Tire Technology Expo 2026 - Zeppelin Systems
14 Feb 2026
Sponsored article:Written by John Eaton, general manager, rubber sales team, Zeppelin Systems GmbH
Next-generation tire manufacturing technology shaping the future of production
At first glance, a tire may appear to be a simple black industrial product. In reality, it is a highly engineered high-tech component.
Modern tires are made from up to 40 different rubber compounds and around 50 raw materials, including natural and synthetic rubber, carbon black, silica, oils, plasticizers, and performance additives.
Increasingly, recycled materials such as recovered carbon black from end-of-life tires and functional liquid rubbers are becoming essential – especially for electric vehicles.
This growing complexity highlights a fundamental shift in tire manufacturing. New vehicle concepts, stricter sustainability regulations, and volatile supply chains are reshaping the industry. Manufacturers must now deliver maximum quality and flexibility while maintaining cost efficiency in an increasingly demanding market.
A Market Under Transformation
The global tire market continues to grow steadily, expanding from approximately USD 143 billion in 2024 to an estimated USD 195 billion by 20331.
Even more dynamic is the market for sustainable “green tires,” which is expected to reach nearly USD 90 billion by 2035, with annual growth rates close to nine percent2. At the same time, global demand for raw materials is rising sharply, with more than 57 million tons forecast for 20253.
While this growth creates opportunities, it also brings significant challenges. E-mobility requires new low-wear rubber compounds with high silica content.
Regulations targeting microplastic emissions and circular economy principles are raising the bar for production processes and recycling solutions.
Meanwhile, fluctuating raw material prices and unstable supply chains are putting pressure on manufacturers’ cost structures. With raw materials already accounting for roughly one-third of total production costs, efficient material handling has become a decisive competitive factor.
The Mixing Room: Where Quality Is Defined
The mixing room is the heart of tire manufacturing. This is where complex recipes must be implemented with absolute precision and reproducibility. Even minor deviations can compromise entire production batches.
Zeppelin Systems focuses on this critical process by providing integrated plant solutions that cover the entire mixing room – from raw material intake and storage to conveying, weighing, dosing, and automation.
Modular silo systems such as the Bolt-Tec concept offer storage capacities of up to 1,000 m³ and can be expanded as required, creating valuable buffers against supply chain disruptions. Specialized pneumatic conveying technologies ensure the gentle transport of sensitive materials like carbon black and silica, minimizing pellet breakage and material loss.
Highly accurate inline and offline dosing systems guarantee that every component is delivered in the exact quantity and at precisely the right time. For liquid additives, dedicated volumetric systems enable the simultaneous and fully automated injection of multiple components. Open automation architectures with track-and-trace functionality ensure full transparency, consistent quality, and seamless recipe changes – even when recycled materials are used.
Sustainability Embedded in Production
Today, efficiency alone is no longer sufficient. Sustainability has become a core requirement in tire manufacturing. Zeppelin Systems therefore integrates recycling processes directly into production operations.
Rubber scrap, filter dust, and other production residues can be reintroduced into the process, while oils can be recycled and reused multiple times at the mixer. Process gases generated during recycling can also be utilized as an energy source.
One particularly innovative solution is the technology for producing CO?-neutral carbon black from end-of-life tires.
Through thermal treatment at temperatures between 350 and 700 °C in an oxygen-free environment, valuable oils and gases are recovered for energy use, while high-quality carbon black is produced for reuse in new tire compounds.
This closed-loop approach conserves resources and significantly reduces emissions.
From Concept to Reality: The Toyo Tires Project
How these technologies perform in practice is demonstrated by the Toyo Tires project in Serbia.
For the Japanese manufacturer’s first European plant, Zeppelin Systems supplied the complete mixing room technology, including seven Bolt-Tec silos, specialized conveying systems for carbon black and silica, precise inline and offline dosing, liquid additive systems, and comprehensive automation.
Since its commissioning in 2023, the plant has been producing three million tires per year – on schedule, with consistent quality and the flexibility to accommodate future material developments.
Conclusion
The tire industry is undergoing a profound transformation. Rising raw material volumes, the shift toward e-mobility, mandatory sustainability targets, and uncertain supply chains are redefining production requirements. To succeed, manufacturers need technology partners who offer integrated, future-ready solutions rather than individual components.
With end-to-end expertise – from raw material handling and mixing room technology to recycling integration, automation, and digital planning – Zeppelin Systems delivers comprehensive solutions designed for both today’s demands and tomorrow’s challenges.
References
¹ Market Data Forecast (2024): Global Tire Market Report 2024–2033, marketdataforecast.com
² Future Market Insights (2025): Green Tires Market Outlook 2025–2035, futuremarketinsights.com
³ Smithers (2025): Performance & Sustainability in Tire Raw Materials, smithers.com
