Jeremias Neuhaus: “One of the biggest challenges in adopting data-driven solutions in the tyre industry is the availability of data and convincing customers not just of the solution itself but of the value of data transfer and real-time monitoring."

The tyre industry faces a significant challenge in data availability with fragmented supply chains, a lack of standardisation and minimal digital infrastructure limiting operational efficiency. Despite the growing importance of predictive maintenance, many manufacturers still rely on manual processes, while competitive concerns and regulatory restrictions further restrict data sharing. This absence of real-time insights hampers decision-making, making operations reactive rather than proactive. However, digitalisation and advanced data analytics are gradually reshaping the landscape. Solutions like HF Xplore aim to bridge this gap, offering real-time monitoring and predictive capabilities that can drive efficiency, sustainability and cost reduction.

Data availability is a challenge in the tyre industry due to fragmented supply chains, lack of standardisation and limited digital infrastructure. Manufacturers, distributors and recyclers operate in silos, making data consolidation difficult. Many businesses still rely on manual processes, while competitive concerns and regulatory restrictions further limit data sharing. Tracking end-of-life tyres (ELTs) is particularly challenging, impacting recycling efficiency.  

However, data availability is crucial for optimising operations, sustainability and innovation. Real-time data enables predictive maintenance, helping fleet operators reduce downtime and improve safety.

Accurate tracking of tyre usage and recycling supports circular economy initiatives and regulatory compliance. It also enhances research and development initiatives for advanced tyre materials such as electric vehicles and off-the-road (OTR) tyres, ensuring better performance and durability.

Improved data transparency can drive smarter decision-making, cost efficiency and sustainability in the industry. Digitalisation and data standardisation are key to overcoming these challenges.

However, HF Group’s Global Head of Digital Solutions, Jeremias Neuhaus, told Tyre Trends, “One of the biggest challenges in adopting data-driven solutions in the tyre industry is the availability of data and convincing customers not just of the solution itself but of the value of data transfer and real-time monitoring. Many decisions in the industry are still based on gut feeling rather than data-backed insights. Our focus is to bridge this gap by providing transparency into machine performance, enabling customers to make data-driven decisions instead of relying on intuition. By implementing real-time monitoring, we can significantly reduce downtime and help customers optimise processes. Even in the first step of implementation, simply visualising machine health and performance brings immediate value. Customers receive notifications for potential issues, allowing them to take preventive action before costly breakdowns occur.”

“The biggest opportunity in this space lies in the fact that data-driven insights can drastically improve operational efficiency. Once machines are connected and data is flowing, customers gain a much deeper understanding of the equipment, leading to better decision-making and optimised production cycles. Predictive maintenance and AI-driven analytics will further enhance operations by identifying potential failures before they occur. This is particularly crucial as manufacturers aim to reduce carbon emissions and energy consumption while increasing efficiency. Our approach stepwise towards AI-powered predictive solutions bring even greater efficiency and cost savings,” he added.

A critical concern in the tyre industry is data security and confidentiality, given how secretive manufacturers are about the respective production processes. “We address these concerns by focusing strictly on machine data rather than the proprietary tyre-making process. Our solutions do not need the actual process details to provide valuable insights. Additionally, the real, detailed data remains visible only to the customer, ensuring that they retain full control. In cases where AI-driven analytics are implemented, we collaborate closely with customers to develop models tailored to specific needs without compromising sensitive production data,” revealed Neuhaus.

The company launched the HF Xplore few years ago as a condition monitoring solution purely for curing presses. One of the significant developments following the merger of HF Mixing Group and HF Tire Tech Group has been the integration of previous initiatives into a joint project, creating a common condition monitoring solution. As a result, HF Xplore is now available for both curing presses and mixer lines. This expansion allows the company to offer real-time monitoring and predictive insights across two of the most critical processes in tyre manufacturing curing and mixing.

MONITORING TYRE FORMULATIONS

Curing and mixing are fundamentally different processes in tyre making, which presents a challenge in making HF Xplore compatible with both. The solution is to split monitoring into two layers viz-a-viz a common monitoring framework and machine-specific components.

The common framework includes monitoring cycle times, alarms, key performance indicators (KPIs) and production progress – elements that apply to both curing presses and mixer lines. However, each machine type has unique components that require dedicated monitoring.

For curing presses, especially electric-curing, HF Xplore focuses on monitoring hydraulic power unit and the electric curing, which is a crucial aspect of efficiency and quality control. On the other hand, for mixers, the system focuses on critical mechanical components such as the RAM movement, feeding mechanisms and drop doors, which are key areas that directly impact mixing performance and consistency. The drop doors, for instance, play a crucial role   in ensuring a smooth transition of rubber to the downstream process, making their monitoring essential for operational reliability.

The user interface of HF Xplore is designed to maintain familiarity across different machines. The dashboard layout remains consistent, so users who are accustomed to using it for curing presses will find a similar experience when working with mixer lines. This consistency reduces the learning curve and makes the system more intuitive for users handling both curing and mixing equipment.

Behind the scenes, the company is investing heavily in data modelling to refine and improve predictive capabilities. The company is developing individualised, flexible data models tailored to each machine type.

These models analyse operational patterns, detect anomalies and provide real-time insights to minimise downtime. By combining machine-specific expertise with data-driven intelligence, HF Xplore continues to evolve into a powerful predictive maintenance and performance optimisation tool for the tyre manufacturing industry.

INTO DATA MODELS

HF Xplore captures machine data but doesn’t analyse it directly. Instead, the system applies background logic to determine whether values are within acceptable limits. Currently, its primary function is real-time status monitoring, giving users an overview of machine condition. However, future iterations will introduce predictive maintenance capabilities, allowing companies to anticipate and address potential failures before they happen.

“At this stage, HF Xplore detects and predicts issues but does not provide specific solutions. As the technology evolves, it will go beyond identifying potential failures to offering actionable recommendations. This shift will help businesses move from reactive maintenance to a more proactive approach, reducing downtime and improving operational efficiency. To refine predictive maintenance, the system is being trained with large datasets in collaboration with customers. Over time, this will enhance the system’s accuracy, enabling it to not only flag potential issues but also suggest corrective actions,” informed Neuhaus.

AI and machine learning will play a central role in the company’s future roadmap, following a structured three-step approach – visualise, analyse and predict.

The first step will provide real-time machine status and process transparency. In the analyse phase, the company’s solutions will move beyond monitoring to offer deeper insights. The system will evaluate performance trends, identify operational limits and provide status feedback. The final phase will be where AI and machine learning take centre stage by analysing vast amounts of historical and real-time data. AI models will identify patterns, forecast failures and recommend preventive actions.

Commenting on whether implementing HF Xplore for a curing press or a mixing system presents different challenges, he said, “While both require detailed monitoring, mixing systems are more complex due to the interconnected components including upstream and downstream processes. Unlike curing presses, which operate as standalone units, mixing lines require data collection across multiple machines for effective monitoring. However, HF Xplore benefits from deep integration with its own equipment, leveraging PLC data to ensure seamless functionality across different systems.”

But for this to be a reality, different data models are pivotal. “The data model is essential for structuring and standardising the information displayed on the dashboard,” informed Neuhaus.

RETROFITTING HF XPLORE

HF Xplore is compatible with both greenfield and brownfield machines, though older models with outdated PLCs may have limitations. “While we cannot retrofit machines that are using old automation solutions, HF Xplore can be integrated into machines from the past few years, especially for condition monitoring. With electric-curing, it also enables precise tracking of electric curing performance, enabling deeper insights,” informed Neuhaus.

“One key challenge is data governance and security. Traditionally, machine data remained within the plant, but HF Xplore connects operational technology with information technology, raising concerns about data ownership and security. To address this, we have implemented user-based access controls, IP-based security and data encryption,” informed the executive.

For tyre plants with a mix of HF and non-HF machines, HF Xplore offers a custom dashboard creator with low-code functionality, allowing users to integrate and visualise data from different machines in just a few hours. A flexible data model further ensures standardised visualisation, even when machine types vary. While full integration with non-HF machines may require additional work, HF Xplore provides a comprehensive plant-wide monitoring solution for optimising performance.

“HF Xplore can potentially integrate with machines from other companies, but it depends on data accessibility and PLC compatibility”, contended Neuhaus, who highlighted the flexibility and modularity of their solution. 

United States-based Aperia Technologies has launched ‘Nearby Issues’, a new feature on its Halo Connect platform to further enhance fleet tyre safety.

The addition, which is now available in the Halo Tech App, uses a technician’s real-time location to display trucks nearby that have tyre issues.

The company is a leading provider of tyre management technology, which focuses on providing solutions to maintain optimal tyre pressure for vehicles. It addresses the issue of tyre under-inflation, initially for the commercial trucking industry, but its expertise now extends to various vehicle architectures and markets.

Aperia's main products and services revolve around its 'Halo Tire Management Platform', which combines automatic inflation with predictive maintenance.

This new capability allows technicians, whether at a yard or on the road, to pinpoint the specific vehicles and tyres needing attention, proceed directly to the truck and resolve the issues immediately. While technicians already access tyre issue information through Halo Connect, Nearby Issues converts insight into instant, location-based action, enhancing convenience and efficiency.

Ralph Dimenna, CCO, Aperia Technologies, said, "Technicians don’t need more alerts; they need the right insights at the right time. Nearby Issues gives them a faster, smarter way to prioritise and resolve tire problems based on where they are, closing the gap between knowing an issue exists and getting it fixed."

With the new feature, technicians can:

• See What’s Nearby: View vehicles nearby that have tyre issues instantly.
• Prioritise for Action: Access a ranked list of trucks based on issue severity and count, enabling decision-making.
• Access Live Tyre Data: Connect over Bluetooth to view real-time tyre pressures and confirm that repairs are complete.
• Gain Full Transparency: Review detailed issue data, tyre health history and the vehicle’s exact location.
• Navigate with Ease: Use an interactive map with GPS positioning and severity-based colour coding.
• Stay Secure: Rely on controlled access available only to authenticated users physically near the vehicle.

Aperia Technologies stated that adding Nearby Issues to the Halo Connect platform via the Halo Tech App continues its aim to help fleets stay proactive, cut maintenance costs and maximise vehicle uptime.

Fornnax Technology Pvt Ltd has introduced the R-MAX3300, a new secondary shredder presented as the largest in its category. The official launch occurred on 14 October 2025 at the prominent IFAT India environmental technology exhibition in Mumbai. The unveiling ceremony was a significant industry event, attended by numerous leaders from the cement and waste management sectors. Key figures present included executives from GEPIL India, Zigma Global, Prism Johnson Ltd, Shree Cement Ltd and Mangalam Cement Ltd.

This shredder is positioned as a major technological advancement for India's recycling and waste processing infrastructure. It is designed to provide a powerful solution for Cement Alternative Fuel and Resource plants as well as waste-to-energy facilities. While the established R Series shredders are known for processing high-density materials such as tyres and cables, the R-MAX3300 is specifically engineered for low-density waste streams. These targeted materials include Municipal Solid Waste, Commercial and Industrial waste, Construction and Demolition debris, bulky items, legacy waste dumps and wood waste.

The machine integrates advanced shredding technology to efficiently produce Refuse Derived Fuel and Solid Recovered Fuel, achieving an optimal output particle size between 30 and 50 millimetres. Its construction emphasises durability, operational versatility and high performance to meet the demands of large-scale industrial applications requiring consistent fuel quality.

The R-MAX3300 is built for high-volume processing of pre-shredded or coarse materials. Its applications are expected to be crucial in producing solid recovered fuel, preparing waste for composting and reducing waste volume for more cost-effective transportation. The shredder is anticipated to be a key asset in Integrated Waste Management Projects and bio-mining operations across India and international markets.

Jignesh Kundaria, Director and CEO, Fornnax Technology, said, “The R-MAX3300 represents a monumental leap forward in our vision to become a global leader by 2030 in recycling technology through innovation. With the rising challenges of waste management in India and globally, this machine is not just a product; it’s a powerful tool for change. We engineered it to handle the most difficult waste streams with unparalleled efficiency, turning what was once considered unusable waste into a valuable resource. It directly addresses the urgent demand for effective, large-scale shredding technology that can support cement kilns and waste-to-energy facilities in achieving the desired output. Our commitment goes beyond just selling machinery; it's about empowering our customers to achieve lasting efficiency, sustainability and growth. We see ourselves as a trusted partner who stands beside them at every step – from technology deployment to ongoing support, ensuring they can rely on Fornnax not only for performance but also for consistency, dependability and long-term value.”

A new collaborative development from rFpro and Siemens Digital Industries Software (Siemens) introduces a significant advancement in simulation technology. This innovation seamlessly connects Siemens' Simcenter Tire software with rFpro's TerrainServer platform, which creates highly precise, millimetre-accurate digital replicas of real-world road surfaces. Through this integration, the sophisticated MF-Tyre and MF-Swift models within Simcenter can directly access and process the detailed terrain data. This allows for the calculation of highly realistic tyre forces and moments, which is a critical factor for virtual testing in both the automotive and motorsport industries.

The partnership was built on ensuring the solution's reliability across diverse applications, from desktop engineering to cloud-based and real-time simulator environments. This development reinforces rFpro's commitment to an open and agnostic simulation platform, providing users with the flexibility to select their preferred models and tools. This strategy of integrating best-in-class third-party technologies protects customer investments and increases their return, as digital assets can be utilised across different departments with varying modelling requirements.

The combined power of TerrainServer's high-fidelity road models and Simcenter Tire's advanced modelling enables engineers to conduct in-depth evaluations of vehicle dynamics, including handling, ride quality and grip. Performance can be assessed objectively through data and subjectively using driver-in-the-loop simulators. This comprehensive approach allows for a more informed development process, leading to better-validated designs before physical prototypes are built, thereby saving substantial time and cost. The new interface is now commercially available and is already being widely adopted by OEMs and Tier 1 suppliers globally for programmes focused on ride comfort and vehicle dynamics.

Nick Harrison, Development Director, rFpro, said, “We aim to be the most open simulation environment on the market and this integration is another key example of this. Our platform-agnostic approach means engineers can pick and choose the best tools for the job. They have the ability to combine specialised technologies from different vendors to create the most effective simulation solution for their particular development challenge.”

Willem Versteden, Senior Technical Product Manager, Siemens Digital Industries Software, said, “Tyre behaviour depends heavily on the surface it’s interacting with. By integrating our Simcenter Tire software with rFpro’s TerrainServer, engineers can now simulate that interaction with a much higher level of detail. It’s a valuable step forward for users demanding greater accuracy in virtual vehicle development.”

A groundbreaking collaboration between technology giant Continental and kitchen manufacturer nobilia is presenting a new vision for the kitchen, transforming it from a utilitarian space into an intelligent and responsive living environment. This joint innovation project, set to debut at nobilia’s international exhibition in Verl, harnesses the material science expertise of Continental’s ContiTech group, drawing directly from its advanced work in automotive interiors.

The concept, titled ‘Evolution of Senses’, showcases how functional materials can redefine everyday experiences through comfort, safety and seamless design. The core of this innovation lies in revolutionary translucent surfaces. These specialised materials are light-permeable and serve as a host for printed electronics, enabling an array of hidden functions. This technology allows a kitchen countertop to discreetly incorporate wireless smartphone charging, create specific heating or cooling zones to keep food and drinks at their ideal temperature and feature touch-sensitive control panels. All these elements remain completely invisible when not in use, preserving a clean aesthetic. This principle of surface technology is also demonstrated in a kitchen niche, where a screen is hidden behind a translucent film with a wood-like finish, only appearing when activated.

The commitment to modern living extends to sustainability, with the use of durable and resource-efficient materials. The chairs, for instance, are upholstered in an artificial leather that is composed of over 90 percent bio-based and renewable raw materials, including organically grown cotton.

Further enhancing the kitchen's intelligence are smart AI features, engineered by AUMOVIO Engineering Solutions. Adapted from Continental's automotive technology, these systems can recognise food items, offer recipe recommendations and provide nutritional insights. They also contribute to family safety by issuing alerts for potential hazards like boiling water or objects that might be dangerous for children.

While some of these technologies are production-ready and others are still in the prototype stage, they collectively offer a concrete and exciting preview of the future, where the home environment is both intuitively connected and sustainably crafted.

Ralf Imbery, Head of Design, Marketing and Strategy for Continental’s global surface materials business, said, “For many decades, our materials and technologies have shaped modern living spaces – from vehicle interiors to home furniture. With this concept kitchen, we’re showing how our expertise can be transferred to new requirements: for greater functionality, user-oriented design and technology in everyday life. For us, cooperation projects of this kind are an important strategic tool that allow us to test innovations at an early stage and, together with partners, develop new perspectives for future living environments.”

Florian Degenhardt, Head of Innovation, nobilia, said, “The collaboration with Continental is a real game-changer. It enables us to create intuitive surfaces that respond to the user while at the same time preserving the elegant design of modern kitchens.”