Anyline, a global leader in AI-powered mobile data capture, is disrupting industries by enabling instant scanning of everyday data with smartphones.

In an era where data is king, Vienna-based Anyline aims to carve out a significant niche, transforming everyday data capture into a seamless, mobile-first experience. What began as a computer vision research project, exploring the intricate ways machines could ‘see and interpret the world’, has blossomed into a global commercial platform.

This evolution was driven by a clear recognition of how urgently businesses across various sectors needed reliable, efficient and mobile-first data capture solutions. Anyline’s innovative approach now empowers frontline workers across diverse industries, from the complexities of logistics and the precision of manufacturing to the dynamic environments of retail and public safety and, notably, the high-stakes world of the automotive sector.

“Anyline was founded with the vision of making everyday data – like barcodes, serial numbers, IDs and tyre codes – instantly scannable using nothing more than a smartphone,” explained Peio Elustondo, VP of Inside Sales and Growth Marketing at Anyline. “We quickly saw how urgently businesses needed reliable, mobile-first data capture. The demand was undeniable, and our technology provided a straightforward, scalable answer.”

The company’s advanced AI-powered technology is now extensively deployed in over 100 countries, serving a distinguished roster of leading brands such as Discount Tyre, a giant in the automotive aftermarket; PepsiCo, a global food and beverage leader and IBM, a technology and consulting powerhouse. Elustondo highlighted their core mission, which remains steadfast despite their expansive growth, “Whether it’s helping technicians inspect tyres, retailers manage inventory or police verify vehicle data, our mission remains the same: to empower frontline workers with smart, scalable technology that makes everyday tasks faster, more accurate and more efficient. We believe in putting powerful tools directly into the hands of those on the ground, enabling them to work smarter, not harder.”

Anyline’s global footprint and tangible impact speak volumes, with millions of scans performed each month and a continuously expanding ecosystem of enterprise partners who place their trust in its software to digitise critical operations in the field, at the point of action.

REVOLUTIONISING TYRE INSPECTIONS WITH TIREBUDDY

One of Anyline’s most impactful and strategically significant innovations in the automotive space is TireBuddy, a dedicated mobile application meticulously designed to streamline the often-cumbersome process of tyre inspections. Traditional manual methods, which have long been the industry standard, are frequently plagued by inconsistencies, subjective interpretations and outright errors. These issues present a significant and persistent challenge for businesses striving for efficiency and accuracy.

“Tyre inspections are often manual, time-consuming and prone to errors – from misreading DOT codes to inconsistent tread depth checks,” Elustondo noted, painting a clear picture of the industry’s struggle and underscoring the dual nature of the problem. “The challenge is not only speed but also standardisation. Without reliable digital tools, even experienced technicians can struggle to deliver consistent results, especially under pressure or in high-volume environments.”

TireBuddy directly and comprehensively addresses these pain points, bringing powerful, AI-driven capabilities directly to the workshop floor, all without the need for expensive, dedicated hardware.

“It was built specifically for the needs of independent tyre dealers and service teams who want to modernise their workflows without investing in costly hardware or infrastructure,” Elustondo stated, highlighting the app’s accessibility and cost-effectiveness. The app empowers technicians to effortlessly scan and capture crucial data points such as DOT codes, tyre size, brand and Vehicle Identification Numbers (VINs) instantly.

Furthermore, TireBuddy provides precise tread depth measurements through a guided mobile workflow, ensuring that tyre health is assessed consistently and accurately, eliminating the need for traditional, often inaccurate, physical gauges. Remarkably, all of this critical data capture and verification happens in under a minute per tyre, with the results being rigorously AI-verified for unparalleled accuracy and reliability.

“All of this happens in under a minute per tyre and the results are AI-verified for accuracy and reliability,” Elustondo confirmed, emphasising the speed and precision that define TireBuddy.

He then explained the broader and more profound benefits that extend far beyond mere operational efficiency, “Beyond just speed and convenience, the true value of TireBuddy lies in what it unlocks. It gives technicians a digital record of each tyre’s condition, streamlines compliance documentation and enables more transparent conversations with customers about when a tyre truly needs to be replaced. This boosts customer trust and opens the door to more confident service recommendations.”

This digital record not only enhances internal record-keeping but also serves as a powerful tool for customer education, allowing technicians to visually demonstrate wear and tear and clearly justify service recommendations, thereby fostering greater confidence and loyalty. Because TireBuddy is mobile-based and cloud-connected, it also integrates seamlessly into existing backend systems – whether those are inventory management platforms, Customer Relationship Management (CRM) tools or point-of-sale systems. For businesses, this translates into a cascade of benefits, superior data quality, a significant reduction in manual errors and enhanced overall efficiency across their entire operational spectrum. Ultimately, TireBuddy empowers tyre shops of all sizes, from small independent garages to large chains, to offer a more modern, professional and data-driven customer experience – a capability that is fast becoming essential in today’s increasingly competitive and digitised service landscape.

ACCURACY AND IMPACT ACROSS INDUSTRIES

Anyline claims its AI-powered visual inspection offers a significant and demonstrable leap in consistency and reliability when compared to traditional manual methods. The inherent variability in human performance, particularly in repetitive and detailed tasks, often leads to discrepancies.

“Manual inspections often vary from technician to technician, especially when it comes to tasks like reading DOT codes or estimating tread depth. Our technology standardises these processes, capturing data instantly and removing the risk of human error, typos or misinterpretation. This means every inspection, regardless of who performs it, adheres to the same high standard of accuracy,” said Elustondo.

While acknowledging that real-world factors such as challenging lighting conditions or extreme tyre wear can influence accuracy, he assured that “our tools are continuously trained and tested on a wide range of conditions to ensure performance is reliable in the environments where they’re used most. The result is not only faster inspections, but repeatable, verifiable outcomes that technicians and service managers can trust implicitly.”

The profound impact of solutions like TireBuddy is clearly evident in Anyline’s impressive client base, which spans a wide array of automotive industry players, including leading automotive original equipment manufacturers (OEMs), extensive aftersales networks and crucial logistics providers. One of their most significant and long-standing partners is Discount Tyre, which stands as the largest independent tyre and wheel retailer in the US.

Discount Tyre leverages Anyline’s cutting-edge technology to streamline their tyre inspection processes and digitise key vehicle data across their vast service network, significantly enhancing their operational efficiency and customer service.

“Our ability to serve both independent dealers and enterprise-scale players is a key strength. Whether it’s through our TireBuddy app or via custom integrations using the Anyline SDK, we help clients bring mobile inspection capabilities directly into the hands of technicians – no matter the size or complexity of their operation. This flexibility ensures that businesses of all scales can benefit from our advanced AI,” averred Elustondo, highlighting Anyline’s versatile approach.

Beyond the automotive sector, Anyline’s solutions are also used by government agencies for vehicle data verification, rental fleets for efficient vehicle check-ins and commercial vehicle operators seeking to improve safety, compliance and overall operational efficiency through AI-driven inspections. This broad applicability underscores the universal need for accurate, mobile data capture.

A GLOBAL FOOTPRINT AND FUTURE VISION

Anyline’s global reach extends significantly to India, a market Elustondo described as “important for us – both in terms of talent and innovation partnerships.”

He highlighted a particularly significant collaboration that exemplifies Anyline’s impact in the region: a partnership with Tata Power Delhi Distribution (Tata Power-DDL). Through this collaboration, Anyline launched an industry-first mobile meter reading solution utilising OCR (Optical Character Recognition) and AI-powered anti-spoofing technology. This innovative solution was deployed across North Delhi, dramatically improving billing accuracy, reducing non-technical losses and streamlining field operations for an astounding 1.9 million metres.

“That collaboration showcased how AI and mobile data capture can solve real-world infrastructure challenges at scale,” Elustondo added, pointing to the measurable impact on operational efficiency and data quality. This project marked a pivotal moment, being the first time Tata Power-DDL had adopted mobile OCR for utility meter reading, demonstrating a clear shift towards digital transformation in critical infrastructure.

Looking ahead, Anyline remains steadfastly committed to its software-first approach, a strategic decision that deliberately avoids the need for specialised, proprietary hardware.

“Our focus is on delivering AI-powered software solutions that run seamlessly on everyday mobile devices like smartphones and tablets. This software-first approach eliminates the need for specialised hardware, making our technology far more accessible, scalable and cost-effective for users around the world. It means businesses don’t have to invest in new, expensive equipment; they can leverage the devices their teams already use, significantly lowering the barrier to adoption,” Elustondo affirmed.

This philosophy ensures that Anyline’s solutions are not just technologically advanced but also practically viable for a wide range of businesses globally.

The company’s future plans involve a continuous and ambitious expansion of its AI-powered capabilities specifically tailored for the automotive industry. “Expect more integrations, real-time diagnostics and predictive maintenance features – all accessible via mobile,” Elustondo revealed, hinting at a future where vehicle maintenance is more proactive and data-driven. These advancements promise to further empower technicians with instant insights, enabling them to identify potential issues before they escalate and provide even more precise recommendations to customers.

The company shared that TireBuddy, in particular, stands as a powerful testament to its responsiveness to genuine industry needs and its ability to rapidly develop and deploy effective solutions.

“One development we are especially proud of is TireBuddy. It was built in direct response to feedback from the field, where independent dealers and service teams told us they needed a faster, more accurate way to assess tyre health without investing in expensive equipment or retraining their teams. We listened and we delivered,” Elustondo stated.

The app’s success has been resounding, with positive feedback echoing across the industry. “The response so far has been incredibly positive. Dealers are telling us it is improving the professionalism of their service while also reducing the friction that often comes with inspection-based upselling. It transforms a traditionally manual process – DOT code reading, tread depth measurement, VIN capture – into a digital workflow that’s intuitive, consistent and verifiable. It helps technicians provide clearer documentation, make more confident recommendations and ultimately earn greater trust from customers,” Elustondo said.

He envisions TireBuddy as far more than just a single product: “We see TireBuddy not just as a product, but as the foundation of a broader ecosystem of AI-powered tools designed to support the future of vehicle service – where data, transparency and customer trust take centre stage. This is about building a more efficient, reliable and customer-centric automotive service industry for tomorrow.” 

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VMI has announced that it will showcase multiple new automation solutions at The Tire Cologne, aimed at advancing the retreading process. Among the innovations is an automatic splice unit, which will be on display and available for short demonstrations at the event. VMI account manager Ronald Noppers is scheduled to present on automation in retreading on 11 June at 12:45.

The company is introducing the automatic splice unit and automatic recipe loading as initial steps towards greater industry automation. Designed for applying extruded hot cushion gum to buffed tire casings, the VMI RETRAXX system currently relies heavily on skilled manual labour, a resource that is becoming scarcer and more expensive. To address this, VMI introduced an automated wingformer setting upgrade for the RETRAXX in 2024, allowing operators to start an automatic cycle that positions the wingformers without manual intervention.

Key advantages of these automation solutions include reduced operator dependency and improved uniformity and product quality. VMI will be located in hall 7 at stand number C-041.

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MESNAC made a notable return to the Indian market by participating in the 2026 India Rubber Expo, held in Delhi from 7 to 10 April. After an eight-year absence from offline professional exhibitions in the country, the company presented its advanced machinery and intelligent manufacturing solutions. This participation highlighted its strong technical expertise and service capabilities within the rubber machinery sector while also signalling a renewed commitment to long-term growth and a deep-rooted presence in the region.

At the event, MESNAC’s Vice President, Wang Zhiming, and his team held productive discussions with representatives from several local tyre manufacturers, including long-established industry leaders and existing clients. These conversations focused on technical exchanges regarding core equipment. The company’s exhibition booth attracted nearly 100 professional visitors each day, which helped strengthen ties with long-term partners and facilitated in-depth technical dialogues with potential new collaborators.

Given the steady expansion of India’s tyre industry, MESNAC is dedicated to further strengthening its local market position through a focus on both technology and service. By supporting the sector’s continuous upgrade, the company aims to play a key role in the industry’s evolving landscape.

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China’s Tercelo Tire Group is taking a measured, niche-led approach to global expansion, with India’s fast-growing mining sector firmly in its sights.

At a time when global tyre markets are being reshaped by regulation, geopolitics and intense pricing pressure, China’s Tercelo Tire Group is pursuing a strategy that favours clarity over scale. Rather than chasing volumes across crowded segments, the company is focusing on specific markets and applications where long-term demand fundamentals are strongest.

Nowhere is this approach more evident than in India, where Tercelo is positioning itself squarely within the off-the-road (OTR) tyre segment, aligned with the country’s rapidly expanding mining and infrastructure ecosystem.

The Chinese company, part of the Fortune 500 company Wuchan Zhongda Chemical Group, is a nine-year-old tyre maker selling products under the Tercelo, Transmate, Superhawk, Yingba, Three-A and Rapid brands, among others. The company claims to have over USD 7.2 billion in annual operating revenue and growing.

In an exclusive interaction with Tyre Trends, Akash Gupta, Country Manager – India & Africa, Tercelo Tire Group, said, “We are very new in this segment. We can say we are a small baby (in India) right now. But we are entering the market with a very clear mindset – slow growth, strong quality focus and very specific targeting.”

For a Chinese tyre manufacturer, India is not the easiest market to enter. It is fiercely competitive, dominated by strong domestic brands and governed by increasingly strict trade and quality regulations. Yet, Gupta believes that these very challenges make India strategically compelling.

“India is a very big market for the tyre industry. People like economical tyres – affordable tyres. Historically, Chinese brands always had some presence because of price competitiveness. Even a 10 or 20 percent market share is very big in India,” he said.

However, that landscape has changed significantly over the past few years.

CHOOSING INDIA AMID REGULATION AND RESISTANCE

India’s tyre market has undergone a sharp regulatory shift, particularly in response to rising imports and the government’s push to strengthen domestic manufacturing. Anti-dumping duties, mandatory BIS certification and tighter customs scrutiny have fundamentally altered the playing field – especially for Chinese manufacturers.

“The government started anti-dumping because they are giving scope to local manufacturers. If you don’t protect them, it becomes very difficult,” Gupta explained.

As a result, entire segments are effectively closed to Chinese imports. “PCR, motorcycle and some other tyres – nobody can bring them from China now. So Chinese tyres are not coming into India in these segments,” Gupta said.

While tyres continue to enter India from countries such as Indonesia, Thailand and Japan, Gupta dismisses suggestions that Chinese manufacturers can simply reroute shipments through third markets.

“It’s not possible. A lot of people tried Dubai, but it failed. The cost is very high. You send tyres to Dubai, then again to India – the margins simply don’t make sense,” he stated firmly.

Faced with these realities, Tercelo made a deliberate strategic decision. “That is why our focus is not TBR or PCR. Our focus is only OTR,” Gupta said.

Unlike passenger or truck tyres, OTR tyres cater to a specialised industrial customer base, are less price-elastic and are closely tied to capital-intensive sectors such as mining, construction and quarrying. For Tercelo, this segment offers a more stable entry point.

He said, “OTR is a growing sector in the Indian market. We have Coal India, Adani, Reliance – a lot of mining companies. And now the government is also encouraging many small companies to enter mining.”

RISING THROUGH COVID-19

Tercelo’s rise has been shaped by disruption. The company began its manufacturing journey in 2019 — just as the Covid-19 pandemic brought global industrial activity to a standstill.

“When Covid started, all the factories in China were shutting down. But what our company did was something very different,” Gupta recalled.

Instead of retreating, Tercelo expanded. “They bought four factories in China – two for TBR, one for OTR and one for PCR. These were very major factories,” he said.

Among them were Super Hawk and O’Green Group, established manufacturing facilities with strong domestic reputations. “We started from there,” Gupta added.

This bold move allowed Tercelo to build scale quickly once markets reopened. “Today, we are selling more than one million tyres every year – OTR, TBR and PCR combined,” he said.

The company has also structured its brand portfolio carefully to address different geographies and customer expectations. “Our premium brand is Transmate/Tercelo (PCR, TBR and OTR),” Gupta explained. “Then we have Routeck (TBR) for the mid-segment, which is an economical tyre.”

For highly price-sensitive markets, Tercelo operates distinct brands. “StepRising (TBR) and EcoSaver (TBR) are only for Africa. Africa market prefers cheap tyres – low price, low quality. That is the reality,” he said.

This segmentation, Gupta believes, is critical. “You cannot sell the same tyre in Europe, India and Africa with the same positioning. Every market has its own mindset,” he averred.

INDIA’S OTR OPPORTUNITY: MINING, INFRASTRUCTURE AND LONG-TERM DEMAND

India’s mining sector is undergoing a structural expansion, driven by rising energy demand, infrastructure development and policy reforms aimed at increasing private participation.

“The government has given a lot of tenders to small, small companies to participate in mining. We believe the mining business for the next five years is going to be very big,” Gupta said.

While large conglomerates continue to dominate, the emergence of smaller operators is creating opportunities for mid-segment OTR tyre suppliers – exactly where Tercelo wants to position itself.

“We are manufacturing from small OTR to giant OTR tyres. But in India, we see ourselves more in the mid-segment of giant OTR (16.00-25 to 12.00-24),” he said. These tyres serve large dumpers, loaders and haul trucks used in coal, iron ore and limestone mines. “Big vehicles used by companies like Adani, Reliance – that is where our focus is,” he explained.

Rather than chasing aggressive volumes, Tercelo is targeting measured penetration. “We are not trying to take a big share. We are trying to enter gradually,” Gupta reiterated. The numbers reflect this caution. “We are targeting maybe two or three percent of the market initially. In the next three years, my target is five percent. I don’t want anything more,” Gupta explained.

For the executive, this is a realistic and sustainable ambition. “We are only six years old,” he says. “There are many Chinese companies – Triangle Tires, Techking Tires, Advance, Maxam – they are veterans of 20, 30, even 40 years.”

Competing with them requires patience. “Quality, consistency and service – that is how we will succeed,” he added.

REGULATORY CONTRADICTIONS AND MARKET REALITIES

Despite his pragmatic outlook, Gupta does not shy away from critiquing India’s regulatory inconsistencies, particularly in the TBR segment.

“The government has anti-dumping, but at the same time, some Chinese companies are getting BIS. Companies like Sailun, Jetsea and Double Coin – they have BIS (TBR),” he pointed out.

As a result, these brands are able to sell significant volumes. “They are selling 20,000–30,000 tyres every year, sometimes more,” Gupta revealed. For him, this creates mixed signals. He argued, “If your rules are rules, then stick to them. Why give loopholes?”

He adds that such decisions also affect domestic manufacturers. “Somehow, you are taking market away from MRF, Apollo Tyres and JK Tyre also. This feels negative,” he said.

These contradictions reinforce Tercelo’s conservative India strategy. “That is why we don’t want to get into grey areas. OTR is clean, focused and aligned with India’s growth story,” he explained.

AFRICA AND EMERGING MARKETS: VOLUME THROUGH PRICE

While India is a story of regulation and selective opportunity, Africa represents a completely different dynamic – one dominated by price sensitivity and limited technical awareness.

“I worked in Africa for almost 20 years. I know the market very well,” Gupta recalled. According to him, African customers prioritise upfront cost above all else. “They don’t want to invest a lot of money on premium tyres because their awareness is very little,” he explained.

Basic practices such as load management and tyre pressure maintenance are often ignored. “They don’t know how to drive vehicles properly, how to maintain air pressure – it’s just load and run,” Gupta said.

Premium tyres do have a niche audience. “If transporters are Indian or British, they understand quality. But local African customers want a USD 100 tyre. That is enough for them,” he said.

This lack of maintenance awareness drives high replacement demand – a reality Gupta acknowledged candidly. “Replacement is very high everywhere – India, Africa, even some parts of Asia. And trust me, all manufacturers love this problem,” he said.

He explained with disarming honesty that if customers started maintaining tyres properly, checking pressure, loading correctly, then the replacement market will reduce and business will go down. “And Frankly speaking, nobody wants that,” he said.

A MEASURED VISION FOR THE ROAD AHEAD

Unlike many new entrants who promise aggressive expansion, Tercelo’s leadership is deliberately cautious in its outlook. He averred, “We are not chasing big numbers. We are chasing stability.”

In India, that means aligning closely with mining growth, building credibility with fleet operators and gradually expanding product acceptance.

He reiterated that while the competition is severe, it is important to acknowledge that Tercelo Tire started in 2019. “Six years is nothing in this industry,” he pointed out.

Yet, Gupta remains confident that discipline will pay off. “If we maintain quality, service and pricing balance, five percent market share is more than enough for us,” said an optimistic Gupta.

As global tyre markets continue to fragment and regional strategies become increasingly important, Tercelo’s approach is looking at an alternative playbook strategy for India – focusing on a niche before building up to a larger play.

“We are starting slowly. But slow growth with the right direction is always better than fast growth with no control,” Gupta concluded. 

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Artificial intelligence (AI) is steadily moving from experimentation to practical deployment in tyre manufacturing, where complex processes and variable raw materials often limit the effectiveness of fixed production standards. By analysing large volumes of plant data and responding to real-time process conditions, AI-driven optimisation systems are helping manufacturers improve efficiency, reduce waste and stabilise product quality. In an interaction with Tyre Trends, Vincent Barjaud of Braincube explains how such systems are transforming key production stages including mixing, extrusion and curing while complementing operator expertise.

The tyre industry indeed depends heavily on raw materials with significant variability, particularly those derived from natural sources and petrochemicals. These materials change over time and therefore are not always consistent in terms of quality and performance. Because industrial processes operate under constantly changing conditions, fixed production standards often create a hidden performance ceiling. Systems capable of adapting to real-time conditions allow plants to consistently reach the best achievable operating point.

Artificial Intelligence (AI) is helping manufacturers move beyond fixed production standards towards more adaptive approaches. Real-Time Process Optimisation (RTPO) processes historical and real-time plant data to continuously adjust operating setpoints based on live process conditions. By responding to variability in raw materials, equipment behaviour and operating environments, RTPO enables plants to consistently operate closer to their optimal performance point.

Speaking exclusive to Tyre Trends on the integration of AI, Technical Partner Manager at France-based Technology firm Braincube, Vicent Barjaud, said, “Our AI-driven solution provides real-time process optimisation by recommending the exact action operators should take, on which actuator and at what moment. Instead of suggesting a broad operating range, the system recommends the precise optimal value in real time. Because operating context evolve during production, this optimal value may change within hours. The system continuously adapts to these changes to maintain optimal performance.” The company devises solutions to address the entire tyre manufacturing process, but the software is particularly effective in compound mixing, extrusion and curing, where material transformation through machine actuation makes these stages highly process-oriented and suitable for optimisation.

The implementation typically takes six to twelve weeks from project kick-off to go-live. During this phase, plant data sources are connected and structured for AI analysis without requiring access to confidential compound formulations.

Since most industrial players maintain historical data through data historians, this data is injected into the system, enabling real-time optimisation and recommendations from day one, and in rare cases where no historical data exists, a few weeks are required to gather sufficient operational data.

The solution can be implemented in any plant equipped with PLC-based automation systems, while additional digital systems such as MES, ERP or LIMS improve recommendation accuracy, although valuable real-time operator guidance can still be delivered with only historian data and basic inputs.

ROOM FOR IMPROVEMENT

According to Barjaud, one of the biggest opportunities for improvement lies in the uniformity of the final tyre, particularly during quality control at the end of production. This is largely due to the curing stage.

“Plants often operate dozens of different curing moulds. Each mould functions as an individual asset, but many manufacturers treat them as if they were identical. In reality, each mould behaves slightly differently, which can affect tyre uniformity. Recognising and optimising these individual differences can significantly improve efficiency and product consistency,” he added.

It is considered beneficial to treat each curing mould individually because every mould has distinct characteristics including differences in lifetime, behaviour, wear patterns, maintenance history and the time since its last servicing.

When moulds are treated as identical, these variations are overlooked. By managing each mould separately rather than as part of a uniform group, process optimisation can be achieved more precisely, resulting in improved efficiency and performance.

“Strong optimisation results have also been observed in extrusion, where start-up phases of new process orders typically generate scrap as the first few metres of material are discarded before reaching a steady state. By adjusting process parameters more precisely, the time required to reach this steady state can be reduced, thereby lowering start-up waste,” noted Barjaud.

Braincube’s optimisation approach works similarly to navigation apps such as Waze or Google Maps, which continuously adjust routes based on real-time traffic conditions to reach a destination faster.

In the same way, Braincube dynamically updates manufacturing parameter recommendations as process conditions change. Similar to navigation applications such as Waze or Google Maps, the system continuously adjusts the optimal ‘route’ for the process as new conditions emerge.

The approach also applies to extrusion processes, where significant material waste often occurs during machine ramp-up. By helping operators set the correct parameters from the first seconds of operation, the company reduces the amount of material that must be scrapped at start-up.

INTO MANUFACTURING

Braincube works with tyre plant engineering teams to define ideal performance targets such as acceptable tyre uniformity ranges. It analyses production data to identify the actuators and operating conditions that drive optimal results and provides real-time insights to operators so processes can be adjusted to keep tyres within the desired ‘super zone’ of uniformity.

In mixing, its system addresses inefficiencies during product changeovers. Since the first batch after a changeover starts under different conditions such as temperature, roll distance and machine state, it separates the recipe for the first batch from subsequent batches, ensuring consistent viscosity and composition while reducing the higher scrap rate typically seen in the first batch.

For curing, Braincube performs real-time optimisation by adjusting parameters such as steam injection, temperature and curing duration based on the specific mould and its operating conditions. It also helps extend mould lifetime by identifying moulds that can safely operate beyond the usual maintenance threshold of around 3,000 tyres, potentially extending their life by 20–50 percent.

Overall, waste reduction comes from replacing fixed production standards with dynamic optimisation, where the system continuously analyses real-time conditions and recommends adjustments to recipes and operating parameters, improving efficiency while lowering scrap and environmental impact.

“In one case with a top-five global tyre manufacturer that deployed Braincube across its factories, we observed waste reduction of around 70 percent during the extrusion start-up phase. This level of improvement can significantly reduce both material losses and production costs,” noted Barjaud.

MACHINE NEEDS MAN

Braincube approaches root-cause analysis by identifying the drivers of success rather than only analysing defects. Instead of focusing solely on scrap and deviations, the system studies past production data to determine the conditions under which the best tyres were produced.

By analysing the highest-performance production runs including machines, operators, raw materials and process conditions, it identifies the key factors behind superior performance and recommends settings that help replicate those results consistently.

Installing Braincube mainly involves resolving material traceability across the plant. During a six-to-twelve-week integration phase, the system connects to existing data sources and reconstructs where each product was at specific times in the factory.

Once this mapping is completed, Braincube can continuously process data and perform automated optimisation. Plants with strong traceability systems integrate more easily, while others may require certain assumptions during setup.

“Our solution’s recommendations typically achieve more than 90 percent accuracy, but the system is designed to assist operators rather than automatically enforce actions. Operators receive recommendations but remain fully in control of whether to apply them. If a recommendation is rejected, the system immediately recalculates a new suggestion based on the updated operating conditions,” explained Barjaud.

He added, “This human oversight is important because some real-world conditions may not be captured in the dataset. For example, a lower operating temperature may have produced good results in the past because a machine door was open, affecting process conditions. If that factor was not recorded by sensors, the system may initially recommend the same temperature again even though the door is now closed. In such cases, operators can reject the suggestion, ensuring that AI insights are balanced with practical judgment.”

Barjaud contended that operator expertise remains essential when using AI systems. While the system provides data-driven recommendations, experienced operators play a critical role in deciding whether to apply them.

Their deep understanding of the process ensures that AI insights are used appropriately, making the combination of human expertise and AI analysis key to achieving the best production results.

IMPLEMENTATION AND SAFETY

The company also partners with machine manufacturers through white-label agreements, allowing them to offer Braincube-powered optimisation services alongside their equipment. This enables customers to benefit not only from the machinery itself but also from continuous performance optimisation.

In the tyre industry, Braincube currently focuses on mixing, extrusion and curing and still sees major opportunities to expand optimisation in these processes. Even when analysing a specific stage such as curing or tyre uniformity, the system incorporates data from upstream operations like building and other production steps to understand the factors affecting final performance.

The emphasis on optimisation ultimately centres on the final KPI, since this reflects what customers pay for, which is finished tyre quality and uniformity. By integrating data from across the entire plant including upstream processes and raw materials, Braincube helps manufacturers consistently meet required product performance standards.

Also, many tyre makers have more than one manufacturing unit. Integrating Braincube’s solution across each one requires a simple collaborative excursive involving the French company’s team and a ‘Champion’.

“Most companies appoint a champion or a dedicated engineer responsible for replicating successes across plants. This person ensures that the best practices identified in one plant are standardised and implemented across other facilities,” explained Barjaud.

He added that companies usually deploy Braincube as a technical solution while also establishing a human organisational structure to drive replication and standardisation. The combination of technology and internal leadership ensures that improvements are scaled across multiple plants.

Besides, data security is a top priority for Braincube, especially because industrial manufacturing data is highly sensitive. The system complies with major cybersecurity standards such as ISO 27001 and SOC 2, and in its 18 years of operation, it has never experienced a data breach.

The company regularly conducts external penetration tests, maintains a dedicated cybersecurity team and operates under the supervision of a Chief Information Security Officer (CISO) responsible for vulnerability management and system protection.

Regarding concerns about job replacement, Barjaud reported little resistance from engineers or operators. “Industrial environments have evolved through successive technological stages, from manual decisions to PLCs, closed-loop control, advanced process control and now AI. In this context, AI is generally viewed as the next step in improving efficiency, helping people make better decisions rather than replacing them,” he noted.

MARKET VIEW

Braincube operates globally with a full operational office in Europe but also has offices in United States and Brazil, which has supported the Latin American market for about 15 years.

From Europe, the company manages both European and Asian markets and works with several software distribution partners worldwide including in Thailand, India, Poland, Germany, Spain, Switzerland, UK and Italy, collaborating with firms such as Ematica to deliver and integrate its solutions.

In Asia, particularly in India and Southeast Asia, Braincube mainly relies on local partners rather than establishing its own offices. These partners, often industrial software distributors already working with automation systems, MES platforms and data historians such as AVEVA, handle integration and customer engagement.

The company is also engaging with new tyre manufacturers in Asia, typically through those partners who add Braincube’s AI-driven optimisation to their existing portfolios of PLC, SCADA and MES solutions.

Concluding the interaction, Barjaud pointed out that one of the biggest challenges for AI providers in the tyre industry is balancing multiple objectives such as throughput, energy consumption, material usage and product quality. n

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