A proposed bill in Brazil’s Chamber of Deputies has ignited fierce opposition from the country’s tyre retreading sector, which sees the legislation as an ill-conceived and uninformed attack on an industry that plays a crucial role in the economy and sustainability efforts. The bill seeks to ban the use of retread tyres on buses and trucks operating on state and federal highways, a move that the industry argues is both impractical and detrimental.

Brazil is the world’s second-largest retread market, following only the United States. This achievement has been attributed to the reliability and quality of work carried out by retreaders, which has earned the market’s trust.

In September 2024, a draft bill was introduced in Brazil’s Chamber of Deputies to exercise a ban on the use of retread tyres in buses and trucks operating on state and federal highways. The Brazilian Association of Tyre Retreading (ABR) lashed out at the proposed draft, labelling it as ‘misguided and uninformed’.

Subsequently, ABR President and Federal Senator of Mato Grosso, Margareth Buzetti, told Tyre Trends, “The proposed bill focuses on retread tyres rather than broader factors such as overloading, poor road conditions or inadequate maintenance practices due to sheer misinformation on the part of the person who proposed the project. It is a simplistic and populist proposal that promises to increase road safety by fighting the wrong enemy. Tyres retreaded in Brazil undergo extremely rigorous inspections to ensure that they reach the transport companies safely and reliably.”

“We, as retreaders, meet Inmetro standards that define the technical requirements for tyre retreading, following the standards of excellence practiced in other countries. We are talking about large companies that have strict quality standards. We are in no way inferior to new tyres in terms of safety,” she added.

According to Buzetti, no reputable company would compromise on tyre safety as doing so could lead to financial losses from accidents and endanger lives. She also pointed out that the sector’s ability to generate approximately 300,000 direct and indirect jobs is a testament to the high quality of retreaded products.

Commenting on how the proposed bill might influence public perception about the sustainable practice, she noted, “The way it was proposed is terrible because it gives people the impression that retread tyres in Brazil are of poor quality and are responsible for road accidents. This is absurd misinformation. However, I do not see this issue as something that concerns the general population. Transport companies, which are the largest users of retread tyres, are aware of the reality.”

“Entities linked to both the reform and transportation sectors sent dozens of letters to the Chamber of Deputies against the proposed bill. We will continue this pressure in 2025,” she added.

The association plans to seek out the rapporteur and the author of the bill so that they understand the seriousness of the work carried out by the sector. “The right thing to do would be for the congressman to withdraw the bill he presented and file another one that focuses on combating illegally-made reforms or the poor-quality tyres that are imported from Asia without any control whatsoever. Then they will have our support. Otherwise, we will seek out partner congressmen to wage a real battle within the Chamber against the advancement of this absurd proposal,” contended Buzetti.

IMPLICATIONS OF THE BILL

Buzetti noted that if the proposed bill was implemented, then the implications would be ‘catastrophic’. “If the bill were to become law, the long-term impact on Brazil’s tyre industry would be devastating. Companies are already struggling with the rising cost of raw materials due to increase in the Dollar-Brazilian Real exchange rates. Banning tyre retreading would further cripple the sector, leading to significant financial and operational challenges,” she said.

Currently, tyre retreading saves Brazil BRL 7 billion in transportation costs. If the proposed bill becomes law, which the ABR believes is unlikely and will actively oppose, it would effectively force transportation companies to buy only new tyres overnight, causing a massive rise in costs.

Alluding to the potential impact of this legislation on Brazil’s carbon neutrality and sustainability goals, Buzetti emphasised, “The sector was recently recognised by the Ministry of the Environment as an important asset in the circular economy. This was a milestone that we achieved at great cost, and the government is finally beginning to see our importance for environmental sustainability. I believe that 2025 will be the year in which we will be able to make even more progress on this issue. We cannot ignore the importance for the environment of a sector that retreads 14 million tyres per year.”

While the association can furnish data demonstrating the safety and reliability of Inmerto-certified retread tyres to battle the proposed bill, Buzetti, attacking the project makers, said, “Can the deputy who created the project present data that guarantees that the lack of safety on the roads is caused by retread tyres?”

Commenting on the bill’s impact on small and micro enterprises if implemented, Buzetti said, “Tyre retreading supports 300,000 jobs in Brazil today. It is a well-established market. Banning retreading would be like taking food off the table for thousands of Brazilians who rely on this sector.”

ALTERNATIVE ROUTE

According to Buzetti, the legislative year ended with this bill being presented to the Chamber of Deputies’ Transport and Roads Committee and it did not receive any amendments within the statutory deadline. Now, in February, discussions on the proposal can begin and she highly doubts that it will move forward. As a senator, she will not participate in the votes in the Chamber but will personally go to the committee to talk to all the deputies to demonstrate the quality of tyre retreading in Brazil.

Speaking on the steps that the government should take to address any lingering safety concerns and prevent future proposals like this, in case the bill was withdrawn, Buzetti said, “Inspection of poor-quality tyres entering the country and incentives for tyre retreaders to continue operating within the law is a necessary step. I presented a bill that is currently pending in the Chamber of Deputies that provides tax exemption for tyre retreading companies, as a way of attracting them to formality.”

She also noted, “Instead of banning retread tyres, we could have greater oversight of imported tyres that enter Brazil illegally. We are talking about tyres that are so bad that they don’t even need to be refurbished. These should be a priority for parliamentarians. And, of course, improving road conditions and oversight of the rules that must be followed by transport companies (such as not exceeding the maximum load) are also important steps to increase road safety.”

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Continental’s Mount Vernon, Illinois, tyre facility has achieved a significant corporate milestone by becoming the company’s first US location to attain ISCC PLUS certification. This globally acknowledged standard verifies the transparent tracing and documented use of recycled and renewable feedstocks in manufacturing. The achievement aligns with Continental’s broader goal of incorporating at least 40 percent sustainable materials in its tyres by 2030, reinforcing its dedication to sustainable mobility in the American market.

This certification follows similar accomplishments across Continental’s European tyre plants and its facility in Hefei, China, underscoring a worldwide strategy. The Mount Vernon site itself has a long manufacturing history, having operated for over five decades. Originally opened in 1974 and acquired by Continental in 1987, the plant now produces tyres for passenger vehicles, light trucks and commercial vehicles. With an annual output of roughly 11.4 million tyres, the 320,000-square-metre location employs nearly 3,900 people.

Central to this material transition is the mass balance approach, a chain-of-custody method that allows certified sustainable materials to be mixed with conventional ones in production while being tracked through meticulous accounting. This system enables Continental to precisely attribute specific quantities of alternative raw

Nik Pearce, Head of the Continental tyre plant in Mount Vernon, Illinois, said, “We are very pleased that our plant has received ISCC PLUS certification. This certification confirms our commitment to increasingly sustainable production processes and recognises the outstanding efforts of our entire team. Together, we are implementing Continental’s global sustainability strategy at the local level – transparently, responsibly and with a clear focus on the future.”

Jorge Almeida, Head of Sustainability, Continental Tires, said, “We rely on transparent and traceable supply chains. That’s a fundamental prerequisite for making our tyres increasingly sustainable. The certification of our largest US plant marks another important step in this direction. It enables us to integrate more sustainable materials into our product portfolio in every region where we operate.”

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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.

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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.”

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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.

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