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Special Issue – April, 2012
0 © India Transport Portal
April, 2012
© India Transport Portal, 2012
INSIGHTS
&
ANALYSIS RADIALISATION IN INDIA
Special Issue – April, 2012
1 © India Transport Portal
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
2 © India Transport Portal
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.”
Special Issue – April, 2012 Rise of radialisation
3 © India Transport Portal
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.”
Special Issue – April, 2012 Rise of radialisation
4 © India Transport Portal
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
5 © India Transport Portal
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
Special Issue – April, 2012 Chinese radial tyres
6 © India Transport Portal
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
Special Issue – April, 2012 Chinese radial tyres
7 © India Transport Portal
-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.”
Special Issue – April, 2012 Chinese radial tyres
8 © India Transport Portal
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.
Words: India Transport Portal
Back to table of contents
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
9 © India Transport Portal
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.”
Special Issue – April, 2012 Different types of radial tyres
10 © India Transport Portal
-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.”
Special Issue – April, 2012 Different types of radial tyres
11 © India Transport Portal
-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.
Words: India Transport Portal
Back to table of contents
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
12 © India Transport Portal
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.”
Special Issue – April, 2012 Fuel savings
13 © India Transport Portal
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’.”
Special Issue – April, 2012 Fuel savings
14 © India Transport Portal
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
Special Issue – April, 2012 Fuel savings
15 © India Transport Portal
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.
Words: India Transport Portal
Back to table of contents
“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
16 © India Transport Portal
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
Special Issue – April, 2012 Retreading
17 © India Transport Portal
-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.”
Special Issue – April, 2012 Retreading
18 © India Transport Portal
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
Back to table of contents
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
19 © India Transport Portal
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.”
Special Issue – April, 2012 Radial technology
20 © India Transport Portal
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.”
Special Issue – April, 2012 Radial technology
21 © India Transport Portal
-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.
Words: India Transport Portal
Back to table of contents
“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.”
Special Issue – April, 2012 JK Tyre
23 © India Transport Portal
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.”
Special Issue – April, 2012 JK Tyre
24 © India Transport Portal
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.
Back to table of contents
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
25 © India Transport Portal
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.”
Special Issue – April, 2012 ATMA
26 © India Transport Portal
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.”
Special Issue – April, 2012 ATMA
27 © India Transport Portal
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.
Back to table of contents
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.
Back to table of contents
“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
29 © India Transport Portal
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.”
Special Issue – April, 2012 Apollo
30 © India Transport Portal
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.”
Special Issue – April, 2012 Apollo
31 © India Transport Portal
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.
Back to table of contents
“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
32 © India Transport Portal
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
33 © India Transport Portal
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.
Back to table of contents
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
34 © India Transport Portal
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.”
Special Issue – April, 2012 Michelin
35 © India Transport Portal
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.”
Special Issue – April, 2012 Michelin
36 © India Transport Portal
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.
Back to table of contents
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.
Special Issue – April, 2012
37 © India Transport Portal
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