Radialisation in India ITP tyre

Special Issue – April, 2012

0 © India Transport Portal

April, 2012

© India Transport Portal, 2012

INSIGHTS

&

ANALYSIS RADIALISATION IN INDIA



Table of contents

Click on the article you wish to read to reach it directly. Click on the link “back to table of contents” at the end of each

article to come back at the articles list.

Articles:

The rise of radialisation in India p.2

Impact of Chinese radial tyre on India p.5

Different types of radial tyres p.9

Radial tyres and fuel savings p12

The other lives of radial tyres p.16

The progress of radial technology p.19

Interviews:

JK Tyre: “The only way to compete is to provide quality tyres” Dr. R.

Mukhopadhyay, Director (R&D) p.22

ATMA: “The Daimler choice speaks volumes about the quality of Indian tyres” Mr.

Rajiv Budhraja, Director General p.25

Clean Air Initiative: “Long range trucks have the greatest potential for fuel

savings” Mr. Parthaa Bosu, Head of Indian Office p.28

Apollo Tyres: “The faith that customers shows in our products is a testimony” Mr.

Satish Sharma, Chief India Operations p.29

CEAT: “CEAT TBR became instant success” Mr. Vinod Kumar is Vice President –

Marketing at Ceat Limited p.32

Michelin: “76 billion liters of fuel can be saved with Michelin tyres” Mr. B. Kumar,

Country Head – Distribution p.34

Credits

Special Issue – April, 2012 Rise of radialisation


The world’s tyre industry is now converging towards radial

trends that constitute one of the biggest technological

breakthroughs in tyre manufacturing. India has also become a

party to this world-wide radial revolution. Radialisation is not a

new phenomenon in this country. Way back in 1977, radial

technology made its debut in India through native

manufacturer JK Tyre and since then, there has been a steady

penetration of radialisation. The trend, however, has largely

been restricted to the passenger car segment.

A booming economy coupled with an enhanced level of

motorization and Original Equipment Manufacturers’ (OEM)

increased radial preferences have taken the PCR level to

almost 100%. This same transition has not been witnessed in the

arena of commercial vehicles but thanks to a number of

structural changes, the laxity has now seen a reversal. In his

sector too, especially, in the truck and bus category, radial

inroads have gathered significant momentum.

The current trend in the T&B radialisation

According to a report by ICRA Limited, the Indian T&B sector is

at a ‘structural inflexion point’ as far as radial trends are

concerned. This sector currently has a radialisation of 9-10%

and the figure is expected to double by FY 2013.

This is still a meager figure compared to the world’s average of

68%. This figure will yield hope, nevertheless, if one looks at the

previous trends. In 2005 the radial rate in the truck category

was a mere 1% - this increased to around 5% in 2008. A steady

positive growth over the years is clearly discernable but still the

country lags behind even in Asia. In countries like China and

Thailand, the shift towards this technology has been quite

pervasive. China has registered almost 75% radialisation at an

industry-wide level. Compared to that, India is still in an

embryonic stage.

The rise of

radialisation

in India

28

19

13

18

19

3

Domestic tyre market share in T&B segment (%) Source: SMC, companies, 2011

Apollo

MRF

CEAT

JK Tyres

Birla

Others

The Passenger Car Radial (PCR) level is almost at

100% but the Truck and Bus Radial (TBR) level is

way behind. Looking at the current trend in TBR,

the reasons for the recent growth with the focus

on what thwarted the previous growth in this

sector. How can radialisation play an important

role in providing sustainable mobility and where

the trend is heading towards?

“The Indian T&B sector currently has a

radialisation of 9-10% and the figure is

expected to double by FY 2013.”



The driving factors in the recent upward trends in radialisation

There were important infrastructural shortcomings in India that

made the country lag behind the global trends towards radial

convergence. The poor road conditions were a major factor

behind the slow development and uptake of tyres with radial

technology in the T&B sector. The varied road networks of

India, often in an appalling state, were detrimental to the

tyre’s condition and reduced its shell life. However due to

systematic overhauls and recent improvements in the road

network, the situation has improved. The government has

pumped in large capital investment to improve the condition

of roads. India is expected to build 35,000 km of roads over the

next two years, according to U.S. research and consulting firm

Frost & Sullivan. These projects like the Golden Quadrilateral

and highways providing connectivity in the North-South and

East-West corridors have made the use of radial tyres feasible.

Truck overloading was also another issue. It was not

uncommon to see trucks that have a maximum capacity of 9

tons carrying around 13 tons of weight, causing irreparable

damages to the tyres. The excessive pressure on the vehicle

due to this mishandling caused frequent accidents as well. The

2005 Supreme Court judgment brought about a refreshing

change in this overloading scenario. The verdict stated that

trucks should be loaded only as per the dictates of the Central

Motor Vehicle Rules and accordingly the state governments

were directed to act.

This change has definitely turned the table for radialisation in

this segment. The rise of multi-axle vehicles or MAVs further

played a catalytic role. These vehicles have increased

efficiency of the trucking industry. These new trucks are

capable of carrying more loads; around 50% more than what

was possible by normal trucks and have redefined freight

movement in a large way. With this new vehicle type, ‘hub

and spoke’ transportation has become popular and with the

advent of modernization trends in the heavy vehicle segment

the drive towards radialisation has become easier.

Knowing the benefits of radial tyres

The lack of knowledge about the advantages of radial tyres

also was an inhibiting factor especially in the case of the end

users. The initial investment for such tyres is far higher than the

other standard types i.e. the cross-ply type. The low rolling

resistance force due to the non-crisscross of the plies is one of

the reasons for that. Naturally, this tyre can guarantee more

mileage as well as better longevity than the bias type that

involves low investment.

57

11

9

10

8 5

Product Wise Tyre Demand (%) Source: SMC

T&B

PV

LCV

2/3 W

Tractor

Other

“The 2005 Supreme Court judgment

stated that trucks should be loaded only

as per the dictates of the Central Motor

Vehicle Rules. This change has definitely

turned the table for radialisation in this

segment.”



In the context of the global oil reserve crunch, skyrocketing

fuel prices and also high tyre prices, the transition towards

radialisation seems to be the best option. The environmental

friendliness of these tyres owing to less emission of greenhouse

gases is another plus point that can hardly be ignored in the

era of global warming. Thus to fulfill the goal towards

sustainable mobility, India needs to incorporate fast

radialisation trends across all segments of transportations.

Where is the radialisation in India heading towards?

The current scenario in India definitely looks promising with the

infrastructural revamps happening but some other factors also

need to be worked out to keep on a positive path.

The OEM’s effort is also vital in this and their interest towards

radial fitting will determine the future of this tyre standard. Tata

Motors and Ashok Leyland, the two leading manufacturers in

India’s commercial vehicle segment, have come up with new

truck ranges like Prima and U-Truck that are apt for radial tyre

fittings. The dealer’s awareness is as critical as that of the end-

users because it is from the former the initiative for generating

the technical know-how will come. Service of the tyre is

another component that the dealer must take care of as an

adequate network of service centers can go a long way in

promoting radialisation.

Leading tyre manufacturers like Michelin who are furthering

their radial interest in the country have come up with the plan

to educate dealers and especially for end-users to popularize

the usage of tyres with radial technology.

Clearly, the perception of the tyre manufacturers toward the

radial market of India has changed. The earlier capacity

constraints of the domestic market, which have paved the

way for inferior radial varieties in the country, will no longer

continue to plague the market, as investing in this sector is no

longer a risky affair.

Major capital investment plans for capacity augmentation has

been drawn by Indian tyre companies since 2008. This will

reach its peak in the FY of 2013 when the industry is expected

to increase capacity by 25%. Foreign makers are also not far

behind in the fresh capacity incremental plans. These efforts

will stop the entry of bad quality products as well as increase

price competitiveness that will further the boom of

radialisation.

Words: India Transport Portal

Back to table of contents

23

13 64

Tyre Segment Wise Volume (%) Source: SMC, companies

Export

OEM

Replacement

”Leading tyre manufacturers like Michelin

who are furthering their radial interest in

the country have come up with the plan to

educate dealers and especially for end-

users to popularize the usage of tyres with

radial technology.”

Special Issue – April, 2012 Chinese radial tyres


Radialisation is one of the important structural changes that

the tyre industry of India has begun to embrace. The bulk of

the passenger car segment (almost 99%) has come under the

ambit of this technology and radialisation trends over the

years show that of late the commercial vehicle or CV segment

has also warmed to the technologically-advanced radial

trend.

In the truck and bus radial market (TBR) especially, which was

earlier dominated by the cross-ply variety, a positive growth

has been witnessed in recent times. It is in this segment that

imports from China have made great progress and as early as

2008 Chinese radials came to occupy around 60% shares of

the Indian TBR market.

Indian tyre companies have now started to wake up to this

technology originally developed by Michelin in 1946 and

introduced to trucks and buses in the 70’s. Taking advantage

of the radial capacity constraints of the native manufacturers,

Chinese radial tyres gained a strong foothold on Indian soil.

The huge demand-supply gap in the Indian market (in 2010

the demand for tyres reached 2.7 million unites and the supply

came short by 1.7 million units) opened the door for Chinese

products and this has been heavily reflected in radial import

figures. If one looks at the import trends of TBRs, a steady

positive double digit growth in the last five to six years can be

seen with the financial year (FY) 2010 -11 showing a growth

rate of around 43%.

Competitive pricing structure is the key to Chinese radial’s

success

Chinese manufacturers like Hangzhou Zhongce Rubber

Company, Giti Tire Company and Weifang City Gunaite

Rubber Co Ltd along with Double Coin, Infinity, Aeolus,

Westlake and Super Ranger are predominant in the Indian

market mainly because of their aggressive pricing policies.

Impact of

Chinese

radial tyre

on India

0

20

40

60

80

100

120

140

0

200

400

600

800

1000

1200

1400

1600

FY07 FY08 FY09 FY10 FY11

Source: ICRA

Importedradial tyres (In'000 Nos)

Growth (%)

Chinese radials

Chinese radial tyres are entering the Indian

market. But can a radialisation being done on

price and not on quality be beneficial to India?

”Indian tyre companies have now started

to wake up to this technology originally

developed by Michelin in 1964 and

introduced to trucks and buses in the

70’s.”

Import trends of TBR



China already has a high overall radialisation rate compared

to India. In terms of radialisation trends in the truck and bus

categories, the world averages at 68%, Asia’s share is set at

52% whilst India lags behind at about 17% (FY 2012).

Naturally Chinese manufacturers will have several cost

advantages in their kitty. They have the benefits of economies

of scale, which coupled with subsidies from the government,

make the landing cost of Chinese radial tyres low (almost 25 to

30% cheaper than native products) and on par with Indian

cross-ply variants.

Regional Trade Agreements (RTA) of India along with the

inverted duty structure has made the situation easy for

Chinese players. Under the Asia Pacific Trade Agreement the

custom duty for countries like China is 8.6% which is 2.4% lower

than the normal rate.

Another issue that has resulted in the competitive price is the

fraudulent invoicing policies undertaken by black marketers

and independent sellers of Chinese radial tyres. These tyres are

sold without VAT on a direct cash transaction policy that keeps

the price low.

The attractive pricing structure has outweighed possible

quality issues associated with them. This dumping of Chinese

imports in India has led to heavy losses for the exchequer of

the country amounting to a monthly loss of around 60 to 80

crore (11, 600, 000 USD), according to Automotive Tyre

Manufacturer’s Association’s (ATMA) Director General Mr. Rajiv

Budhraja.

Within the context of a pricing war in the truck and bus radial

tyre segment in India, what does not help India is if the industry

does not extract the maximum benefits from radialisation due

to poor quality products. Benefits such as significant fuel

savings, longer-lasting and longer-running products, and

significant raw material savings from retreading would never

be fully extracted.

Protection of the domestic market: Anti-Dumping Duty

This Chinese radial penetration has definitely raised concerns

for Indian tyre companies. To counter the seemingly unfair

competition and to provide Indian manufacturers with the

same platform, a very important step was taken in the form of

an anti-dumping duty (ADD).

India is not the only country to have done so as the USA also

adopted the same policy on Chinese radials. In November

2008, TBRs came under the restricted list and finally in February-

“To counter the seemingly unfair

competition and to provide Indian

manufacturers with the same platform, a

very important step was taken in the form

of an anti-dumping duty.”

Radialisation Trend – By Segments

0

10

20

30

40

50

60

70

80

90

100

FY09 FY10 FY11 FY12

Source: ICRA, Annual reports

T&B

LCV

Passenger Car



-2010 definitive ADD was imposed by the government on TBRs

(included both tyre and tubes) from China as well as Thailand.

As part of the ADD, a price bracket of US$24 -US$90 per tyre

has been imposed on Chinese products; despite this though,

tyres remained cheaper and continued to make their

presence felt in India. This move however has not been

welcome by the automobile industry as the import restrictions

are bound to affect the sector negatively as pointed out by

the Society of Indian Automobile Manufacturers.

In the face of the domestic line’s incapability to cope with the

rising demand, naturally vehicle manufacturers have no

choice but to rely on Chinese radial imports as is the case with

auto giant Tata Motors. The restrictions therefore will thwart the

growth of the auto sector. Halfway through 2011, however, this

import restriction was lifted by the Excise and Service Tax

Appellate Tribunal post the filing of a plea by Bridgestone

India, Tata Motors and Chinese companies. This has yet again

raised concerns among Indian manufacturers who are back

at the level of direct competition with Chinese companies.

The expansion ventures of Indian manufacturers to counter the

Chinese radials

The suppuration of demand for radial tyres especially in the

T&B sector has prompted the Indian tyre industry to undertake

major investment ventures for brown and green field

operations. Plans for investment worth around 6, 000 crore

were undertaken by the Indian tyre industry as early as 2009-10

and between 2010 and 2013 the industry will attract an

investment worth 17, 500 crore (3, 500, 000, 000 USD).

Out of which the truck and bus radial market is expected to

wrap up around 50% of the investment share followed by that

of the passenger car sector. Most Indian companies have

taken the radial push. One of the major players JK Tyre has

investment plans worth 1, 500 crore (300, 000, 000 USD) for TBR

and PCR that are expected to be completed by March 2013

whereas MRF Ltd is all set to pump 1, 372 crore (274, 400, 000

USD) for PCR projects.

Similarly Kesoram Industry (Birla) has made a 1, 000 crore

investment for TBR and PCR. New plants have been set up by

JK Tyre in Mysore whereas Apollo Tyres has started new radial

operations from Baroda. The latter has invested to the tunes of

around 1, 100 crore (220, 000, 000 USD) for the same. In fact,

top international brands have set up radial operations in India

directly. The largest and most ambitious project is the Michelin

one with more than 4, 000 crore (0.8 billion USD) for its TBR

Chennai plant. Bridgestone is following in their footsteps.

“Plans for investment worth around 6,

000 crore were undertaken by the Indian

tyre industry as early as 2009-10 and

between 2010 and 2013 the industry will

attract an investment worth 17, 500

crore.”



The Future Direction

The significant local investment in radial technology today will

help bring India over the next years closer towards the Asian

average in radialisation. Radial offers from Indian tyre

companies may start to dilute the Chinese effect. However,

the challenge remains that with the ADD waived, Chinese

tyres will continue to make their way in the Indian market at a

lower price than native units.

However, as this still youthful part of the tyre industry evolves

and matures in India, radial tyres should start to be considered

not just on price but on the total value (or savings) it brings to

users. The trend should therefore start to move from a price-

driven model to a value-driven model. Clearly, it would be in

India’s interest to extract the most from radial technology and

to accelerate towards creating the right platform that supports

sustainable transportation.



0

10

20

30

40

50

60

70

80

90

100

T&B Tyres (in %)

Source : ICRA, Annual reports

“It would be in India’s interest to extract

the most from radial technology and to

accelerate towards creating the right

platform that supports sustainable

transportation.”

Radialisation Trend

Special Issue – April, 2012 Different types of radial tyres


The radial sector is one of the most forthcoming domains in the

tyre industry of India and in recent times has attracted lots of

attention. Radialisation trends have not penetrated the

country in the same way as they have done on a global level.

Infrastructural shortcomings such as bad road conditions,

overloading issues intertwined with low awareness level have

thwarted the growth pace of radial tyres in India especially in

the truck and bus (T&B) segment. Of late, however the trends

have seen a reversal. Like the passenger car sector (99%

radialisation rate) the truck and bus radial market is also

making waves and has a registered a 9-10% growth – it is

expected to reach around 25% within the next three FYs.

Radial tyres entail great returns in the long run

There is no denying the fact that radial tyres are of cardinal

importance in the transport sector especially for T&B. In fact,

the long term benefits that these tyres generate have gone a

long way in displacing the earlier conservative notions

attached to them. Compared to the much in demand cross-

ply bias variant, tyres with radial technology offer better

mileage and most importantly are much more fuel efficient

(saving at least 5% and 3% more fuel for old and new vehicles

respectively). The robust build of the tyres ensure almost 80%

longer life but due to high performance capacities the initial

investment for these tyres is higher than the bias types,

although in the long term they are much more cost-effective.

The table 1 clearly testifies that.

Quality is key to the choice of radial tyres

In India, although the radial push for all sectors has come

pretty late compared to a world-wide level, in recent times the

Indian tyre industry is flooded with various types of radial tyres

and manufacturing companies. Buyers can choose from both,

Indian and foreign brands. But with the inroads of Chinese

manufacturers an alarming trend has come to light. Taking

advantage of the recession, the growth of radialisation in India

has been marked by Chinese brands overtaking sales thanks

to their attractive pricings which have heavily contributed-

Table 1: Average Indian Radial vs. Cross Ply T&B tyres

Metric Bias Radial

Price (Rs) 13 ,000 17, 500

Life of new tyre (Km) 55, 000 100 ,000

Cost per retreading (Rs) 3, 800 4, 200

Total cost of retreading (Rs) 7, 600 12, 600

Increase in life after retreading (Km) 82, 500 225, 000

Total life of tyres 137, 500 325 ,000

Retreading Possible (Times) 2 3

Mileage (Km/l) 4.5 4.7

Diesel Cost (Rs/l) 37.8 37.8

Fuel Cost/Km (Rs/Km) 8.4 8

Effective Cost/Km (Rs/Km) 8.5 8.1

Source: ICRA Rating Feature, April 2011

The importance of radial tyres is crucial as there

are various types of radial tyres produced by

different manufacturers. But as the cheapest

varieties heavily compromise on quality, it could

ruin the efforts for the improvement of situation

in the form of major investments by both top

rated Indian as well as foreign brands.

Different

types of

radial tyres

“Radial tyres are of cardinal importance in

the transport sector especially for T&B.”



-to their success. Post the removal of anti-dumping duty in 2011

the problem has become worst. The Chinese radials that are

dumped in the native market are however, not considered of

good quality. Varieties that are of lower quality rule out the

very efficacy of radial tyres in the first place. It is true that tyres

with radial technology require initial huge and capital-

intensive investments and are priced higher than the normal

varieties (20% more in terms of selling price) but the benefits

that they incur outweigh the price issue. Good radial tyres

make the vehicles more fuel-efficient and are crucial in

containing carbon emissions that trigger environmental

hazards. Their longer lifespan and maneuverability ensure safer

driving conditions. The hallmark of a quality radial tyre is better

handling capacities that will ensure minimal tread wear. Such

attributes require innovation that naturally pushes the price of

the products. Top rated tyre companies create innovative

designs to make such high quality tyres. In October last year,

MRF for example launched tubeless radial tyre MRF Z.L.O that is

tailor made to offer high speed driving capabilities. This tyre is

equipped with advanced polymer alongside stable ring

construction and can be used in domestic as well as imported

cars.

French manufacturer Michelin that supplies tubeless radial

tyres for passenger cars has come up with special tyres in the

TBR sector like XDE2 XDY3, XZE2 & XZY3 that are designed with

technologies especially suited to Indian roads. Along the same

line, Goodyear launched the GT3 radial tyre that is equipped

with Bubble Blade TM tread block design taking safety to a

different level. For consumers choosing cheaper varieties of

tyres it means having to trade down on quality. The only good

news is that with the rising demand in the CV segment Indian

tyre makers have finally woken up and are now taking great

initiatives to stem the penetration of inferior products.

Government measures like improved road conditions and

restrictions on vehicle overloading have also eased the

situation.

The growth map of various manufacturers: Indian and foreign

The Indian tyre industry has come a long way from the time JK

Tyre first launched radial tyres in the country in the 1990s. In the

year 2010-11 the capacity of the tyre industry increased by 8%

and in the years 2011-13 the industry is poised for a robust 25%

capacity enhancement plans. The major thrust of the

investment plans is focused on developing tyres with radial

technology and a significant level of finance has been

pumped into the green field operations dedicated to the TBR

sector. Almost all the top tyre companies of India be it Apollo

Tyres Ltd, Bridgestone India or JK Tyre and Industries Limited are

rolling out massive plans for increasing radial capacities.

Ceat’s 700 crore investment in the green field Hallo plant is-

“Michelin has come up with special tyres

in the TBR sector that are designed with

technologies especially suited to Indian

roads.”



-also dedicated towards the radial operations only. The table

above (Table 2) details projects and the level of investment

various manufacturers have undertaken. Foreign tyre

companies are also not far behind and they are eager to get

their share of the Indian market.

French manufacturer Michelin has pumped in investment to

the tune of 4,000 crore (0.8 billion USD) in a Chennai plant that

will start to be operational by the end of 2012. This plant is

targeted to produce 300,000 radial tyres in its first year which

will be tapping into the replacement market mostly. The radial

tyre industry is enjoying continuous growth at the moment

despite the worldwide recession. Unfortunately cheaper

products and smaller disposable incomes have meant that

many customers are now choosing the cheaper options of

tyres. However, the benefits of radial tyres are undeniable and

providing customers can overlook their initial higher costs, this

sector is set to continue growing on both a domestic and

international front offering more and more choices to buyers.



Table 2: Major projects by the Indian tyre companies that are in pipeline

Company Location Product Capacity Investment (Rs. crore)

Apollo Tyres Limited

Oragadam, Tamil Nadu PCR tyres (2 phases) 9, 000 nos / day 2, 100

Chennai, Tamil Nadu TBR tyres 4, 700 nos / day

Vadodara, Gujarat Tyres 200

Balakrishna Industries P

Ltd.

Bhuj, Gujarat Speciality tyres 110, 000 tonnes / annum 1, 200

Pneumatic tyre, tube &

flap 150, 000 tonnes / annum

Rajasthan & Maharashtra Tyres 200

Bridgestone India P

Limited

Chakan, Pune TBR 2, 600

PCR 260

Pithampur TBR 200 nos / day 90

Radial tyres 6, 000 nos / day 260

Ceat Limited Ambarnath, Maharashtra Speciality Tyres 200 tonnes / day 340

Dunlop India Limited Guwahati, Assam Truck & Earthmovers

tyres 50 tonnes / day 450

Falcon Tyres Limited Haridwar, Uttarakhand Tyres 60 lakh units 570

JK Tyre & Industries

Limited

Mysore, Karnataka Tyres 200, 000 nos / day 315

Sriperumbudur, Tamil Nadu PCR Tyres (2 phases) 2, 500, 000 nos / day 1, 500

TBR tyres 400, 000 nos / day

Source: ICRA Rating Feature, April 2011

“French manufacturer Michelin has

pumped in investment to the tune of

4,000 crore in a Chennai plant to produce

300,000 radial tyres in its first year.”

Special Issue – April, 2012 Fuel savings


With the shift towards radialisation the global tyre industry has

benefited from a large number of structural changes. One of

the most enduring results of this radial trend comes from the

fact that these tyres are highly fuel efficient. Ecological

hazards largely stem from carbon gas emissions and tyres that

promote fuel economy can contain this situation.

Radial tyres, although more expensive, garner returns that

outpace the price factor. The fuel saving technology of these

tyres is very much in tune with the green initiatives that are

being undertaken all over the world to help preserve the

environment.

How does a tyre make the engine consume more fuel?

A number of operational forces act on any moving vehicle. In

order to continue the mobility, these forces need to be

countered. The engine of the vehicle thus produces a force

opposite and greater in magnitude to continue the operation.

To produce the energy of this force, the engine uses fuel.

Naturally, the higher the percentage of the operational forces

on the vehicle, the higher the level of fuel consumption will be.

Now, one of the forces that act on the

moving vehicle is the Tyre Rolling

Resistance. This force created by the tyres

accounts for around one-third of the total

force that the engine eventually needs to

compensate. When the tyre rolls on the

ground this resistance force is created. The

rubber element of the tyre naturally

absorbs energy and that is dispersed once

the tyre flexes followed by a rolling. The

Table 1 clearly shows that across different

terrains rolling resistance is one of the most

important forces that the engine needs to

counter.

Radial tyres

and fuel

savings

How much a tyre is responsible for fuel

consumption? What is the use of radial tyre for

fuel savings? What are the factors that make the

radial tyres work towards fuel economy?

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Aerodynamics

Rolling resistance

Mechanical friction

Inertia forces

Gravity

Table 1 Distribution of energy consumption

Source: Michelin

“The fuel saving technology of these tyres

is very much in tune with the green

initiatives that are being undertaken to

help preserve the environment.”



Factors that can induce fuel savings

The impact of this rolling effect is lessened with tyres that have

radial technology. In these tyres, plies of cord are placed

across the tire and each ply cord lies at 90 degrees or

perpendicularly to the direction of travel. This significantly

reduces the rolling friction as the plies do not crisscross over

each other. According to reports based on a test conducted

by Bridgestone Ltd., the shift from a cross-ply tyre to a radial

tyre brings about a significant decrease in fuel consumption of

about 10 per cent and also a corresponding decrease in

rolling resistance between 30 and 40 per cent.

It is important to remember though that tyre rolling resistance is

an important factor, but not the only one in the fuel

consumption equation. Thus a percentage change in rolling

resistance does not necessarily bring about the same

percentage change in fuel saving although if the vehicle is

more aerodynamic in design, then the rolling resistance will

definitely create a substantial difference to the amount of fuel

consumed.

Within the radial tyre itself the degree to which it contributes

towards fuel economy varies. Different parts of a radial tyre

contribute towards the creation of rolling resistance force. Thus

the way a tyre is constructed by the manufacturers holds the

key point. The frictional force that is created between the tyre

and the road surface is influenced by the type of tread used in

the making of the tyre.

Tread pattern and tread design constitute one of the

important factors that has a direct bearing in generating this

force apart from the surface of the road. According to an

estimate by Goodyear, ‘Smooth-textured highway surfaces

provide the lowest rolling resistance, while coarse-textured

surfaces give the highest tire rolling resistance and the lowest

fuel economy’

The latter factor is not always easy to change but the former

can be taken care of to tackle the problem of fuel

consumption. Tread or the outer envelope of the tyre is

definitely one of the most vital parts contributing to tyre rolling

resistance force because it is this part of the tyre that is in

direct contact with the road. A percentage of around 35-50 %

can be attributed to the compound that is used in the making

of the tread as being responsible for generating this force

(Graph 2).

35 – 50%

50 – 65%

Graph 2: Contribution of tire

components to rolling resistance

Source: Bridgestone

“According to an estimate by Goodyear,

‘Smooth-textured highway surfaces

provide the lowest rolling resistance’.”



Compounds like silica or various types of rubber - both natural

and synthetic engineering variety can help in reducing

frictional resistance and hence result in lower fuel

consumption. Sometimes top manufacturers design the tyre’s

tread with a dual layer. In this kind of ‘cap base’ tread the

outer cap compound that is used offers better traction and

longevity so that the best performance can be achieved but

at the same time this attribute generates more heat (Graph 3).

Thus an intermediate layer is created between the outer cap

and carcass which is lined with a cooler compound. This type

of engineering keeps the temperature of the tyre at an opt

imum level and thus adds to fuel efficiency. Tread design also

contributes to energy saving. Generally treads with rib design

are considered to be better in this respect than those with lug

or block designs. The depth of the tread is also important and

according to a report by Bridgestone, tyres with shallow treads

are more helpful in preventing carbon emissions than the other

category.

Fuel saving tyres from leading manufacturers

Leading tyre companies come up with tyres with these

features and add on further innovations to make the radials

more optimized for fuel savings. French manufacturer

Michelin’s tyres are dedicated to this in a large way.

According to a ground test conducted by the company, its

truck and bus tyres with radial technology are capable of

saving around 8.62 and 4.16 per cent. This fuel consumption

test conducted in Malaysia was carried on two identical buses

and trucks but fitted with different types of tyres.

Compared to the bias tyre types, the Michelin tyres that were

tested -10.00 R20 (for trucks) and energy radial tyres (for buses)

proved to be more efficient in terms of fuel. Similar tests were

conducted in various other countries including India and

yielded similar results with the fuel efficiency ranging from 6.5

to 11 per cent.

In fact, Michelin has always lived up to its commitment of

freeing its customers from the ordeals of high fuel prices. The

products of this company prove that. The company was the

pioneer in the usage of silica in rubber. In its Energy Tyres this

compound was used for the first time and its less heat

consumption that intertwined with its slight nature resulted in

less consumption of fuel. In addition, tyres of this maker are

generally labeled with MICHELIN Green X. This marking on the

side walls of the tyre ensures high energy efficiency along with

an optimum performance level.

“According to a ground test conducted by

Michelin, its truck and bus tyres with

radial technology are capable of saving

around 8.62 and 4.16 per cent.”

Cap

Base

Graph 3 : Cap & Base

construction

Source: Bridgestone



Other leading companies also design their products along the

same line. Bridgestone recently launched in India its eco-

friendly range of tyres under the name of ECOPIA EP100A. This

specialized range is engineered especially to offer low

resistance force that consequently will cater the needs of fuel

efficiency programs as well as fulfill the mission of delimiting

emission hazards.

Another leader in the industry, Goodyear, also aligned its

products for the same cause. The 3 Zone technology that the

brand uses in designing its tyres keeps the resistance force to a

minimum level resulting in fuel economy in a large way. The

products imbued with this technology have a special

composition of silica along with an advanced polymer.

Radial tyres have definitely beckoned major technological

benefits for the tyre industry as a whole. Good quality radials

are suitable for keeping the environment safe and at the same

time give high end performances. The internal build makes

radial tyres more beneficial than the bias types and even

newly retreaded tyres offer higher fuel savings than the normal

cross-ply variants. Thus a shift towards this trend is considered

to be wise and expected to continue growing in popularity.



“Goodyear also aligned its products for

the same cause. The 3 Zone technology

that the brand uses in designing its tyres

keeps the resistance force to a minimum

level resulting in fuel economy.”

Special Issue – April, 2012 Retreading


With the rise of radialisation, the Indian transport sector has

come of age and is steadily getting on par with the global

standards. The benefits of radial trends, however, come with a

heavy price tag. Considering the long term returns, the initial

large investment can be overlooked but there is no doubt that

the use of good quality radial tyres has increased the running

cost of vehicles especially in the commercial vehicle segment

(CV). The good news is that these tyres, coming from the

stable of leading manufacturers, can have additional lives as

well. This can be done through the tyre retreading process.

What is tyre retreading and what benefits does it incur?

Tyre retreading is essentially the process by virtue of which the

worn out tread of the tyre is replaced with a new tread. This

part of the tyre forms its outer layer and is in constant contact

with the road. Quite naturally this part is more susceptible to

wear and tear processes. In addition, tread is one of the vital

components that determine the tyre’s rolling resistance and is

key to the performance of the tyre. Thus refurbishment with a

new tread gives the tyre a new lease of life and thanks to this

technological advancement tyres can now achieve a

mileage as high as 1, 609, 000 km. The two processes that are

commonly used for retreading are as described in figure1. Tyre

retreading is highly advantageous in terms of operational

costs. In the entire scope of the manufacturing costs of a tyre,

tread represents only about 20-25%. Naturally, replenishing a

tread can be done at a much lower price than the original

cost of a new tyre.

According to industry estimates, the process can be attained

at less than half the price of a new tyre. This means that a

significant amount savings can be made in the course of the

life of a tyre. Thus from the customer’s point of view this other

life of the radial tyre is a highly effective especially because

radial tyres incur huge cost at the first place. The best part is

that even after retreading performance is never an issue.

According to the laboratory test by Goodyear, tyre rolling

resistance (key point to an engine’s performance) is almost

same in case of radial tyres with original tread and those with-

The other lives

of a radial

tyre

What is tyre retreading and how beneficial is it?

What are the key factors in the retreading

process? What is the market in India?

Conventional Process Precure Process

Done through the process of

vulcanisation wherein the strips of

rubber of unvulcanised nature are

moulded on to the tyre’s buffed

casing. This process is also

known as ‘mould cure’ or ‘hot

cure’.

Done also through the process

of vulcanisation but here the

pattern of the rubber strip is

pressed and pre-cured from

before. The strips are applied to

the casing which merges

seamlessly with the latter

through a layer of cushion or

bonding gum that is made from

a specially prepared uncured

rubber. This process is also

known as ‘cold cure’.

“Thanks to this technological

advancement tyres can now achieve a

mileage as high as 1, 609, 000 km.”

Figure 1: Retreading processes



-retread. Interestingly both the types have exhibited less

resistance force than a new cross-ply tyre. Retreading of tyres

is not only beneficial from the point of view of cost but also is

advantageous from the environmental point of view. Such tyre

recycling procedures saves the ecology from massive wastes

of worn out tyres and use of remanufactured tyres saves oil

resources in a large way as well.

Prerequisites of tyre treading: good casing

For tyre retreading it is vital that the body of the tyre or the

carcass on which the process has to be accomplished is in a

desirable condition. If the casing of the tyre is in a bad shape

then the whole retreading process will become useless and

the tyre will be unable to deliver an optimized performance.

The quality of the casing is therefore the basis of a good

retreadable tyre. With radial tyres produced by top

manufactures such quality concerns are never an issue.

Michelin tyres for example, are equipped with specially

engineered casings that offer the robustness required for

seamless and secured retreading and can infuse the tyre with

multi-life. Even after retreading Michelin tyres can enjoy the

same benefits of fuel economy and the maker’s Durable

Technologies as with a new tyre. Tyres manufactured by

Michelin are equipped with features like protection plies in the

bead area, inner liner that is air tight, elastic cable in

protection ply, casing ply with humidity proof cable etc. All of

these attributes are the hallmarks of a durable casing that

gives enhanced endurance, longevity and at same time

provides a safe drive.

This kind of casing enables retreading of the tyre even more

than once – which is often required in the case of trucks and

buses. Thus in the case of such quality casings even after the

end of their first life, tyres can get another life.

Retreading market in India

The Indian market for tyre retreading has belatedly woken up

just like its radial trends across all transport segments. Naturally,

the retreading sector is still at a nascent stage and at times is

disorganized. Companies functioning through proper

franchisees or to be precise organized companies dealing with

retreading businesses are very few in this country. MRF, Apollo,

ELGI, Midas, Sundaram Industries, Annamalai Tyre retreading

Corporation, Indag and Staines Tyres are some of the well-

known companies that are associated with this industry in

India. Many of them have technological partnerships with

foreign companies that enable the remanufacturing of worn

out tyres according to global standards. A large part of the

business, however, is in the hands of unorganized players. Source: Purcelltire.com

“After retreading, Michelin tyres can

enjoy the same benefits of fuel economy

as with a new tyre.”



This is a definite sign of worry because under such

circumstances inferior retreading processes may be adopted.

This will create less reliable tyres in terms of durability, handling

and can even compromise on passenger safety. There are

other problems as well for the Indian market. The procured

treading process, which is more effective than the

conventional process, is practiced on a global level, whereas

in India the latter’s share is as high as the former. The

conventional retreading method can create distortion in the

tyre and can put undue stress on various parts of the vehicle

like engine, suspension etc. which will impact on the driving

convenience in the long run.

The future direction: prospects and problems

This process of tyre recycling that enables the optimum usage

of the product is all set for a positive growth in the CV segment

of India (retreading largely loses out in the passenger car

segment due to aesthetics concerns) because of the practical

financial advantages attached to it. Structural changes like

increased thrust towards radial trends, new National Highway

projects and the emergence of multi-axle trucks has made the

retreading of tyres the most economic and wise option in the

T&B sector.

There are, however, challenges to meet as well. The input cost

of tyre retreading has increased sharply over the years. Both

tread and sheet rubber have faced price hikes. Secondly, with

the move towards radialisation, the market for retreading in

India has faced a new challenge in terms of technology. Now

with the upgraded technological inputs for radial tyres,

different from those for bias types, were required in the

retreading process.

This involves huge investment, which many small players in the

business cannot afford and are forced to close down. This

could lead to a new phase in this market as big and renowned

players will get the

chance to operate more

than the disorganized

ones. Quality is the

defining point for the

growth of this industry and

unless that is ensured, the

use of remanufactured

tyres makes no sense.

Words: India Transport

Portal


Source :

Purcelltyre.com

Source :

SunTyre.suntex.com

Retreading

Tyre Retreading at Sun Tyre

“With the move towards radialisation, the

market for retreading in India has faced a

new challenge in terms of technology.”

Source: SunTyre.suntex.com

Special Issue – April, 2012 Radial technology


Ever since the launch of radial tyres by Michelin in 1946, this

breakthrough technology in tyre manufacturing has become

the standard practice across the globe. Although India made

a late entry in this domain, its commercial vehicle segment is

currently a hot bed for radialisation. In fact, according to a

report by DNA, the growth rate of truck and bus radials (TBR)

will go up two-fold within the next two years from the existing

radialisation level of around 15% and radial trends in this sector

will be at the forefront of the revenues for tyre manufacturers

in India who have suffered from low margins recently.

The development of radial technology for trucks

India’s first try with radial technology happened in the hands

of JK Tyre in 1977 but that was for passenger radials. It was only

in 1999 that the first all steel radials for trucks got introduced in

India and JK Tyre also gave the country the first radial plant for

manufacturing truck radials. Within the last decade the truck

radials scene has undergone a vast change. All the major

players in the tyre manufacturing industry - both domestic and

international like Ceat, Apollo, MRF as well as Michelin and

Bridgestone are seen to be vying for the Indian market and

they have also ramped up their production facilities for truck

radials.

Ceat has made a 700 crore rupees (137, 900, 000 USD)

investment in its Halol plant, Michelin will pump in 4, 000 crore

rupees (0.8 billion USD) in its Tamil Nadu plant, and the 2, 300

crore rupees (453, 100, 000 USD) invested in Apollo’ Chennai

plant is 70% dedicated to the production of radials for trucks

along with bus radials.

Nikolai Setzer, the tyre division head of the German brand

Continental, which is set to produce radials in India from 2013,

has remarked that “radialisation will be the driving force in the

Indian truck tyre market” and accordingly the company has

made an investment to the tune of 50 million Euros (Rs 336

crore) for producing truck radials alone in the country.

The progress

of radial

technology

for trucks Radialisation is becoming an important issue

especially regarding trucks. Indian and foreign

players are investing massively to answer the

growing demand. But what are the characteristics

of a TBR?

“Michelin launched the first radial tyre in

1946. India’s first try with radial

technology happened in the hands of JK

Tyre in 1977.”



The numerous investment plans by tyre majors are a clear

indicator that radial trends are set to continue growing in

India.

The increase in capacity is one of the most significant

developments for truck radials in India and this has happened

due to a number of structural changes in the country besides

the heavy demand in the commercial vehicle segment arising

out of the burgeoning economic needs.

The progress of radial technology for trucks is directly related to

the improved conditions of the roads in India and the

upcoming Express Highways as well as National Highways in

the country which mean that trucks fitted with radial tyres are

becoming more efficient and cost effective. Ever since the

Supreme Court’s ban on the overloading of trucks in 2005, new

generations of vehicles with multi-axles and needing radial

tyres have been created to keep their performances at an

optimum level. The promotion of radial tyres by automobile

manufacturers like Tata Motors as well as Ashok Leyland

through their new age trucks like Prima and U-Truck has helped

truck radials consolidate their position in India and made them

a more acceptable choice for end-users.

Awareness campaigns by the Original Equipment

Manufacturers or OEMS have also largely helped the progress

of radial technology for trucks. The Michelin Caravan, an

‘event-on wheel concept’ was an innovative effort aimed at

popularizing the company’s radials for trucks that have been

manufactured with the conditions of Indian roads in mind.

The improvements in performance

The awareness of these advantages was critical for the

penetration of radial technology for trucks in India because

the initial investment for truck radials was capital intensive

compared to the traditional bias variant; despite this the

popularity of radial technology has overtaken that of bias

types.

Radial tyres come with obvious benefits in terms of fuel savings,

mileage and longevity. New trucks fitted with radial tyres have

a fuel efficiency of about 5% higher than the ordinary cross-ply

variant. Thus the usage of radial tyres has a positive impact on

the environment as greenhouse gas emissions are lower. In

terms of shell life, these tyres last twice as long as cross-ply

tyres. In addition, one can retread radial tyres three times,

unlike tyres with older technology that can be retreaded only

twice. The aspect ratio is also better with these tyres. The

aspect ratio of a tyre is the height of the tyre sidewall

expressed as a percentage of the tyres width. It gives tyres

with radial technology the advantages of better handling-

“The Michelin Caravan, an ‘event-on

wheel concept’ was an innovative effort

aimed at popularizing the company’s

radials for trucks that have been

manufactured with the conditions of

Indian roads in mind.”



-and manoeuvrability. According to an estimate by the

Economic Times from 2010, the overall saving of using a

vehicle fitted with radials is approximately 25 thousand rupees

(492.5 USD) more than that of the cross-ply tyre.

The architecture and components of a truck radial

The performance benefits of a radial tyre stem essentially from

its unique architectural build and the engineering of its casing.

The most important part of the casing that lies beneath the

tread or the outer envelope of the tyre comprises the plies of

cord. Unlike conventional bias tyres where the ply cord runs

across the tyre in a criss-cross fashion, plies in tyres with radial

technology run perpendicular to the direction of travel of the

tyre. This orientation of ply cords usually built with polyester or

steel in the case of truck radials creates lower resistance and

saves the engine from consuming more fuel. This structure also

helps keep the temperature of the tyre cooler compared to its

old counterpart which adds to the durability of radial tyres in

general.

Ply cord is only one of the components that make up the

radial tyre. Over the plies of cord come the protective belts,

usually made of steel, although other materials are also in

vogue like aramid synthetic fibre. These belts provide

protection to the carcass from any external shocks and wear

and tear. In the case of truck radials, over the ply cords there

can be more than one layer of protective belts so that the tyre

can bear the heavy weight of the vehicle. There are also other

important parts in the body of the tyre like bead that holds the

tyre to its wheel rim. This part comes coated with rubber and is

made of solid steel wires. Side Walls, that are intertwined

between the beads are layered with compounds of rubber,

adds to the lateral stability of the tyre and is another important

aspect of its casing. This part of the radial tyre is more flexible

than the bias tyre, and this along with the powerful steel belts,

provides the tread of the tyre better grip and does not allow

the tread to squirm which adds to the increased mileage

factor for radials in trucks. Extra layers of protective fabrics

made of polyester may also form the body of the radial tyre.

This part is known as cap plies but this is mainly a feature for

high speeding vehicles.

The internal build and orientation of the radial tyre sets it apart

from the conventional bias tyres and holds the key for its robust

performance. With India relying so much on road

transportation, the development and improvement of radial

tyres of trucks has been instrumental, and this radial trend is set

to continue.



“With India relying so much on road

transportation, the development and

improvement of radial tyres of trucks has

been instrumental, and this radial trend is

set to continue.”

Radial Truck Tyre

Bias Truck Tyre

Source: jktyre.com

Source: jktyre.com

Special Issue – April, 2012 JK Tyre

© India Transport Portal 22

India Transport Portal: During the Green Freight India Seminar,

you made a presentation that focused on green technology

for tyre industry. How would you balance the immediate need

for transportation that India is facing and environmental issue

which rhymes with investment and technology adoption?

Dr. R. Mukhopadhyay: Global automobile is in transition and

facing two major challenges to ensure sustainable growth in

future – reduction of Green House Gas Emissions (GHGs) and

reduction of oil dependency. To reduce GHGs emissions, Govt.

agencies in respective countries imposed strict legislations and

regulations related to automobile and tyre industry. Under

such global environment regulations and legislations India

should work towards restraining demand of automobile

through providing good mobility and accessibility by:

- Increasing public transport,

- Charging full cost vehicle use (pollution, energy, security,

greenhouse gas emissions) via fuel, vehicle and usage

taxes.

They should also adopt a strategy to restrain vehicle use which

provides:

- Urban land use management,

- Pricing of vehicles use and ownership,

- Improving public transportation,

- Innovative mobility technology,

o Bus rapid Transport,

o Small, neighborhood cars,

o Safe bicycle lanes,

o Car sharing.

Besides above, Govt. of India should encourage continual

investment in Research and Technology development for eco-

friendly technology in automobile and tyre industry with

special emphasis on Development of much cleaner, more

efficient and safer vehicles and other auto components

including tyre.

“The only way

to compete is

to provide

quality tyres”

Dr. R. Mukhopadhyay speaks about the need for

the Indian Tyre Industry to focus on innovation

and green technologies in order to take

advantages of radialisation and to compete

against Chinese players.

“Govt. of India should encourage

continual investment in Research and

Technology development for eco-friendly

technology.”



India Transport Portal: You claim for green technologies in the

Indian tyre industry. What an ecofriendly tyre should like?

Dr. R. Mukhopadhyay: Environmental sustainability of tyre

begins with design (lower weight, radial construction, low

aspect ratio), selection of raw material (preferably ecofriendly

& non petro based material, recycled material, natural

materials like silica in place of carbon black), energy efficient

manufacturing process (use of non-conventional energy),

elimination of waste/scrap during manufacturing process,

minimized testing and field evaluation, use of simulation and

predictive techniques for design, testing and evaluation and

avoid unnecessary field tests. The sum of above provide eco-

friendly green tyre.

India Transport Portal: The passenger car segment is well

radialised but there is still a lot to do for the truck & buses

segment. How the transportation sector could gain from

radialisation (performances on fuel savings, carbon emission,

road safety etc.)?

Dr. R. Mukhopadhyay: The transportation sector has much to

gain through radial tyres over conventional tyres. We can list

several benefits to radial tyres that lead to greater road safety

and less carbon emissions while providing better

performances:

- Longer Tread Life – Almost up to 100% more wear life.

Since the tread is free from lateral deflection, the tread

wear is less,

- Lower Rolling Resistance– Due to lack of lateral deflection

of tread elements, the rolling resistance of Radial Tyre is

less. The energy for traction is almost completely utilized

(10% improvement in rolling resistance will provide

average. 2% fuel saving),

- Higher cornering power and smaller slip angle,

- Better tractive and braking grip – due to greater area of

contact patch, the ground pressure is slightly lower and

more evenly distributed. That leads to greater safety,

- Better high speed performance,

- Better riding comfort – this is because of greater flexibility

and suppleness of the sidewall which can easily

accommodate the dumping vibration,

- More resistance to bruise impact or impact,

- Environmental friendly – fewer raw materials are required

to produce a tyre reducing consumption of natural

resources. Lower fuel consumption brings down

greenhouse gas emissions. Better tyre life leads to less no.

of used tyres

HASETRI is an India’s research Centre which fulfills

need for developing newer and better

technologies for tyres and polymers. This Institute

was established in October 1991 as an

independent Research and Testing Laboratory, to

cater to the need of rubber and allied industries at

National and International level.

“The transportation sector has much to

gain through radial tyres over

conventional tyres.”



India Transport Portal: Chinese competitors are entering the

Indian market. It is often said that they have a low cost offer.

What does it mean especially regarding materials that are

used in tyres (rubber, carbon black, additives and other

material) and in the way they are produced? Do you think that

such competitors can provide an answer to such concerns

(fuel savings, road safety etc.)?

Dr. R. Mukhopadhyay: Chinese manufacturers can offer

products at lower cost compared to manufacturers in other

countries for several reasons. They receive support from

Chinese Government that is driven by greater environmental

pressure and energy consumption. The Chinese government

has also started stronger incentives to promote cleaner

technologies in automobile industry. There is also a Mass

Product Environment because China possesses ample

resources to achieve low cost production.

However, Chinese cost of manufacturing is continuously

increasing and will be comparable with other countries as

soon as Chinese Government withdraws their support.

Regarding quality, China produces various qualities of tyres -

prime tyre and economic tyre. Prime tyre quality & cost is

competitive with other countries. Economic tyres are lagging

on that. Besides quality and cost, product like tyre require after

sales service, which is lacking by Chinese manufacturers in

India compared to their counterpart in India.

India Transport Portal: How Indian manufacturers such as JK

Tyre plan to compete in such environment, between western

manufacturers and low cost players?

Dr. R. Mukhopadhyay: The only way to compete in such

environment is to provide quality tyres at competitive price

through technology development and manufacturing

excellence.

India Transport Portal: You made an important observation with

the tyre disposal. How do you consider the retreading issue?

Could it be a solution to ensure a better life cycle for radial

tyres?

Dr. R. Mukhopadhyay: Radial tyre has got better life cycle

compared to conventional tyres with respect to quality, cost

per km and safety. As radialisation increases in the commercial

vehicle segment, the cold process retreading will increase

proportionally. By enhancing retreading capacity in Truck/Bus

Radial segment, the tyre disposal can be minimized.


Dr. R. Mukhopadhyay, M.Sc. & Ph.D. from Indian

Institute of Technology is presently Director (R&D)

of JK Tyre & Industries Ltd, Director & CE of

HASETRI and Chairman of the Indian Rubber

Institute. He wrote more than 150 research and

technical papers. He filed six Patents. He is a

specialist in green technologies.

“Besides quality and cost, product like

tyre require after sales service.”

Special Issue – April, 2012 ATMA


India Transport Portal: Chinese radials came to occupy around

60% shares of the Indian TBR market. How do you explain such

success?

Mr. Rajiv Budhraja: While 60% could seem to be a substantial

percentage, it needs to be understood in the context that TBRs

so far accounted for just about 10% of the total truck & bus

tyre segment. Bias tyres have accounted for the major share of

the T&B tyres both in OE and replacement market. So success

of Chinese radials, if it can be so called, needs to be seen in

that limited context only.

Meanwhile the demand for TBRs is growing in view of

introduction of new generation of vehicles, better road

infrastructure and an awareness drive on superiority of radial

tyres launched by Indian tyre industry. The industry has lined up

Rs 13, 000 crore of investments a large part of which is for TBRs.

The investments have been planned so as to be ahead of the

demand curve as the demand for TBRs is poised to rise

exponentially as happened in the case of car radials over the

last two decades.

At another level, yes, the rising import of Chinese tyres of all

kinds is a continuing concern with Indian tyre industry. While

Indian industry is not against the legally imported tyres, a large

percentage of tyres from China are being dumped in India

through unfair means such as under-invoicing & under

valuation and that’s a big concern. Anti-dumping duties

imposed on the Chinese tyres have, however, been helpful in

curbing such imports.

“The Daimler choice speaks

volumes about the quality of

Indian tyres”

Mr. Rajiv Budhraja explains how the Indian Tyre

industry is facing the Chinese competition and

how it is able to compete successfully by focusing

on quality and an efficient, service support.

“Success of Chinese radials needs to be

seen in its limited context only.”



Chinese manufacturers also enjoy a cost arbitrage over Indian

manufacturers for a variety of reasons. The export

incentivisation policy of China has also played its part in

helping Chinese tyres garner market in countries such as India.

These facts also merit consideration while discussing the import

of tyres from China to India.

India Transport Portal: China already has a high overall

radialisation rate compared to India. Does it mean that China

gained a strong experience regarding the TBR manufacturing?

Mr. Rajiv Budhraja: The process of radialisation in T&B tyres in

China preceded that of India. To that extent, yes, Chinese

companies have a longer experience. However Indian

manufacturers are well placed to launch TBRs that compete

with the best in the world. The Indian manufacturers have

already shown their prowess in case of car radials, where

again the radial revolution caught up late in India.

India Transport Portal: It is often said that Chinese players have

several cost advantages. What are the advantages of the

Indian tyre industry that could help to compete against such

manufacturers?

Mr. Rajiv Budhraja: Indian companies certainly don’t enjoy a

level playing field in comparison to their Chinese counterparts

when it comes to cost advantage. Tyre manufacturing is a raw

material intensive industry. China went ahead and made

available the import of Natural Rubber, the key raw material,

to its industry at a comparatively much lower price than

available to Indian manufacturers much before the Indian

Government awoke to the reality.

Despite challenges, Indian tyre manufacturers have been able

to compete successfully in view of unmistakable focus on

quality and an efficient, reliable and nation-wide back-up

service support.

India Transport Portal: A pricing war in the TBR segment in India

would surely lead to poor quality products. But TBR are quality

driven products because of the benefits that result by using

them. On the other hand, tyres get more expensive as rubber

prices rise. How to cope with such reduced flexibility?

Mr. Rajiv Budhraja: Pricing strategy is at the root of a market

driven economy. But I cannot agree with the contention that

pricing war always leads to poor quality products. As

marketing experts have us believe, gradually low quality

products are weeded out and the manufacturers who offer a

good tradeoff between pricing and quality win the market.

ATMA was set up in 1975. The primary function of

the Association is to be a conduit between

Government Departments and the tyre companies

in having two way communication. The

Association projects the views of the industry on

various subjects to respective Government

departments. Conversely, the expectations of the

Government from tyre industry are conveyed to

tyre companies.

“Indian manufacturers are well placed to

launch TBRs that compete with the best in

the world.”



We have seen that happening in case of car radials where the

quality of products has consistently improved over the years

while keeping prices within reasonable & affordable limits. Yes,

rising cost of raw materials is a challenge. And each tyre

major, in its very own way, is devising strategies to overcome

the challenge through a combination of resource

rationalization, better efficiencies, better product portfolio etc.

The fact remains that tyre companies have not been able to

pass on entirely the increased cost of raw materials to

customers in view of tough competition leading to immense

pressure on the bottom lines.

India Transport Portal: India transportation is facing several

challenges: fuel savings, carbon emission and road safety. To

what extent Indian tyres can help to achieve success

regarding these issues?

Mr. Rajiv Budhraja: As proved by repeated researches, tyres

are instrumental in meeting the all three challenges that you

have mentioned. An awareness drive is on by tyre

manufacturers is helping the transport sector to aim for and

realize the desired gains.

India Transport Portal: Daimler India’s Bharat Benz trucks

recently announced their choice for JK Tyre. Do you consider

this move as a strong message to be given to Indian tyre

industry?

Mr. Rajiv Budhraja: Definitely it speaks volumes about the

quality consciousness of Indian tyres. In fact it mirrors the

scenario in car radials where almost all the popular

international models of cars are being rolled out on tyre

manufactured in India.


Mr. Rajiv Budhraja is Director General of

Automotive Tyre Manufacturers' Association

(ATMA), the apex Industry Association

representing tyre sector. ATMA membership

spreads across 10 largest Indian tyre

manufacturers, who account for nearly 95% of the

Indian tyre production.

“Tyre companies have not been able to

pass on entirely the increased cost of raw

materials to customers.”

Special Issue – April, 2012 CAI

© India Transport Portal 28

Five million registered trucks

and vans consume about half

of fuel from road transport in

India thus significantly

contribute to global warming

and air pollution. So there is a

lot of work that can be done

regarding fleets to achieve

greener standards and fuel

efficiency as the situation is

very critical.

The fact is that Asia lags far behind Europe regarding

environmental standards. Since the year 2000, India started

adopting European emission and fuel regulations. Today, the

Bharat Stage IV is equivalent to the Euro IV norms. Europe

plans to introduce Euro VI norms in 2014. So there is still a lot to

do regarding the legal and political framework. Some would

say there is a mismanagement regarding the fleet system but

the truth is that there is not any management at all. It has

never existed and it has to be entirely built up.

A Green Freight Program in India has to be set up to achieve

progress towards fuel savings and carbon emissions. The truck

sector in India is highly fragmented. Most part of drivers own

their trucks and only 6% of companies have more than 20

trucks. The highly fragmented nature of the trucking industry

without strong government regulations makes it difficult to

promote the use of newer vehicles and the adoption of better

technologies. There is a lot of waste as multiple logistics centers

around many of the Indian cities are limiting the coordination

of trucks. This all contributes to the high percentage of empty

hauls of trucks.

Almost 20% of a vehicle’s fuel consumption is caused by rolling

resistance. Long-range trucks have the greatest potential for

fuel economy improvement and GHG emissions savings

through technology applications. Stakeholders have to be

educated on various aspects and, considering this

background, tyre and tyres technologies are part of the

solution towards a green fleet management.

Green tyres, depending of their compounds (silica etc.) are

more environmental friendly. There is a need to educate

stakeholders to radialisation so they can consider tyres as a

tool towards greener fleet management. It is part of available

strategies in international best practices that stakeholders

have to learn from.


“Long range

trucks have

the greatest

potential for

fuel savings” The Clean Air Initiative (CAI-Asia) and the Society

of Indian Automobile Manufacturers (SIAM) co-

organized the Green Freight Seminar during 11th

Auto Expo. They call for a better stakeholder

education and clean technologies adoption. India

Representative Mr. Parthaa Bosu explains his

position regarding green fleet management and

radialisation.

Comments gathered by India Transport Portal

Mr. Parthaa Bosu has more than 11 years of

combined experience in corporate affairs,

corporate communications. Before leaving SIAM,

he was heading the Corporate Communications.

Currently he is heading the India office of the

Clean Air Initiative (CAI Asia), which works on

sustainable urban transport and air pollution.

“There is a lot of work that can be done

regarding fleets to achieve greener

standards.”

Special Issue – April, 2012 Apollo


India Transport Portal: According to Mr. Rajiv Budhraja, chinese

radials came to occupy around 60% shares of the Indian TBR

market. How do you explain such success?

Mr. Satish Sharma: I am not sure when exactly this data was

applicable, but in the current scenario the Chinese truck-bus

radials would constitute less than 2 to 3% of the commercial

vehicle (CV) radial market in India.

With our Chennai plant producing 4, 000 truck-bus radials

every day, and other manufacturers also ready with their

radial capacities, there has been a significant increase in the

domestic truck-bus radial capacity, which has resulted in lower

imports.

India Transport Portal: How would you compare the

radialisation trend between China and India? What lessons

can be drawn from this experience?

Mr. Satish Sharma: With more than 75% of the commercial

vehicles run on radial tyres in China, the level of radialisation

there is high. Having said that, the CV segment in China also

took its own time to reach the level where it is now, and it

didn’t happen overnight.

So, Chinese tyre manufacturers and the segment, has also

evolved with time and gained experience. Indian

manufacturers are not far behind, with most of them putting

radial capacities to meet the growing domestic demand.

“The faith that

customers

shows in our

products is a

testimony”

Mr. Satish Sharma explains how Apollo Tyres has

the potential to overcome the Chinese

competition. The tyre company has been the

market leader in the commercial vehicle segment

for the last two decades and provides high quality

services.

“There has been a significant increase in

the domestic truck-bus radial capacity,

which has resulted in lower imports.”



India Transport Portal: Regarding this situation, in what way is

Apollo Tyres different from its competitors?

Mr. Satish Sharma: From being a company which was 100%

into CV tyres in India and the first one to segment the market

according to load and mileage requirements in different

regions of the country, Apollo Tyres understands its customers

and their requirements the best.

The fact that customers have reposed their faith on us

consistently and we have been the market leaders in the

commercial vehicle segment for the last 2 decades clearly

shows the advantage that we enjoy over our Chinese

counterparts.

Our continuous interaction with the customers and fleet

owners, educating them about the benefits of radial tyres,

proper fitment and maintenance, also comes to our

advantage. Also the commercial user is highly service

dependent. For us, being located here, with the infrastructure

to provide that service and hand-holding, and the

understanding of the customer is most definitely an

advantage.

India Transport Portal: How do you balance the need for

innovation with the cost issue?

Mr. Satish Sharma: The Indian tyre industry has been surviving

on wafer-thin margins for many years. Despite that we have

continuously supported, and sometimes led, the growing

domestic automotive industry with better technology

products. Very few, like Apollo, have been able to remain

profitable in such circumstances, where there is constant cost-

push, but the competitive scenario doesn’t allow a price

correction to be affected.

India Transport Portal: How would you describe the products

Apollo is offering, both on quality and cost issues, regarding

this environment?

Mr. Satish Sharma: The faith that customers have been

showing in our products, making us the market leaders --both

in the truck-bus radial and cross-ply segment is in itself a

testimony to our product offering. With our manufacturing

presence and experience of operating in 3 continents with

diverse customer needs, we believe that we have the best

product to offer at competitive prices to Indian consumers.

“For us, being located here, with the

infrastructure to provide that service and

hand-holding, and the understanding of

the customer is most definitely an

advantage.”



India Transport Portal: Indian Transportation is facing huge

challenges such as road safety, carbon emission and fuel

savings. How is Apollo positioned to tackle such issues?

Mr. Satish Sharma: Being the largest tyre manufacturer in India,

we feel that it is our corporate responsibility to educate

customers on road safety and to work towards greening the

environment. Through the Apollo Safe Drive initiative, we are

educating drivers and vehicle owners on various aspects of

tyre care and maintenance.

This activity, which is conducted on highways, residential

locations and corporate offices, informs motorists about the

importance of maintaining correct tyre pressure, use of valve

caps, tyre rotation and wheel alignment & balancing. This Safe

Drive campaign from Apollo Tyres has also been recognized

and awarded by the International Institute of Road Traffic

Education, UK.

We have been working with alternative sources of energy

wherever possible. For example, our largest manufacturing unit

in Vadodara, Gujarat has a tie-up with Gas Authority of India

Ltd (GAIL) for waste heat recovery from GAIL’s gas turbines

exhaust. This is a Clean Development Mechanism (CDM)

project under the Kyoto Protocol.

Our technology team is constantly working towards increased

usage of environment friendly raw materials for our products.

Carbon Black is gradually being replaced with Silica, which

reduces the rolling resistance of a tyre.


“Our technology team is constantly

working towards increased usage of

environment friendly raw materials.”

Mr. Satish Sharma guides all aspects of Apollo’s

largest and most crucial market – India. Prior to

this, he was Chief of Marketing. A Chemical

Engineer from the National Institute of

Technology, Mr. Satish Sharma studied business

management and international marketing at the

Institute of Management Technology and Indian

Institute of Foreign Trade. He began his career

with JK Tyre before joining Apollo.

Special Issue – April, 2012 CEAT


India Transport Portal: Chinese radials are entering the Indian

TBR market with a 60% market share. It seems that Chinese

competitors are in good position to take the lion share, how do

you consider the Chinese competition?

Mr. Vinod Kumar: Chinese came in India when there was a

gap between supply and demand. Only JK Tyre was

producing decent volume. Apollo, MRF was struggling to get

foothold in the market and establishing their product. Now

that Indian tyre Companies have ramped up production and

products are well accepted in market the Indian tyre

companies will have majority share. But the Chinese will still be

a threat.

India Transport Portal: A lot of market commentators say that

Chinese competitors provide a cheap quality offer. How do

you consider the Indian TBR market? Innovation or cost driven?

Mr. Vinod Kumar: Indian customer is willing to pay more for

premium product. All tyre companies are increasing share of

their premium products. TBR Customers are willing to pay more

for good quality products.

India Transport Portal: How would you describe the products

CEAT is offering, both on quality and cost issues, regarding this

environment?

Mr. Vinod Kumar: CEAT did three years extensive customer and

market study before launching TBR tyres in India. CEAT is one of

the very few companies who got it right the first time. While

other Indian Tyre companies took time to establish their

products, CEAT TBR became instant success with good

acceptability in market.

“CEAT TBR

became

instant

success”

Mr. Vinod Kumar presents the CEAT strategy. He

explains that the tyremaker is well prepared to

fully satisfy the Indian market.

“All tyre companies are increasing share

of their premium products. TBR Customers

are willing to pay more for good quality

products.”

Special Issue – April, 2012 CEAT


India Transport Portal: As you said, CEAT is focusing on

radialisation and has aggressive plans with new products to

capture this market. What are the CEAT advantages in this

competition?

Mr. Vinod Kumar: Ceat has aggressive plans for TBR. We are

already approved by Tata Motors & Ashok Leyland. This is

going to give us good replacement demand. Also CEAT is also

strong in export markets and our TBR tyres are performing

extremely well in international markets too. Ceat has already

established two service centers: one in Sankari (Tamil Nadu)

and another in Kodad (AP) to give one stop service for all

Truckers.

India Transport Portal: India Transportation is facing huge

challenges such as road safety, carbon emission and fuel

savings. How is CEAT positioned to tackle such issues?

Mr. Vinod Kumar: Radial Tyre is more environment friendly as

vehicle fitted with TBR consume 5- 10% less fuel then

conventional truck tyre which will lead to low carbon emission

also. We at CEAT have taken up the issue of Road safety and

are running programs to educate school children on road

safety. Our BeIdiotSafe bike tyre campaign also highlighted

the need for road safety.


Mr. Vinod Kumar is Vice President – Marketing at

Ceat Limited. He is responsible for driving all

Marketing & Customer Service agenda and

processes. He has 15 years of qualitative

experience in the areas of Marketing. Mr. Vinod

Kumar is graduated of the Symbiosis Centre for

Management and Human Resource Development

and the Osmania University.

“Ceat has aggressive plans for TBR. We

are already approved by Tata Motors &

Ashok Leyland.”

Special Issue – April, 2012 Michelin


India Transport Portal: Radialisation is starting to rise in India in

the commercial vehicle segment. What would you consider to

be the key elements to ensure the Indian market to continue

its development of radialisation?

Mr. B. Kumar: While the passenger car market in India is almost

radialised, the big movement in India is radialisation in the bus

and truck tyre segment. In India in 2010 around 14.5% of all

heavy vehicles used radials and this will grow steadily.

Globally, the rate of radialisation in the truck and bus segment

is over 60%. Michelin is convinced that this technology enables

the development of tyres that deliver fuel efficiency, safety

and longevity benefits, thus providing newer and better value

products to the Indian consumer.

We feel that trends like infrastructure development – improving

road conditions and development of national highways will

further push the demand for radial tyres in commercial vehicle

category. Vehicle evolution and the entry of more and more

hybrid vehicles in the market and a globalized truck park are

most definitely going to act as an impetus to radialisation in

India. The Indian auto industry continues to grow and so do

the opportunities for us Michelin. We continue to launch new

products, expand our distribution network and continue to

work towards strengthening our partnerships with OE

manufacturers.

India Transport Portal: There is a tough competition.

Notwithstanding the Indian players, Chinese “low cost”

competitors are entering the Indian market. How do you plan

to compete in this environment?

Mr. B. Kumar: The Indian market is one of the few emerging

economies (e.g. Radialisation in Brazil is around 76% and China

is around 60%, the world average is 65%) where the Bias tyre

“76 billion

liters of fuel

can be saved

with Michelin

tyres” Mr. B. Kumar explains how Michelin considers the

Indian market. He speaks about the experience of

the giant manufacturer regarding radial tyres and

how the French company can benefit from its

cutting edge technology.

“The Indian auto industry continues to

grow and so do the opportunities for us

Michelin. We continue to launch new

products, expand our distribution network

and continue to work towards

strengthening our partnerships with OE

manufacturers.”



market is still much more prevalent and will remain so for the

foreseeable future. However, the move to radial technology,

where Michelin has its roots and a wealth of know-how

throughout the world, is inevitable given the improving

infrastructure in India. Radialisation was at 14.5% in 2010 and

we feel that this rate will go up to 50% by 2020, the potential is

massive and we wish to be a part of this growth.

Today customers are demanding more efficient logistics and

supply chain and this is also seen in the context of the sale of

higher HP commercial vehicles. The use of the Radial tyre not

only helps the consumer save fuel but also runs longer thereby

reducing the “cost per kilometer”. This tangible benefit to the

fleet owners is encouraging the shift from nylon tyres to radial

tyres. Michelin is in India to contribute to this shift towards

radialisation and we are committed to ensuring the

improvement of Indian mobility in the long term.

India Transport Portal: On a qualitative issue, it is often said that

not all radial tyres are made alike? What is your opinion about

it? What are the Key Performance Indicators that need to be

considered in buying a radial tyre?

Mr. B. Kumar: The differentiation begins right from the quality of

raw materials used in the production of the tyre and then

other factors like the tread design based on conditions of use,

number of plies etc. play a crucial part in determining the

outcome of how the tyre will perform.

The key parameters to be considered for purchase of a Radial

tyre are:

- The brand-assurance of quality and experience,

- The tread design based on conditions of use,

- The main expectations: fuel Saving, retreadability,

mileage,

- After sales service, advice and setup for repairs,

alignment etc.

India Transport Portal: You are very committed with sustainable

mobility. It includes road safety, fuel savings and carbon

emission. But India is facing a terrible need for transportation

that is mostly cost oriented. How do you plan to balance these

factors?

Mr. B. Kumar: The Indian market is a very demanding one and

the plant that we will operate in the country will produce

radial tyres for both trucks and buses to suit all major

applications prevalent in India. Michelin is focused on its

strategy to be a key participant in the “Radialisation” of the

Indian Truck and Bus tyre segment. This is important for us as

this technology enables the development of tyres that deliver

fuel efficiency, safety and longevity benefits, thus providing

“The move to radial technology, where

Michelin has its roots and a wealth of

know-how throughout the world, is

inevitable given the improving

infrastructure in India.”



newer and better value products to the Indian consumer and

helps driving his costs down. Fuel costs form a huge chunk of

the total operating costs of a fleet owner. Michelin Tyres, the

world leader in tyre technology, estimates that about 76 billion

liters of fuel can be saved annually should all trucks running on

bias tyres today switch to using Michelin radial tyres. Fuel

savings of this magnitude, in the face of significantly rising oil

prices, could potentially have an impact on the overall

balance of trade for the government as well.

Longer tread life, lower cost per kilometer, reduced fuel

consumption, Retread technology for radial tyres, reduced

downtime are some of the benefits that the end consumer

derives by using Michelin truck radial tyres. To demonstrate

and showcase the reduced fuel consumption advantage

Michelin conducted a test to highlight savings.

India Transport Portal: What should be the best business model

for a tyre company that focuses on quality and innovation and

not only on price?

Mr. B. Kumar: The growth rates for such companies will not be

rapid but a steady progress. Creating brand awareness, right

advice on the tread pattern and regular tyre monitoring will be

the key differentiators to demonstrate the performance and

delivering overall economics through the usage of tyres for the

transporter.

India Transport Portal: What are the critical factors to ensure

the best benefits of radial technology?

Mr. B. Kumar: The consumer needs to be mindful of the

following things while investing in a radial tyre in order to be

able to reap full benefits from his radial tyre:

- Selecting the right tread pattern based on conditions of

use,

- Proper fitment methods,

- Regular monitoring and air pressure corrections as

required,

- Tyre husbandry, proper rotation and turning on rims,

- Alignment,

- Quality Radial Tyre repairs at the right time,

- Use of valve caps,

- Removal of tyres at the right time (Minimum tread depth

of 2mm),

- Quality Retreading.


Michelin interview

“To demonstrate and showcase the

reduced fuel consumption advantage

Michelin conducted a test to highlight

savings.”

Mr. B. Kumar is Country Head – Distribution at

Michelin India Tyres. He was previously Head –

Trucks and Buses at Michelin India Tyres. Prior to

this, he spent more than ten years at Castrol India

Limited where he was National Manager –

Distributors.



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INDIA WAREHOUSING SHOW

April 26 – 28, 2012

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May 10, 2012

New Delhi

SIGNALLING AND TELECOMMUNICATIONS: ASIA

May 17 – 19, 2012

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May 17 – 19, 2012

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September 12 – 14, 2012

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India Transport Studies:

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- Major achievements Indian Railways in 2010.


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