Emerson, a global automation solution supplier, is known for its solutions that help tyre manufacturers to have efficiency, safety and precise operations in five production areas- mixing equipment, wire and fabric calendars, extruders, tyre building machines, curing presses and finishing process.

Currently, the company is focusing more on solutions for the tyre curing process, which consumes the greatest amount of energy during the tyre production. If tyre curing process does not work correctly, it could also lead to tyre scrap and even breakdown.

“Today, we are focusing on increasing our value as a solution provider to monitor the health and performance of the curing system. Within the curing process, we are not just supplying valves or components, but we also deliver the controller, pneumatic valves and sensors that monitor each step of the process,” said Chris Bart, Director Business Development Automotive & Tire at ‎Emerson Automation Solutions.

According to Bart, the challenge in the tyre curing process is to have precise control on temperature and pressure. With Emerson’s technologies, tyre manufacturers can maximise output and reduce energy and costs through better diagnostics, sensing and monitoring.

 “The main challenge is the management of steam and nitrogen used to heat the mould and bladder pressure.  So, any small deviation in the inputs can have severe negative effects on the quality of the products and overall productivity of the production line or the plant,” explained Bart.

In the tyre curing process, Emerson’s pressure-operated valves work in demanding steam applications and provide reliable and precise control, enabling rapid cycling and tight shut-off to ensure the curing press operates correctly and efficiently.

“Emerson’s valves system controls the movement of the steam and nitrogen into the process. Our valves are critical to supply steam and nitrogen in the proper time with proper temperature and pressure and make sure that there is no leakage during the cycle or between cycles,” explained Bart.

Digitisation helps Emerson’s steam valves to monitor the travelling time of the steam valve and detect anomalies, which ultimately assist in a predictive maintenance programme. “If any deviation happens, the system alerts the maintenance team, and downtime could be avoided,” said Bart.

Traditionally tyre manufacturing companies put a temperature gauge and a pressure gauge to monitor temperature and pressure in the piping system. “Earlier, it was tough to point out the reason for the deviation in temperature and pressure.  We have developed our products that control the steam and nitrogen and also included the sensors that tell the exact position of the valves. So, we can also monitor the leakage of nitrogen, steam and the air we use in operation. It also monitors the air pressure that opens and closes the steam valves. We can monitor the total consumption of the compressed air as well,” said Bart.

“Today’s typical approach to see the only results, but with our system, we are giving is infinite detailed inside the system. This gives customers actionable insights to improve their tyre curing process.”

Emerson, not only provides the solution in the curing but also extends its offering to other components in the system. Historically the steam traps used to be checked manually.

If not work correctly, either a large amount of steam can escape or damage the valves and pipework. Emerson offers wireless acoustic transmitters that monitor steam trap health and detect failures in real-time. “The steam trap monitoring system is one of our biggest innovations in energy-saving efforts. With this, we can avoid damage or loss of steam and improve energy efficiency,” said Bart.

As part of its product development, Emerson regularly visits tyre companies to understand the pain point in the production processes. “Looking at their process and our expertise with the components as a solution supplier, we always look into further potential scope in monitoring, measuring and reporting in the tyre production,” said Bart.

For the mixing process, Emerson offers flow control and pneumatic directional control devices, such as pressure operated valves that optimise the mixing process. At a manufacturing production plant, the mixing is a crucial stage that decides the quality of tyres. All ingredients have to be mixed with accurate weight and in a controlled sequence. Emerson valves keep the weighing and hopper systems running efficiently and reliably while ensuring batch quality.

Emerson, for Fabric/wire calendars and extruder, provides products that increase reliability and material guidance precision of bead wiring and rubber coating, improves pneumatic system performance to avoid premature valve failures and reduces commissioning time through onsite/pre-set tuning. The overall company solution can significantly increase the lifespan of valves by purifying compressed air and regulating pressure and improve safety conditions for your workers by locking systems down during maintenance.

Repeatable, high precision pneumatic directional control ensures the production meets the highest quality specifications every time. Using Emerson’s modular and compact valve manifolds tyre manufacturing companies can achieve greater application flexibility, reduce costs, simplify commissioning, maximise the availability of tyre building machinery and achieve higher throughput targets. Increased visibility into the health of valves also lowers maintenance costs, says the company.

In the finishing process, Emerson’s products ensure precise and reliable motion control and positional accuracy. By offering higher repeatability and reliability, these devices reduce machinery downtime and maximise throughput. Emerson’s ISO and NFPA-conforming actuators and linear-guided cylinders are extremely durable, providing greater test equipment machinery reliability and extended lifespans.

According to Bart, the growing complexity in each process of tyre manufacturing is a challenge. “Complexity in mixing, calendering, tyre building, curing and in the finished products is growing, and it is demanding more control on each process. The evolution of the tyre manufacturing processes requires more insights and integration of process information. This enables continuous quality improvements and energy savings.,” said Bart.

The order book for Curemaster is strong with a surge in orders during the first two months of the year. The executive anticipates continued momentum throughout the year, driven by increasing global demand for advanced, sustainable curing solutions.

FORWARD INTEGRATION

According to Rudman, digitalisation is playing a crucial role in enhancing the efficiency and reliability of curing presses. “Digitalisation provides real-time visibility into production processes, allowing manufacturers to monitor efficiency and product quality continuously. With a clear overview of operations, manufacturers can identify inefficiencies and ensure production targets are met. The HF XPLORE digital portal offers access to critical data at all times. It provides insights into machine health, predictive maintenance alerts and production performance. The system helps track efficiency, detect potential failures and optimise operations by identifying areas for improvement,” he said.

Artificial intelligence is also slated to play a key role in electrical heating, ensuring stable temperature control within the platens. Machine learning is being developed for predictive maintenance, helping to forecast bladder life and detect potential failures before they occur. These technologies are part of the company’s development roadmap, focusing on improving reliability and efficiency in curing press operations.

He also noted that as tyre compounds evolve, curing requirements will change, making electrical curing a more suitable solution. Unlike steam-based systems, where temperature is directly linked to pressure, electrical curing allows independent control of both factors. This flexibility is crucial for processing new materials that may not tolerate traditional curing conditions.

“In steam curing, the relationship between pressure and temperature is fixed. For example, achieving a temperature of 200 degrees Celsius requires increasing the pressure to 20 bar. With electrical curing, temperature and pressure are completely separate, enabling curing at lower temperatures while maintaining the necessary pressure levels. This capability is particularly significant for future materials, which may require curing at 160 degrees Celsius but at much higher pressures,” explained Rudman.

The shift towards electrical curing is expected to gain momentum, particularly for high-end and specialised tyres that demand more advanced curing strategies. While steam curing will continue to be used for lower-segment applications, the upper range of the market, especially where sustainability and material innovations are key factors, will require the precision and adaptability that electrical curing provides.

OVERLAPPING TECHNOLOGIES

There is a clear trend in the market where customers are seeking more customised solutions rather than standard off-the-shelf curing presses. Manufacturers now have unique requirements including features like electrical curing, digitalisation, automated loading and unloading and seamless integration with factory infrastructure and tyre transportation systems. As a result, the demand for tailored solutions is increasing, making flexibility a key factor in the adoption of new curing technologies.

“Curemaster is designed with upgradeability in mind, ensuring that tyre manufacturers do not have to replace entire presses when looking to modernise operations. Even older HF curing presses that have been in service for more than 20 years can be upgraded to electrical curing without altering the mechanical structure. This allows manufacturers to transition to more efficient curing technology while retaining the existing equipment. At the same time, the new Curemaster is available as a fully electric system from the outset, offering a ready-made solution for greenfield projects,” averred Rudman.

Nonetheless, the biggest business potential currently lies in retrofitting existing curing presses rather than selling entirely new equipment. “Many customers prefer upgrade kits that allow them to transition to electrical curing while maintaining current production setup. While greenfield projects present a significant opportunity for new fully electric presses, the greater demand at present is for retrofit solutions, as it provides a cost-effective way to improve efficiency and sustainability without major infrastructure changes,” he added.

PROCESS OVERVIEW

Most curing press suppliers have introduced electrical curing solutions. There are two main approaches to electrical heating, which are electromagnetic (induction) heating and resistive heating.

Electromagnetic heating method involves placing a coil outside the tyre to generate heat. However, there are concerns about how this method interacts with the tyre’s internal bead wire and breaker package. Since the long-term impact of electromagnetic fields on tyre integrity has not been fully tested or verified, there are still some uncertainties regarding its effects on tyre quality.

In contrast, resistive heating, which the company employs, places coils directly inside the plate, ensuring controlled and targeted heating. This method eliminates any risk associated with electromagnetic interference and allows precise temperature application only where needed. While both technologies are viable, resistive heating offers greater reliability and consistency in maintaining tyre quality.

“One of the key advantages of electrical curing is its rapid heating and cooling capabilities. The nitrogen used in the process can be heated from 20 degrees Celsius to 250 degrees Celsius in less than 20 seconds and cooled back down in the same time frame. This is achieved through continuous nitrogen circulation, where the system directs the flow through either the heater or the cooler as needed. In terms of curing time, electrical heating currently matches steam curing with a typical cycle of 10 minutes per tyre. However, there is significant potential to reduce curing time by 10 to 15 percent as electrical systems can operate at higher temperatures and offer more precise control over the process,” informed Rudman.

Nonetheless, steam curing has a predominant risk of mishaps in the bladder, which could lead to an explosion. The Curemaster is designed with a fully encapsulated dome, ensuring that any pressure build-up remains contained. If a failure occurs, the pressure is released downward instead of sideways, reducing the risk of injury.

The locking system is also unique. Even if there is a total power or hydraulic pressure loss, the press cannot open unintentionally. This containment and locking mechanism ensure a high level of safety during operation.

CHALLENGES AND OPPORTUNITIES

According to the executive, the biggest challenge in the curing press business comes from cost competition as lower-cost manufacturers pose a significant pricing challenge. However, from a technological standpoint, the company offers unique features that set it apart from competitors. While competitors may have cost advantages, HF’s focus on advanced technology, automation and digitalisation allows it to capture market share by offering superior functionality and efficiency.

The passenger car and truck segments remain the company’s primary focus owing to the highest growth potential. Additionally, the company sees an emerging opportunity in motorcycle and bicycle tyre curing, particularly with electric heating technology. HF is among the first to introduce electrical curing for these segments, positioning itself as an industry leader.

While HF is active in the passenger and truck segments, it has opted not to enter the off-the-road tyre market due to its relatively small size and intense competition. The segment still relies heavily on traditional mechanical presses, making it less attractive for innovation-driven solutions.

The company continues to refine the Curemaster lineup by introducing new materials, insulation techniques and design concepts. The company is particularly focused on increasing automation to enhance efficiency and reduce operational costs.

Beontag, one of the world’s largest manufacturers of self-adhesives and smart tags such as RFID, NFC and BLE, has entered into a collaboration with Kumho Tire to develop RFID-enabled tyres for commercial and passenger vehicles.

The partnership will see new Kumho tyres use Beontag's TyreTag RFID technology. Traceability will be possible with the RFID-enabled tyres from the point of origin to recycling and disposal. Following years of research and development, according to both the companies, the new RFID-enabled tyre is very robust and dependable, able to survive high temperatures and pressures over the course of years of intensive use. The new TyreTag-enabled tyres' traceability will also adhere to the forthcoming Ecodesign for Sustainable Product Regulations (ESPR), which will need Digital Product Passports (DPPs) and be in force for tyres starting in 2028–2030.

Thiago Horta, Global VP of Digital Transformation, Beontag, said, “We are extremely proud to share what we have achieved in our partnership with Kumho Tire. Through rigorous testing, we have worked hard to develop the necessary technology and durability capabilities in these RFID-enabled tyres; I look forward to continuing this journey with Kumho Tire for years to come”

Jihon Park, Assistant Manager with Kumho Tire, said, “Kumho Tire has been producing RFID-enabled tyres since 2013. Beontag’s technical expertise and collaborative approach were instrumental in helping us meet our rigorous standards and enhance our technology. We look forward to delivering even greater quality and reliability to our customers around the world.”

Goodyear has launched the Value Simulator, an online tool designed to assist fleet operators in visualising the possible financial and environmental advantages of upgrading their mobility and tyre solutions. The simulator is now available on the company's truck tyre website and is a component of Goodyear Total Mobility, the company's end-to-end solution for commercial fleets.

According to Goodyear, the tool takes into account typical fuel consumption and cost, fleet size and breakdown frequency, vehicle mileage and maintenance trends and the kind of transportation and route profile. After data is entered, the simulator instantly estimates the potential decrease of CO2 emissions, maintenance and fuel costs, and annual breakdown-related cost savings. Additionally, customers can customise simulations according to their own fleet characteristics.

The CO₂ reductions are based on theoretical fuel usage using EU tyre label values as a baseline; real savings may vary depending on factors including driver behaviour, vehicle condition and road conditions. Additionally, based on user interaction, the simulator suggests appropriate Goodyear goods and services. These recommendations can be used as a springboard for talks with Goodyear's staff in order to do a more thorough study and develop a customised fleet plan.

Maciej Szymański, Marketing Director Commercial at Goodyear EMEA, said, “At Goodyear, we are committed to supporting transport fleets in maximising efficiency, increasing competitiveness and promoting sustainability. The Goodyear Value Simulator confirms our dedication to customer-centric solutions and helps fleet managers to make informed decisions that aim to drive tangible benefits for their operations. With the Goodyear Value Simulator, fleets can visualise the potential financial and environmental impact of adopting Goodyear Total Mobility. From reducing breakdown costs to enhancing fuel efficiency, our solutions are designed to deliver real value to our customers.”

Webfleet, Bridgestone’s globally trusted fleet management solution, has launched its new flagship Driver Terminal, the PRO X, designed specifically for truck and van fleets.

By providing direct tablet access to Webfleet fleet management services, the PRO X links drivers and companies to streamline work administration. Fleets can utilise a variety of sophisticated Webfleet features, such as workflow management, electronic Proof of Delivery (ePOD) and two-way communication between drivers and fleet managers thanks to the pre-installed Webfleet Work App. They can also access other Webfleet services, such as Cold Chain, Remaining Drive Times and OptiDrive ranking, which allows drivers to view peer performance.

Van and truck fleets may enjoy the best-in-class professional navigation with the newest technology, like smart warnings for traffic or low-emission zones, major points of interest for trucks and EVs and live ETA reporting, with easy access to TomTom GO Fleet.  Additionally, when paired with OptiDrive, the motorist gets immediate feedback to help them drive better. Pre-installing maps is now simple, and they are updated automatically every month. With its wide anti-glare screen, sturdy construction, detachable battery and user-friendly controls for instant access to essential programmes, the new high-performance Driver Terminal helps professional drivers both in-cabin and on-site.

With an integrated Mobile Device Management (MDM) system that enables fully remote management of the devices' home screen, app auto-start and other features, it is configured for a quick roll-out in the field and can be tailored to fit various corporate demands. Because it is Android Enterprise Recommended and integrates Webfleet's and TomTom's expertise in sophisticated navigation, devices may be more rapidly customised to meet user demands. Beginning in March 2025, the PRO X will be sold in Europe, Australia and New Zealand, with other territories to follow later this year.

Annick Renoux, Vice President, Webfleet Europe, said, “At Webfleet, we are always committed to delivering smart solutions that enhance the working conditions and safety of our customers and their drivers, powered by the latest technology. That’s why we are proud to introduce the new PRO X – now with even more functionality to help fleet managers streamline their operations, boost efficiency and strengthen their connection with field teams like never before.”