As India’s industrial sector accelerates its shift towards cleaner energy, tyre manufacturers are emerging as a critical test case for integrating renewable power into continuous, high-load operations. In this conversation, Kuldeep Jain, Founder and Managing Director of CleanMax, outlines how demand from companies such as CEAT and Michelin is reshaping renewable procurement – from conventional solar contracts to hybrid, round-the-clock solutions – while positioning clean energy as both an operational necessity and a strategic lever for decarbonisation.

Industrial decarbonisation in India is entering a more operational phase, where renewable electricity is no longer a peripheral lever but an embedded component of manufacturing strategy. For CleanMax, this shift is most visible in energy-intensive sectors such as tyre manufacturing, where continuous processes, global supply-chain pressures and ESG commitments are converging to reshape how power is procured and consumed.

Kuldeep Jain, Founder and Managing Director of CleanMax, describes a market moving beyond cost arbitrage towards structural integration of clean energy. Demand from tyre manufacturers – long characterised by high, stable electricity loads – is now influencing both project design and procurement models, pushing developers towards hybrid and round-the-clock renewable solutions. 

Energy-intensive industries are increasingly prioritising renewable electricity to manage power costs and reduce operational emissions. Manufacturing sectors with continuous loads are particularly suited to long-term renewable procurement models such as group captive and open-access PPAs, which provide cost stability while supporting decarbonisation goals,” Jain says.

That demand is already translating into project pipelines. CleanMax’s collaboration with CEAT involves developing 59 MW of hybrid wind-solar capacity to supply renewable power to its Halol and Kanchipuram plants. Similarly, its engagement with Michelin includes an open-access solar power purchase agreement supporting operations at the company’s Chennai facility.

“These projects illustrate how large industrial consumers are integrating renewables into their long-term energy strategy. For instance, globally, the International Energy Agency has already noted that industrial electrification and renewable procurement will drive the next phase of the energy transition. Tyres are firmly in that wave,” Jain notes.

FROM INTERMITTENT SUPPLY TO ENGINEERED RELIABILITY

Tyre manufacturing presents a distinctive challenge for renewable integration. Plants operate continuous processes – mixing, curing and vulcanisation – that require stable baseload electricity and thermal energy. Traditional solar PPAs, while cost-effective, are inherently intermittent, limiting their suitability for such operations.

The industry is therefore evolving towards hybrid models that combine multiple renewable sources. “Hybrid projects are gaining traction because they smooth generation across the day, improving plant load factors,” Jain says. According to the International Renewable Energy Agency, such hybrid systems are among the fastest-scaling formats for industrial decarbonisation.

“As a result, the industry is moving beyond single-source solar PPAs towards wind-solar hybrid projects and open-access group captive models that provide higher plant load factors and more balanced generation profiles across the day. Wind-solar hybrid is increasingly seen as the most practical and efficient pathway to scale renewable penetration in continuous manufacturing environments,” Jain explains.

This shift reflects a broader reframing of renewables – not as intermittent substitutes for fossil fuel power but as engineered systems tailored to industrial demand curves. The emphasis is on aligning generation profiles with consumption patterns, rather than expecting operations to adapt to variable supply.

SECTOR-SPECIFIC DECARBONISATION PATHWAYS

Not all heavy industries decarbonise along the same trajectory. Jain draws a clear distinction between tyre manufacturing and sectors such as cement or steel, where process emissions form a significant share of the carbon footprint.

“If you step back, industries don’t decarbonise in the same way because they don’t consume energy in the same way. A tyre plant is largely powered by electricity. So if you clean up the electricity, you’ve already addressed a meaningful part of its emissions,” he says.

However, the challenge lies in reliability. “These are continuous operations. They don’t switch off when the sun sets or the wind drops. That’s why hybrid becomes important, as a way of shaping energy to demand,” Jain adds.

“In case of cement or steel, a significant portion of emissions comes from how the product itself is made. So the shift we’re seeing is subtle but important. It’s about redesigning the energy profile itself so that clean energy isn’t intermittent in theory but dependable in practice,” he continues.

The implication is that electrification-driven sectors such as tyre manufacturing can achieve faster decarbonisation gains through renewable procurement, provided supply reliability is addressed through hybridisation and system design.

ESG, PRODUCT STRATEGY AND COMPETITIVE POSITIONING

Renewable energy is also assuming a more strategic role within tyre companies’ ESG frameworks. What began as a cost-management exercise is increasingly tied to product innovation, sustainability reporting and global competitiveness.

“The conversation around renewable energy in the tyre industry has clearly evolved beyond cost optimisation. Many manufacturers are increasingly integrating renewable power into their broader ESG strategies and supply-chain decarbonisation commitments, particularly as global automotive OEMs push for lower-carbon sourcing across the value chain,” Jain says.

This transition is evident at the product level. CEAT’s launch of its SecuraDrive CIRCL tyre – produced with up to 90 percent sustainable materials – signals how manufacturers are aligning product design with sustainability objectives.

“Renewable electricity procurement helps reduce Scope 2 emissions and supports the development of lower-carbon products, which is becoming an important factor in both sustainability reporting and global competitiveness. As a result, renewable energy is now seen not only as a cost-management tool but also as a strategic lever for product decarbonisation and ESG positioning,” Jain explains.

TECHNOLOGY MIX AND OPERATIONAL ALIGNMENT

From a systems perspective, no single technology provides a complete solution. CleanMax advocates a portfolio approach that combines generation assets with digital tools and flexible contracting structures.

“A portfolio approach works best. For manufacturing operations with steady electricity demand, hybrid renewable systems combining solar and wind have proven effective, as the complementary generation profiles improve overall availability and plant load factors,” Jain says.

Digital energy management platforms play a supporting role by optimising dispatch and aligning supply with consumption patterns. Flexible procurement structures, including open-access and group captive models, further enhance adaptability across sites and regulatory regimes.

“In practice, hybrid setups combining solar and wind have proven effective because they smooth generation across the day and improve overall availability. That’s what makes renewable power usable at scale,” Jain adds.

The CEAT and Michelin projects exemplify this approach, integrating multiple procurement pathways – onsite solar, offsite generation and open-access PPAs – to increase renewable penetration without compromising operational stability.

POLICY VARIABILITY AND MULTI-LOCATION STRATEGIES

India’s regulatory landscape remains heterogeneous, with state-level policies shaping the feasibility and economics of renewable procurement. For tyre manufacturers operating across multiple locations, this creates both complexity and opportunity.

“Overall, the ecosystem is steadily evolving to support higher renewable penetration practically. Open-access mechanisms are becoming more aligned with industrial needs. Renewable procurement is naturally becoming more location-specific,” Jain says.

Different state frameworks enable companies to tailor their energy mix – combining onsite solar with offsite wind or solar depending on regional resource availability and regulatory incentives.

“In practice, this leads to more balanced and resilient energy portfolios. This is also where developers with experience across markets can add value by structuring solutions that are aligned to each site’s load profile, regulatory context and long-term cost objectives, rather than taking a one-size-fits-all approach,” Jain explains.

GLOBAL SUPPLY CHAINS AND RISING EXPECTATIONS

Pressure from global automotive OEMs is accelerating the adoption of renewable energy in India’s tyre sector. As manufacturers integrate more deeply into international supply chains, emissions performance is becoming a criterion for sourcing decisions.

“As tyre manufacturers become more integrated with global OEM supply chains, expectations around emissions are becoming more defined. Renewable electricity is one of the more immediate ways to address this, especially for Scope 2 emissions,” Jain says.

“What we’re seeing is more about alignment – companies are adapting their energy mix to stay relevant in global markets, where sustainability is increasingly part of how sourcing decisions are made,” Jain says.

This dynamic is likely to intensify as OEMs tighten decarbonisation targets and extend accountability across their value chains, reinforcing the role of renewable energy in industrial competitiveness.

THE NEXT FRONTIER: TRACEABILITY AND CARBON MARKETS

As companies move towards net-zero targets, the focus is broadening beyond direct emissions to include value-chain impacts and verification mechanisms.

“Instruments such as renewable energy certificates and carbon markets help companies transparently account for the renewable electricity they procure. At the same time, there is growing focus on Scope 3 reporting as manufacturers work to address emissions across their broader value chains and align with global supply-chain decarbonisation expectations,” Jain says.

Traceability – ensuring that renewable energy claims are verifiable and auditable – is expected to become increasingly important, particularly for export-oriented manufacturers facing stringent disclosure requirements.

A DECADE OUTLOOK: ACHIEVABLE, BUT CONDITIONAL

Looking ahead, Jain is cautiously optimistic about the pace of renewable adoption in India’s tyre manufacturing sector. The fundamentals – declining costs, expanding capacity and supportive policy evolution – are largely in place.

“Over the next decade, higher renewable penetration in tyre manufacturing is well within reach, especially as clean power availability continues to expand. For electricity-led operations, increasing the share of renewable energy is already a practical pathway, not a distant target,” he says.

However, execution will hinge on system-level factors. “What will make the difference is how reliably this power can be integrated at scale – through consistent open-access frameworks, stronger grid alignment, and wider use of hybrid solutions that better match continuous industrial demand,” Jain says.

The trajectory is clear: renewable energy in tyre manufacturing is transitioning from opportunistic adoption to structural integration. For developers such as CleanMax, the challenge – and opportunity – lies in engineering solutions that convert intermittent resources into dependable industrial infrastructure.

Swarnakaruna Princeton Rubber Industries has built capacity to recycle about 96,000 end-of-life tyres annually after government-backed financing helped the Visakhapatnam company transition from processing buffing waste to recycling whole tyres. The recycler is now targeting larger industrial buyers while exploring tyre imports to lower raw-material costs.

India’s push to formalise its end-of-life tyre recycling ecosystem is creating room for smaller recyclers to scale, but access to capital, machinery reliability, raw-material costs and the economics of producing higher-grade crumb rubber remain significant constraints.

Visakhapatnam-based Swarnakaruna Princeton Rubber Industries Private Limited offers a case in point. The company has expanded from a small operation processing buffing powder to a whole-tyre recycling business capable of producing around 300–400 tonnes of crumb rubber a month following financial support channelled through IFCI Venture Capital under a government-backed programme for Scheduled Caste entrepreneurs.

The business traces its roots to 2014, when Managing Director N Swarnalatha established K.S. Princeton Rubber Industries after approaching the District Industries Centre in Visakhapatnam with plans to become an entrepreneur.

The original operation had a single grinder and relied on buffing powder as its principal feedstock because it lacked the equipment required to process complete end-of-life tyres.

“The company started in 2014, but the setup was very minimal. We had just one grinder and were not capable of recycling a whole tyre, so buffing powder was our raw material,” said Swarnakaruna Princeton Rubber Industries Chief Executive Officer Ashish Kumar Isukapati.

That model began changing in 2018 when the company sought funding from IFCI Venture Capital Limited. The proprietorship was subsequently converted into a private limited company as part of the process of securing the investment. Funding was eventually released in stages, with commercial production from the expanded facility beginning in August 2024.

According to Isukapati, the project received about INR 50 million from IFCI Venture Capital, alongside a promoter contribution of INR 17.1 million. The overall project cost was approximately INR 67.21 million.

The money was deployed largely towards machinery and rebuilding and expanding the existing manufacturing premises.

Isukapati said the financing was particularly significant because conventional access to growth capital can prove difficult for first-generation entrepreneurs.

TYRES TO CRUMB

The expanded operation can process roughly 8,000 end-of-life tyres each month, equivalent to around 96,000 tyres annually, according to Isukapati. At the upper end of production, the facility can manufacture around 400 tonnes of crumb rubber a month, while recovered steel accounts for roughly 25 percent of output by weight or around 100 tonnes at that production level.

The company currently sells entirely into the domestic market, with Kerala representing its largest destination. It also supplies TVS Sundaram Industries in Chennai.

However, the economics vary considerably according to crumb size and end application.

More than 70 percent of the company’s current crumb-rubber production goes to non-tyre applications, particularly rubber-mat manufacturers in Kerala. These customers typically consume 20 and 24 mesh material. TVS Sundaram Industries takes roughly 60–80 tonnes a month, with the company supplying 30-mesh crumb rubber.

Tyre-related customers typically require finer grades such as 40, 60 and 80 mesh crumb rubber. The company has pulverising equipment capable of producing material in those ranges, but finer grinding lowers throughput and changes the economics of the operation.

“We are capable of manufacturing the higher meshes, but the overall output comes down. We have to balance which mesh we manufacture against the quantity we can produce because crumb rubber itself is a relatively low-priced product. The way to generate sustainable revenue is through volume,” Isukapati said.

That volume-quality equation has become particularly important as the recycler seeks to tap larger customers closer to its Visakhapatnam plant.

One of its main targets is HINCOL, which Isukapati said operates a facility locally and requires around 500 tonnes of crumb rubber a month. The company has so far been unable to fully address that opportunity because of the combination of volume, quality specifications and tender pricing.

Isukapati sees similar opportunities with buyers across the eastern and southern tyre and rubber manufacturing belt. He estimates that potential demand within roughly 300 kilometres of its operation could exceed 1,000 tonnes a month.

The challenge is converting that proximity into profitable sales.

PORT OPPORTUNITY

The company currently sources a significant portion of its tyres through Andhra Pradesh State Road Transport Corporation auctions. And the company is also seeking a licence to import end-of-life tyres, a move it believes could allow it to leverage its proximity to Visakhapatnam port and reduce feedstock costs.

“We are trying to capitalise on Visakhapatnam port and have applied for an import licence. If that works out, we could spend less on raw material, which would give us an advantage in offering a more competitive price,” Isukapati said.

The company’s expansion has not been without setbacks. Location presents a significant constraint. The facility operates on a plot of about 980 square yards, where incoming tyres, finished crumb rubber and recovered steel all have to be stored and managed. Expanding towards the 500-tonne monthly volumes sought by larger customers could therefore require the company to address its space limitations.

Technical support and spare-part availability are also more difficult in Visakhapatnam than in established manufacturing clusters, Isukapati said.

BIGGER CHALLENGE

Swarnakaruna does not currently operate a dedicated research and development department. Product development and process adjustments are handled by its production manager and technical staff, while third-party laboratories are occasionally used when customers require test reports.

Beyond the company’s own expansion, Isukapati sees feedstock pricing as one of the biggest problems confronting India’s mechanical tyre recyclers.

Waste-tyre prices can rise when pyrolysis operators increase production, but crumb-rubber producers cannot necessarily pass those higher costs to customers because buyers have multiple competing suppliers.

He also called for greater policy attention to the procurement and channelisation of waste tyres, arguing that mechanical recyclers do not necessarily receive a commercial advantage for converting end-of-life tyres into reusable rubber products.

His comments come as India’s tyre-recycling ecosystem adjusts to extended producer responsibility requirements and increasing competition for waste-tyre feedstock.

For the tyre recycler, the next phase will therefore be less about simply adding equipment and more about achieving scale economically. The company is seeking cheaper feedstock, higher production, access to larger nearby customers and potentially a more formal research and development structure.

Recovered steel also remains important to the economics of the operation. Despite the constraints, he sees a sizeable addressable market around the company’s Visakhapatnam base.

“The opportunity is absolutely there. If we can get the right balance between the mesh we manufacture, the quantity we produce and the price, there is a huge opportunity out there,” Isukapati said.

DUNLOP (company name: Sumitomo Rubber Industries) has confirmed that its proprietary SENSING CORE technology has been adopted for medium-duty truck models. The system, designed to detect the conditions of tyres, vehicles and road surfaces, is fitted to Isuzu Motors' FORWARD medium-duty trucks with a gross vehicle weight exceeding 14.5 metric tonnes, which come standard with the Wheel Detachment Prediction Detection System, one of the functions offered by SENSING CORE.

SENSING CORE is a software technology built on expertise gained from the Deflation Warning System, a tyre pressure warning system. It analyses wheel speed data generated by tyre rotation together with controller area network data transmitted through the vehicle's control system, allowing it to detect various tyre and road conditions, including tyre pressure, wear, load and signs of potential wheel detachment. The Wheel Detachment Prediction Detection System in Isuzu's FORWARD models detects loosening of wheel nuts while the vehicle is in motion, alerting the driver through a warning message and buzzer if an abnormality is found.

This capability complements conventional inspections and driver experience and is expected to play a significant role in preventing wheel separation accidents. Isuzu's FORWARD is a medium-duty truck with a broad lineup designed to meet diverse logistics industry needs, and such trucks are widely used in local delivery, long-haul transport and building and construction operations, serving as a vital means of transportation.

Operated across urban areas and major highways, wheel detachment accidents involving these trucks could cause serious harm to third parties such as pedestrians and cyclists, driving growing societal demand for improved safety. Preventing such accidents requires fundamental inspection and maintenance measures, yet drivers find it difficult to detect loosening wheel nuts while driving, making early-detection technologies essential. The provision of the Wheel Detachment Prediction Detection System to medium-duty trucks enables early detection of signs of vehicle malfunctions and contributes to further improving safety and preventing wheel detachment accidents.

SYMX.AI, a developer of artificial intelligence technology for mobile industrial equipment, has raised USD 6 million in Series A financing led by Ascent Capital Partners and agreed a global technology and commercial partnership with Yokohama Off-Highway Tires.

The Canadian company develops software and hardware for mining, construction and forestry operations. Its platform provides connectivity in areas without network coverage, integrates data from equipment made by different manufacturers and supports fleet optimisation.

Its products cover dispatch, fleet management, enterprise asset management and tyre life management, as well as equipment health, fuel consumption, haul road intelligence, inventory and operator performance. The company also holds patents covering its internet of things and AI technologies, including a patent for its “Greenhouse Gas Emissions Data Collection and Cross-Validation System”, granted in 2026.

SYMX.AI has also launched an AI-powered inspection platform and a chatbot for industrial operations.

“Physical AI has been struggling in mining for simple reasons. The machines are mobile, mixed-fleet data is vendor-locked, and most of the industry has limited to no network coverage. Intelligence needs a body and a nervous system before we deploy a model. Even today, assembling that foundation takes seven or eight vendors and up to twelve months. We deliver it in a week. We built the hardware and the connectivity first, which is why our AI layer delivers real results. I am glad that capital is finally flowing to atoms again, and mining will finally get what it has long deserved,” said Ash Agarwal, CEO of SYMX.AI.

Technology tested in mining operations

SYMX.AI said it had validated its technology through projects across the mining value chain. At Glencore's Onaping Depth project in Ontario, Canada, the company demonstrated battery monitoring, short-interval control and fleet optimisation for battery-electric vehicles.

“The problem SYMX.AI solves is foundational,” said Peter Xavier, Chief Operating Officer of Canada Metals, a Glencore company. “Connectivity and cross-OEM data integration at the point of work are infrastructure gaps the mining industry has struggled with for decades, but SYMX.AI changes the paradigm. Our proof-of-concept validation of the SYMX.AI platform on our OEM BEV equipment successfully supports underground short-interval control, battery monitoring and fleet optimization. This level of integration and insight is exactly what the industry needs to move forward.”

Global partnership with Yokohama

Under the partnership, Yokohama Off-Highway Tires will offer the integrated hardware and software platform to customers through its international commercial network. SYMX.AI will supply the internet of things hardware, connectivity, cloud platform and intelligence capabilities.

Customers will be able to adopt the technology as a standalone tyre intelligence solution or as part of a broader fleet optimisation platform.

“The tyre technology market is crowded with TPMS providers, but most systems monitor pressure and temperature while offering little insight beyond those measurements. Operators are asking a more important question: can the same system help us increase production, protect valuable assets such as tires and reduce fuel consumption? SYMX.AI has built a complete platform that addresses this market need by connecting tire condition with equipment performance, haul road conditions and operator behavior. This helps sites reduce costs, extend tire life and improve overall fleet performance,” said Loïc Ravasio, President of Yokohama Off-Highway Tires. “By working with SYMX.AI and offering flexible business models, Yokohama OTR is becoming a true digital partner to the industry, helping customers optimize their operations.”

Expansion and investment

SYMX.AI is expanding its product range with an AI-driven dispatch and fleet management system and an enterprise asset management platform based on live machine sensor data and fault codes.

The asset management system combines equipment health monitoring, diagnostic alarm management, oil analysis and work order management. The company says the system is designed to reduce reliance on fixed maintenance schedules and manual data entry.

Its products integrate with AVEVA Connect, SAP, Oracle and existing data historians, allowing operators to add the technology without replacing their existing systems.

The company said it supported open-pit and underground operations in Kazakhstan, the US, Mexico, Europe and Asia.

“We have watched this team for three years demonstrating grit, perseverance, and commitment. They build things that work in places most software never reaches, and the customers keep renewing worldwide. That is rare in this industry. The comprehensive IoT, connectivity, and AI app layer is deployed at difficult sites, and I’m glad that the market is finally catching up,” said Jonathan Loeffler, Co-Founder and Managing Partner of Ascent Capital Partners.

The financing will support international deployment, development of the AI platform and a broader range of wireless communication products, SYMX.AI said.

Anyline, a global leader in mobile AI and intelligent data capture technology, has rolled out version 1.9 of TireBuddy, featuring a redesigned inspection report that aims to help customers more easily understand the condition of their tyres and place greater trust in technician recommendations. The updated report is intended to make the information gathered during an inspection simpler for customers to digest.

The report presents tread depth, tyre age and estimated braking distance to convey overall tyre health, while make, model, size and seasonal markings identify exactly which tyres are mounted on the vehicle. The new version also allows technicians to attach images of sidewall and rim damage to the report, transparently documenting issues that require attention so customers can have confidence in the recommended work.

Technicians can now record rim and tyre damage, such as scratches on rims and bulges on sidewalls, during the inspection workflow and display it in the report. Photo evidence of rim and sidewall damage can be attached to technician notes and added to the report. A not-roadworthy flag can also be set for a tyre with healthy tread depth but other serious defects, showing in the report as recommended for immediate replacement. All existing and new elements continue to fit on a single page, which can be saved as an image or PDF for sharing with the customer.

The TireBuddy report addresses a critical issue for workshops by ensuring customers fully understand inspection findings. Verbally conveying such information is not always easy, and traditional inspection forms tend to be dense and text-heavy. Everything a technician finds in the bay needs to be detailed in the report the customer sees, which should serve as visual support for service recommendations. With version 1.9, evidence appears alongside the recommendation, and photos of tyre or rim damage are inserted with other tyre information so customers can recognise findings without entering the bay.

Damages are categorised alongside visual evidence, so a bulge is recorded consistently regardless of technician, location or shift, turning individual reports into a comparable record that still captures the state of every tyre on the inspection day. From version 1.9, every report can carry damage, roadworthiness and photo evidence alongside the tread reading. Smaller changes include an optional pair replacement setting that automatically marks the paired tyre on the same axle for replacement when one tyre is not OK, up to 10 custom fields per account in the vehicle identification step for work order or storage numbers and a redesigned vehicle identification screen consistent with the tyre identification screen.

Lukas Kinigadner, CRO, Anyline, “Every replacement recommendation is a request for trust. With 1.9, the technician doesn't have to ask for it. The damage is on the report, photographed, next to the tyre it belongs to.”