HF Group’s upcoming range of digital solutions will monitor several parameters in the curing process, like cycle times, movements of the machines etc. One of the exhibitors at the Tire Technology Expo, 2022 that was held in Hannover, Germany was HF Group. Dr Bernd Pape, Digital Solutions, HF Group, threw light on the company’s plans to develop a new product line that will enable its customers to digitally monitor tyre curing machines more effectively, the significance of sharing data and having trusted partnerships.

The global tyre industry is steering more towards digitisation to ensure precision and save production time. And in this effort, HF Group seems to be the frontrunner, banking on data warehousing to produce effective monitoring solutions for tyre curing.

“HF is known as a company constantly extending traditional machine solutions. However, we are very well aware of digitisation, and the solutions will change our previous way of doing business at a global level,” said Dr Bernd Pape, Digital Solutions, HF Group, while we interacted with him at the latest edition of the Tire Technology Expo held this year in Hannover, Germany.

“I joined HF last year in June to build up a new product segment. However, due to the pandemic, I had limited chances to visit customers or talk to potential partners for development, and this conference has been an optimum opportunity to perceive an overview of our industry,” Dr Pape mentioned while he talked about the expo.

Digital solutions
HF’s upcoming range of digital solutions will monitor several parameters in the curing process, like cycle times, movements of machines etc. It will then churn out the alarm messages of the machines and correlate them to identify discrepancies. The new-age solutions will monitor machine data at different stages and have communication modules that will share the data from the machine control software to the internet using IoT gateways.

Extra sensors will be placed on the machines to measure certain component parameters like pressure, temperature, energy consumption etc. Leveraging the combination of cycle time monitoring, alarm messages and specific measurements of the sensor technology, the data will be analysed to bring out in-depth information about the machines’ performance.

Answering whether the sensors are capable of identifying the problems, Dr Pape informed, “In order for them to work efficiently to identify problems, we need quite some data. And when we have that data, we can do two things – analyse that data and see if insights can be derived automatically, or work with experts to derive insights and then transfer the knowledge into the digital solutions. He further added, “The entire research and development process demands a lot of communication and learning together with pilot customers, too.”

It’s important to share data
Initially, HF plans to implement the solution in their own curing press and further develop solutions for other machines. “We may need cooperation from customers to better understand other machines or even the OEM of that specific machine. If you look into digital transformation, it’s all about partnership. And if you don’t share data, you will not be able to flourish. And so far, my gut has been that our industry still has room to improve. We can still learn from each other by sharing data. With every new machine, we will have a growing database and knowledge on how to improve production,” Dr Pape asserted.

Digital benefit
HF strives to keep the cycle time of a machine at a constant low level. The curing process for one tyre may take 14 minutes. With the solutions, it can be reduced by 10 to 20 seconds. This would add up for the customer to produce roughly between 500 and 1,500 tyres per press per year, informed Dr Pape. Moreover, the solutions will enhance machine availability by detecting warnings for errors or repair time.

Trusted partnerships
The new solutions will require huge amounts of data to effectively do its task, but protection of proprietary data is a major concern. Speaking in this context, Dr Pape cited, “Digital transformation is about partnership, and you need to share data. So, partnership is all about trust. You need an initial amount of trust to provide data. There is no way around that.”

“On the other hand, once you give me the data, it is on me to keep it carefully and not to share it,” he further averred and went on, “Because if I do not comply, then the alliance will be harmed. So, there is a great opportunity because we are a long-standing partner for the whole industry. Therefore, we have trusted partnerships and projects with a lot of customers.”

Explaining the timeline from implementation to resumption of services, the executive said, “Once we are up and running with this solution, we just need a couple of days to implement it. But for new machine types that have not been analysed before, a couple of weeks are needed. Once knowledge of the specific machine type, how to adjust the software and how to analyse and interpret the data is known, we can configure same machine types within days.”

Current monitoring landscape
According to the executive, currently technicians might face severe problems while monitoring the machines as the industry has witnessed a generation shift. Experienced technicians retire and new ones have to learn the entire process. With the automation of unloading and loading systems, which are getting more and more automated, there might be no operators available who can point out if the machines have any problems.

“If we get the data from the machine and analyse it, we can redirect technicians to the area that causes the problem, so that they are faster in remedying it. The data will also help us to predict problems in the near future,” Dr Pape pointed out.

Stepping into the Indian market
HF has expanded its footprint across the globe and wants to market its products worldwide. The company’s pilot customers are in the Americas, followed by Europe. It also plans to tap into the Asian market.

Speaking on its plans to enter India, Dr Pape cited, “The country has great companies and some of them might be interested in the solutions. For building up a new product segment in India, we have to know what kind of customers are interested. We will then start operations on a remote basis and develop further.”

Collaborations for the long term
HF Group has also collaborated with Possehl Analytics as its solutions partner, which will also allow it to build a network for digital solutions in the industry. On the reference side, HF refers them as their solutions partner, while Possehl Analytics refers HF as a good operations partner.

Change is the only constant
While the tyre industry itself isn’t one that changes every day, we know that digitisation will have a pivotal role in its growth, including the tyre curing process, making sure the final product is of high quality. At the same time, sharing data and making long-lasting partnerships will only make the process and final outcome more competent.

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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.

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Wallace Instruments, a globally recognised leader in rubber testing equipment, has expanded its United Kingdom-manufactured specimen preparation lineup with the launch of the WAS3 Pneumatic Cutting Press. The new device joins the company’s range of rubber testing equipment.

Unlike manual cutting methods, pneumatic systems apply consistent force on every cycle, eliminating operator fatigue and variability. Poorly prepared specimens with uneven edges or internal stress can compromise test accuracy, while the pneumatic approach also reduces repetitive physical strain, supporting technician wellbeing during long production runs.

The WAS3 prioritises safe single-operator use through a two-button activation system requiring both buttons to be pressed within half a second, preventing any hand contact with the cutting area. Additional three-sided protective guards further enhance operational safety.

Delivering 15 kN of cutting force, the press easily cuts through 10-mm thick, 95 Shore A rubber sheet using five bar of filtered air pressure. It works with existing Wallace cutting dies, so laboratories can integrate the unit without replacing current tooling, and its compact footprint suits both lab and production environments.

Chris Norval, Managing Director, Wallace Instruments, said, "Specimen preparation is the foundation of accurate rubber testing. With the WAS3, we focused on practical safety, dependable cutting performance and drop-in compatibility. Labs get a compact pneumatic press that fits the air lines already in place, uses their current Wallace dies and delivers consistent results for every operator – because when specimen quality is controlled, you can have confidence in the results that follow."

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DUNLOP (company name: Sumitomo Rubber Industries, Ltd.) has teamed up with Fujitsu Limited to create an artificial intelligence (AI) surrogate model that predicts tyre performance rapidly and with high precision. The breakthrough was validated in a proof of concept tied to DUNLOP’s digital transformation strategy. When applied to tyre deformation upon road contact, the technology slashed analysis time by 90 percent, from 45 minutes to just 5 minutes while processing nearly 600,000 mesh elements.

Based on these results, both firms will build a design support tool, aiming for deployment at DUNLOP by April 2027. The system runs on FUJITSU MONAKA, a next-generation energy efficient Arm-based CPU.

Tyre design typically relies on finite element method (FEM) analysis, where finer mesh grids boost accuracy but increase calculation time and costs. To tackle this, the partners developed an AI surrogate model that solves FEM equations using past data. The model, based on the Graph Neural Network algorithm, predicted contact shape with 87.7 percent accuracy, enabling faster decisions and lower costs.

Select findings will be shared at the 31st Computational Engineering Conference starting 3 June 2026. By December 2026, both companies will test the model on a FUJITSU MONAKA prototype to refine speed and power use.

Under its long-term strategy R.I.S.E. 2035, DUNLOP seeks to provide new experiential value from rubber. Through this co creation, the tyre maker will enhance its analytical technologies and strengthen innovation. Fujitsu will promote this approach across large scale FEM analysis in automotive and other manufacturing sectors, contributing to carbon neutrality via an AI platform combining FUJITSU MONAKA and GNN.

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Starrett-Bytewise has appointed GL Inspect GmbH as its new European sales representative. The German firm, led by Christian Lantzsch and based in Hargesheim, will oversee regional operations. The partnership aims to provide local expertise for demanding measurement challenges across tyre plants, steel mills and extrusion lines.

Lantzsch and the GL Inspect team bring a sophisticated understanding of non-contact metrology. Their technical background aligns with the diverse industrial sectors served by Starrett-Bytewise, ensuring that European customers receive support tailored to specific materials and production environments. The collaboration strengthens local technical knowledge and on-site application assistance.

Under this agreement, European customers gain direct access to local consultations and expanded on-site evaluations led by Lantzsch’s team. Laser measurement solutions can be better integrated into individual production lines. The partnership also streamlines communication and support, building on existing European infrastructure to enable seamless transitions to automated in-line inspection.

The appointment represents a significant investment in European infrastructure. Having GL Inspect on the ground shortens the distance between Starrett-Bytewise’s U.S. engineering team and local factory floors. Faster application assessments, more frequent site visits and industry-specific language support are key outcomes of the new arrangement.

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