India: How AI is improving tyre production at Apollo Tyres
13 November 2026
Less rework, shorter set-up times: Tyre manufacturer Apollo Tyres is using artificial intelligence to make its production more efficient. The technology automatically adjusts machines during rubber processing – particularly when a new material compound is used.
At a glance
According to Apollo Tyres and its technology partner AWS, the system achieves the following improvements:
- around 26% less rework during the start-up phase
- around 40% shorter stabilisation time until production is running smoothly
The benefits: Less material needs to be reprocessed, the plant can return to regular production more quickly, and additional labour and energy can be saved.
When a new formulation slows down production
Car tyres consist of various components, such as the tread and the sidewalls. Different rubber compounds are processed in their manufacture. A machine presses the material through a specially shaped opening. This produces long strips of rubber, which are later processed into tyres. This process is called extrusion.
When a new rubber compound is used, the machine must be adjusted accordingly. This is because some compounds are, for example, softer, whilst others are more viscous, and can therefore be pressed through the machine at different speeds. To ensure that the tyre components still achieve the correct shape and size, the production speed must be just right. Until now, this required a great deal of experience: staff would adjust the settings incrementally until the desired quality was achieved. This period is known as the start-up phase. The longer it lasts, the more time and material are wasted.
Artificial intelligence takes over the fine-tuning
The Indian company Apollo Tyres uses an AI control system developed in-house, which is based on the Amazon Web Services (AWS) cloud platform. The system automatically adjusts the production speed using data from previous production runs. The technology continuously monitors the process and automatically corrects the settings if the material threatens to deviate from the specified dimensions. This principle is known as ‘Closed Loop’: the machine monitors its own output and adjusts itself based on the measured values. Staff continue to oversee the process.
The aim is ‘First Time Right’ – in other words, to achieve the correct quality on the first attempt wherever possible.
Automation is becoming a trend in plastics processing
Other companies are also working to ensure that production lines can adjust themselves automatically. K-exhibitor battenfeld-cincinnati, for example, is developing solutions in which the film thickness adjusts automatically following a product change. The nip is readjusted without any manual intervention. Another example is provided by K exhibitor Reifenhäuser. On its EVEREX flat film line, an automatic control system handles key settings. When switching to a different product, it can, for example, automatically adjust the die through which the plastic is extruded and the width of the film. This means staff do not have to make these adjustments manually every time.
It is becoming clear where the processing of plastics and rubber is heading: machines are increasingly taking on tasks that previously required a great deal of experience and manual labour. Artificial intelligence is not always necessary for this. Other automatic control systems can also help to maintain stable production. Particularly in light of the skills shortage, automation and the use of AI can help to maintain stable processes and harness the knowledge of experienced specialists for technical purposes.
