portfolio of instrumentation businesses from Indicor.

The businesses, collectively known as Indicor Instrumentation, make equipment for industrial and scientific applications. Their products serve markets that overlap with AMETEK’s existing operations and generate recurring revenue from consumables, services and aftermarket support.

David A Zapico, AMETEK’s Chairman and Chief Executive, said: “We are excited to complete this highly strategic acquisition and to welcome the Indicor Instrumentation team to AMETEK. With its mission-critical solutions, deep technical expertise, and strong positions in attractive end markets, Indicor Instrumentation is an excellent fit with AMETEK. We also see meaningful opportunities to create value through integration into our proven operating model.”

Indicor Instrumentation is expected to contribute about USD 350 million to AMETEK’s sales in 2026 and to be modestly accretive to adjusted earnings for the year.

The acquired businesses will join AMETEK’s Electronic Instruments Group and Electromechanical Group, according to their products and market focus.

The Goodyear Tire & Rubber Company has elected Joe Hinrichs as chairman of its Board of Directors, effective 7 October 2026. He will also chair the board's Governance and Executive Committees. Hinrichs joined the board in 2023 and succeeds Laurette Koellner, who will retire at the 2027 annual meeting under Goodyear's Corporate Governance Guidelines.

Hinrichs most recently served as President and Chief Executive Officer of CSX Corporation. Before that, he held numerous leadership roles at Ford Motor Company, including President of the Global Automotive Business, Executive Vice President and President of Global Operations, Executive Vice President and President of the Americas, President of Asia Pacific and Africa, and Chairman and Chief Executive Officer of Ford China. He also led Ford Canada. Hinrichs holds a bachelor's degree in electrical engineering from the University of Dayton and an MBA from Harvard Business School.

Koellner previously held several leadership roles at The Boeing Company. She joined Goodyear's board in 2015, became independent Lead Director in 2019, and Non-Executive Chairman in 2024.

Hinrichs said, "I would like to recognise and thank Laurette for her leadership, dedication and unwavering commitment to Goodyear. On behalf of the Board, we are grateful for her many contributions throughout her more than a decade of service. I look forward to working alongside my fellow board members and the leadership team as we continue to innovate, strengthen our competitive position, create long-term value for our shareholders and build a stronger Goodyear."

CEAT’s Chennai and Halol plants are the only tyre facilities globally with two WEF Global Lighthouse Network inductions, and the company has also won the Deming Grand Prize for manufacturing excellence.

Yet 30 km from Mumbai, CEAT Specialty’s 49-acre Ambernath plant tells a different story: tyres too heavy for automation, built instead around nitrogen curing, induction presses and orders as small as one unit – a bet that sustainability will win markets in Europe and America.

The stakes: an INR 5 billion investment in all-steel radial technology, capacity expansion to 160 tonnes/day and a Camso manufacturing deal Tolani pegs at up to USD 1 billion – turning a manufacturing constraint into a competitive edge.

Amit Tolani, Chief Executive of CEAT Specialty, does not talk about tyres the way most executives talk about their products. He talks about them the way an engineer talks about a puzzle that keeps changing shape. “The way to look at it is that the manufacturing processes that we follow – how modern they are, how capable they are, how technically efficient – that’s what matters,” he says, sitting inside the plant that has become the nerve centre of CEAT’s off-highway tyre (OHT) business.

That plant – the Ambernath facility, a division of Mumbai-headquartered RPG Group’s CEAT Limited – is not a conventional tyre factory. It builds tyres that can weigh up to over 600 kilogrammes, tyres too large and too heavy for the automation that has transformed the passenger-car tyre business. And it is this constraint, as much as any strategic masterplan, that has shaped how CEAT Specialty has chosen to compete.

A PLANT THAT CANNOT SIMPLY COPY THE ROBOTS

Ask Tolani why Ambernath has not adopted the wall-to-wall robotic automation seen at CEAT’s Chennai or Halol facility, and the answer is refreshingly unglamorous: physics. “PCR tyres can be lifted by an ordinary human being, or a forklift, or robots,” he explains. “For these tyres, which are 600–700 kg, it’s very difficult to have a conveyor that can just lift them.” In the processes that do lend themselves to automation – mixing, calendering, curing – Ambernath’s equipment, he insists, is ‘as modern as the Chennai plant. More modern’. The plant intends to formalise that claim in the coming months by pursuing Industry 4.0 certification.

Where the physical limits of scale end, digital ones have taken over. A SCADA system tracks steam lines running beneath the plant floor. Where a leak once required a worker to walk the line, take manual temperature readings and diagnose the fault, artificial intelligence now flags the location almost instantly. “The point time taken to identify the problem is close to zero,” Tolani says. Every tyre carries a digital identity from raw material to finished good; a single scan reveals the batch, the machine, the operator and the timestamp behind it. AI is also being trained on the plant’s visual tyre inspection – traditionally a human, eyeball-driven task – using high-resolution cameras to catch defects, and on optimising mixing recipes and cycle times, the invisible chemistry that determines how a tyre performs in a paddy field or a quarry.

CURING WITHOUT STEAM

The most technically striking claim to emerge from Ambernath concerns curing – the energy-intensive process of vulcanising rubber under heat and pressure that has, for a century, meant steam. “This plant has already started using nitrogen curing on one of the lines,” Tolani says. Alongside it sit two proof-of-concept induction curing presses – a steam-free process, while the nitrogen conversion has come via LMT. “There are two presses that are already commissioned here,” he says. “We’ve already started working in that direction, where we want to take a lead in this space.”

The bulk of the plant’s newest investment, however, is going into something more conventional in principle but strategically significant in intent: all-steel radial off-the-road tyres. CEAT Specialty has committed INR 5 billion to this latest phase of expansion, representing a decisive shift in product architecture. Where a car’s tyres are universally radial, only 60–70 percent of truck tyres have made that transition, and agricultural and OTR applications lag further still – agriculture because usage is seasonal, OTR because a fabric-belted bias tyre still does much of the heavy lifting. All-steel radial construction changes that calculus by delivering higher load-carrying capacity and greater comfort, attributes increasingly demanded not only by Indian buyers but, crucially, by European and American customers. “It’s for demand from the European market, the US market – and the Indian market is also growing in such a handsome fashion that we want to cater to it,” Tolani says.

LEAN BY DESIGN, NOT BY SLOGAN

CEAT’s manufacturing philosophy is inseparable from its most prized accolade: in 2017, CEAT became the first tyre company outside Japan to win the Deming Prize, the world’s most prestigious award for total quality management; in 2023, it became the first tyre company anywhere to win the Deming Grand Prize, a distinction held by only 33 organisations globally as of 2025. Inside CEAT, this discipline is branded QBM – Quality Based Management – a homegrown fusion of Total Quality Management, the Toyota Production System and Total Productive Maintenance.

“We are a Deming Grand organisation. That means we follow the philosophy of lean manufacturing – not to use resources or have any wastage in the process,” Tolani says. That philosophy is embedded, quite literally, in the plant’s straight-flow layout, which runs from raw material storage through mixing, stock preparation, tyre building, curing and final finish in a single unbroken line. Even small batch sizes, he says, are produced without the wastage, excess labour or lost efficiency – what the plant’s internal vocabulary calls ‘Muri’ – that might otherwise creep in.

That same lean instinct underpins one of Ambernath’s more unusual competitive claims: a minimum order quantity of one. In an industry historically built around economies of scale, the plant will build a single speciality tyre to a customer’s specification without demanding batch aggregation – a capability the company says few OHT plants worldwide can match. Self-managed teams on the shop floor plan and execute changeovers themselves, allowing a highly automated, digitally traceable line to pivot rapidly to low-volume, customised orders. A related innovation, branded Unistage, builds and shapes an agricultural or OTR radial carcass into its final toroidal form on a single drum rather than the conventional two-stage process, reducing the handovers.

AN R&D CENTRE BUILT FOR SPEED, NOT SCALE

CEAT Specialty operates a dedicated in-house research and development facility at Ambernath, distinct from the group’s broader R&D infrastructure, and Tolani is candid about why. Tolani says, “This business is very, very different. There is no Pareto here – no 80/20 rule where a handful of product sizes serve the bulk of demand. Because farm and off-highway equipment come in such a long tail of sizes and configurations, and because the plant supplies numerous international OEMs directly, the time taken to develop, validate and commercialise a new tyre has to be compressed.”

“We needed a dedicated facility, closer to the manufacturing, so that we can quickly pilot, quickly turn around,” he adds. A new Compound Laboratory, opened in September 2025, now anchors materials science work spanning OTR, agricultural and industrial segments, while AI-assisted testing has trimmed, by Tolani’s estimate, roughly a third off the time from concept to market. The centre’s pipeline currently spans all-steel OTR tyres, a newly launched forestry range, very high flexion (VF) agricultural tyres and expanding work in earthmoving and material handling.

CAMSO ACQUIRED FOR BRAND, CHANNEL AND CATEGORY

CEAT Specialty’s move into Camso – a name Tolani values at up to USD 1 billion in brand potential across agricultural tracks, power sport tracks and material handling – may be its most consequential strategic bet. “It was a natural fit for us in terms of completing our portfolio,” he says. Ambernath, built in 2018 solely for agricultural radial tyres, gains through Camso’s new OEM ties (Massey Ferguson, John Deere) and construction-channel access across South America and Europe.

Under a three-year Michelin agreement, CEAT can currently manufacture and sell only compact construction tyres and tracks under Camso, taking over end-consumer sales in that segment – with other categories opening up once the term ends. The impact is already visible: standalone, CEAT Specialty’s off-highway mix is 85:15 agriculture to non-agriculture; with Camso’s, it shifts toward 50:50.

THE NUMBERS BEHIND THE AMBITION

Ambernath is running at 105 tonnes a day, at 92–95 percent utilisation – ahead of schedule. A further phase, due within 45 to 60 days, will lift capacity to 160 tonnes. Camso, still integrating, runs at roughly 50 percent.

Off-highway tyres make up close to 20 percent of CEAT’s speciality revenue, with the agriculture-to-non-agriculture split narrowing from 85:15 to near 50:50 once Camso is included. Domestically, Tolani credits GST reforms for a strong OEM market, led by Mahindra and TAFE, while mining stays flat – a segment Camso’s construction heritage should help lift as the new all-steel OTR line comes online.

When the World Economic Forum inducted CEAT’s Chennai facility into its Global Lighthouse Network in January 2025, it made the Indian tyre-maker the first tyre brand in the world to hold two such honours – Chennai following in the footsteps of the company’s Halol plant. Add to that CEAT’s Deming Grand Prize, awarded by the Union of Japanese Scientists and Engineers for sustained excellence in Total Quality Management, and the company finds itself in rarefied company: one of only a handful of manufacturers worldwide, and the only tyre brand to hold both distinctions.

Behind these accolades sits a quieter, harder story – one of culture change, shop-floor scepticism and years of disciplined, incremental investment in artificial intelligence, the Industrial Internet of Things and automation. In an interview with Tyre Trends, Jayasankar Kuruppal, Senior Vice President, Manufacturing at CEAT, spoke on what these recognitions actually mean on the factory floor, and where the company believes manufacturing is headed next.

AWARDS AS A BY-PRODUCT, NOT THE GOAL

CEAT’s Chennai plant has posted striking numbers since its digital transformation began: a 54 percent improvement in dispatch turnaround, a 25 percent uplift in labour productivity, an 18 percent reduction in cycle times, a 31 percent improvement in operating cost and a 47 percent cut in Scope 1 and 2 emissions. Yet Kuruppal is quick to reframe the narrative around these achievements.

“The awards are lagging indicators, not the goal. What actually matters is what they force us to build: a common language for problem-solving across every plant, real-time visibility into quality and efficiencies and a workforce that trusts data over gut-feel,” Kuruppal said.

“That discipline shows up directly in the numbers – tighter process capability, better efficiencies and faster changeovers leading to shorter lead times. There is a commercial dividend too: global OEMs increasingly audit manufacturing maturity, and being part of the WEF Global Lighthouse Network gives us instant credibility in those conversations,” he added.

WHAT’S REALLY DRIVING THE INVESTMENT

CEAT has been pouring capital into AI, IIoT and automation across its plants. Is this cost pressure, premiumisation or a simple need to stay globally competitive? Kuruppal’s answer suggests it is all three, each playing a distinct role.

Kuruppal explained, “Quality, cost and efficiency is what gets the funding approved. Premiumisation is what’s shaping which lines we automate or upgrade first – you cannot hold the tolerances a premium radial demands with manual, operator-dependent processes.” According to him, global competitiveness, meanwhile, sets the ambition. “We’re not benchmarking ourselves against the best tyre plant in India anymore – we’re benchmarking against the best factories in any industry,” he added.

Asked to rank the three forces, he summarised neatly: competitiveness sets the ambition, premiumisation sets the sequencing and cost discipline keeps the whole effort honest.

REPLICATING HALOL AT CHENNAI: CULTURE OVER CODE

Chennai’s transformation built directly on lessons learned at Halol, the world’s first tyre facility inducted into the Lighthouse Network. And when asked what proved hardest to replicate, the technology, the culture or getting the underlying processes right, Kuruppal said, “Technology was actually the easiest part to copy. A use case that works at Halol can be re-deployed at Chennai in weeks.”

But the real difficulty, as per Kuruppal, was culture, people and change management. At Halol, habits such as daily data reviews, operator ownership of quality metrics and a managerial focus on coaching rather than firefighting were built steadily over several years. Chennai, by contrast, has had to replicate that trajectory on a compressed timeline, with a workforce encountering these practices for the first time.

“We had to resist the temptation to just parachute in dashboards and call it digital. We spent real time getting the underlying process standardisation right first, because AI on top of an unstable process just gives you a faster route to the wrong answer,” Kuruppal said.

Jayasankar Kuruppal, Senior Vice President, Manufacturing, CEAT

WHERE THE RETURNS SHOW UP – AND WHERE THEY HAVEN’T YET

The productivity and dispatch gains at Chennai, he explained, hit the balance sheet in different ways. The productivity improvement lowers conversion cost per tyre and improves absorption of fixed costs as volumes grow. The dispatch improvement is more of a customer-experience story: less finished-goods inventory sitting idle, and OEMs and dealers receiving faster, more predictable delivery windows – ‘which matters a lot when you’re chasing premium and export business’.

Not every initiative has paid off yet, however. Kuruppal was candid about the areas still short of return, singling out ‘some of the more exploratory AI use cases – like computer-vision pilots – which need more data cycles before the accuracy justifies scaling them further’.

QUALITY, MAINTENANCE, OUTPUT: AI TOUCHES ALL THREE

Rather than picking a single area where artificial intelligence delivers most value, Kuruppal argued that its power lies in the way it now touches quality, maintenance and output simultaneously – and that these reinforce one another. “Better quality data feeds better predictive-maintenance models, which reduces unplanned downtime, which directly lifts output,” he said. The most immediate impact shows up in more consistent product quality, higher yields and earlier detection of equipment issues. He pushed back, though, on the idea that AI at CEAT is a single flagship project: “On our floor, it’s dozens of narrow, specific use cases, each solving one operator’s or one supervisor’s actual problem.”

JUSTIFYING THE SPEND IN A MARGIN-TIGHT BUSINESS

Tyre manufacturing is not a business with room for indulgent technology spending, and Kuruppal was clear that CEAT does not fund innovation for its own sake. “Every use case has to show a clear line to quality, efficiency, cost or capacity enhancement before it gets budget,” he said. The company deliberately starts small – piloting on a single line, proving value with real production data, and scaling only what works – a discipline that means ‘the savings from scaled use cases fund the next round of pilots’. He offered a broader rationale too: in a commodity-adjacent business where raw material costs sit largely outside a manufacturer’s control, manufacturing capability itself becomes the differentiator. “If we can’t always control input costs, we can control how efficiently and consistently we convert them into tyres,” he added.

CHENNAI PLANT WIDENS ITS PREMIUM PUSH

CEAT on Oct. 1 announced an expansion of manufacturing capabilities at its Chennai plant across passenger car and SUV, commercial vehicle and two-wheeler tyres. The company said the move targets premium customers in India, Europe and North America.

What’s new

Cars and SUVs: The plant now makes the SportDrive SUV ZR22. CEAT said this makes it the first Indian tyre company to manufacture 22-inch tyres in India. It also makes the 4SeasonDrive+ all-season tyre and the CrossDrive RT rugged-terrain tyre, built for the U.S. market.

Trucks and buses: The plant can now produce seven advanced truck and bus radial sizes, including wide-base tyres that can replace dual-tyre setups, and low-profile sizes. CEAT is also scaling light truck steel radials in 15-, 16- and 17.5-inch sizes.

Two-wheelers: The SportRad Racing Slick range targets track use, and SportRad ST is a sport-touring range for motorcycles above 650cc.

“This investment strengthens our ability to compete in premium segments with products developed and manufactured in India,” CEAT managing director and CEO Arnab Banerjee said.

The 163-acre plant in Sriperumbudur, Kanchipuram, runs on connected machinery and real-time analytics. It also has a 9 MW rooftop solar installation and operates as a zero-liquid-discharge facility.

FROM PILOT TO SCALE: AN OPERATING-MODEL PROBLEM

With a large share of CEAT’s lines now running as ‘smart lines’, when asked what changes when a company moves from isolated pilots to scaling technology across multiple plants, the CEAT executive explained, “The problem changes completely. A pilot is a technology and data-science problem – get the model working, prove the use case. Scaling is an operating-model problem – standard work, training, change management, IT infrastructure that can handle load across sites and governance so every plant isn’t reinventing its own version of the same solution.”

CEAT has built what he calls a central playbook – reusable architecture, common data standards and the ability to roll a proven use case out to a new plant in weeks rather than months. “Just as importantly, ownership shifts: at pilot stage, a project team owns the initiative; at scale, it must become the plant’s own way of working, run by operations rather than a digital team sitting alongside it,” he added.

BRINGING 80 PERCENT OF THE WORKFORCE ALONG

CEAT reports that more than 80 percent of its workforce is now digitally enabled – a transformation Kuruppal admits did not come without resistance. “Yes, and I’d be understating it if I said otherwise,” he said. Crucially, he insists the resistance was never really about technology itself but about ease of operation. What worked, he explained, was making tools visibly useful to the person using them first – an operator seeing a dashboard that helps them hit their own target before it ever becomes a management reporting tool. CEAT invested heavily in shop-floor-specific training rather than generic digital-literacy courses and made a point of promoting from within, demonstrating that digital skills opened up better roles rather than closing off old ones. The company has also created new shop-floor roles beyond data scientists and engineers – ‘Business Translators’ and ‘Champions’ who act as torchbearers driving scaled implementation and wider blue-collar involvement.

CONSISTENCY, NOT JUST DEFECT COUNTS

Asked whether tighter process control has genuinely reduced defects, Kuruppal reframed the question around consistency. “Tighter process control means less batch-to-batch variation, which matters enormously in tyre manufacturing because so much of performance and durability comes down to material consistency through mixing, extrusion and curing,” he said. Real-time monitoring now catches drift early, rather than at final inspection – both a quality win and a material-efficiency win, in the form of less scrap and rework. The habit that has changed most, he said, is that quality data now drives daily decisions on the shop floor, rather than featuring only in a monthly review.

MANUFACTURING FOR A PREMIUM, ELECTRIC FUTURE

CEAT’s push into premium tyres calls for a step-change in manufacturing discipline. “Premium tyres are far less forgiving of variation, so the shift starts with tightening process capability across every stage – not just final inspection. That means more precise equipment, better process capability and closed-loop control,” said Kuruppal. In this context, flexibility takes on a different meaning: a wider SKU mix, smaller batch sizes and faster changeovers are pushing the company towards more modular manufacturing, alongside a workforce increasingly weighted towards process engineering expertise.

Electric vehicles introduce an additional layer of complexity. EV tyres must carry greater weight, handle instant torque and operate more quietly, tightening specifications around structural strength, noise and rolling resistance beyond those of conventional tyres. On the shop floor, that translates into new compound formulations requiring precise mixing, reinforced construction demanding tighter control of building machines and significantly lower tolerance for micro-variation.

CEAT’s existing leadership in the e-two-wheeler tyre segment, Kuruppal noted, is already feeding lessons – particularly on noise and efficiency – into how the company prepares lines for growing e-four-wheeler volumes in India.

SUSTAINABILITY AND RESILIENCE, BUILT IN

Sustainability, once a separate reporting exercise, is now ‘a line item in almost every manufacturing decision’, with energy and emissions sitting alongside cost and quality when evaluating new processes or equipment – Chennai’s 47 percent emissions reduction being the clearest proof point. Resilience, too, has become as much a data problem as a sourcing one. “Real-time visibility into inventory, machine health and production schedules means we can see a disruption coming and reschedule around it rather than reacting after a line has already stopped,” Kuruppal said, pointing also to greater flexibility in shifting product mix between lines and earlier warning signals from digitised supplier and logistics data.

SPEED AS A COMPETITIVE WEAPON

Manufacturing speed and flexibility, Kuruppal argues, have become one of CEAT’s most important competitive dimensions, as OEMs compress their own development cycles and expect tyre partners to match their pace – faster prototyping, faster line trials, faster ramp-up to volume. Chennai’s faster dispatch turnaround is part of the same story. “It’s not just about making tyres faster; it’s about the whole chain from order to delivery being more predictable and quicker,” he said.

GROUND STILL TO COVER

For all its Lighthouse credentials, Kuruppal was refreshingly honest about the distance still to travel. “Being part of that network is genuinely humbling. You see factories in electronics and consumer goods running end-to-end AI-driven planning and quality systems at a level of maturity we’re still building towards – particularly in advanced analytics for demand-and-production planning and in scaling generative-AI use cases beyond pilots,” he said. CEAT’s strength, he believes, lies in shop-floor execution and quality; the next frontier is connecting that data seamlessly across the full value chain, from raw-material sourcing to the end customer.

MANUFACTURING AS A GROWTH DRIVER

Perhaps the most striking shift Kuruppal describes is a change in how manufacturing itself is perceived within the business. “Traditionally, manufacturing was viewed in this industry as a cost centre that executes what sales and product teams decide,” he said.

“Today, our manufacturing capability is directly opening up premium and export opportunities, because global customers evaluate factory maturity as part of their sourcing decision. It works in the other direction too, shaping which premium and EV products the company can confidently commit to launching. Manufacturing has moved from being an execution function to being a genuine input into growth strategy,” he added.

WHAT COMES NEXT

Looking ahead, Kuruppal frames the next horizon as connecting what CEAT has built plant-by-plant into a single, integrated digital thread – spanning raw-material and demand planning, production and distribution – so decisions are optimised end-to-end rather than site-by-site. Generative AI, he said, is increasingly being explored for process and equipment troubleshooting and knowledge capture, making the expertise of CEAT’s best engineers accessible across every plant. Sustainability, meanwhile, will be designed into new lines from the outset rather than retrofitted. “The common thread is moving from isolated smart use cases to a genuinely integrated smart manufacturing system,” he explained.

THE ONE NUMBER THAT MATTERS

Answering the question on if he could track just one metric across every CEAT plant, what would it be, he admitted, “If I’m honest, no single number tells the whole story, but if forced to pick one, it would be Overall Equipment Effectiveness – OEE.”

“As a composite of availability, performance and quality, a healthy and rising OEE generally signals that machines are running, running at the right speed and producing good tyres – which is really the definition of a plant working as it should,” he said. It has its limits – OEE alone won’t reveal a lapse in safety culture or the pace of digital adoption – which is why, in the end, Kuruppal names two figures he watches above all: OEE and safety indicators.