Continental has been setting standards for greater sustainability with its retreading of truck tyres since 1903. The company has been using retreading to extend the service life of tyres for more than 120 years – conserving resources and reducing costs. Continental retreads more than one million truck and bus tyres worldwide every year.
According to a study by the Fraunhofer Institute for Environmental, Safety and Energy Technology (UMSICHT), retreaded tyres reduce CO2 emissions by up to 50 percent compared to new tyres. The amount of recycled and renewable materials in retreaded tyres can be up to 85 percent. In terms of traction, grip and safety, retreaded tyres from Continental are every bit a match for new tyres.
“We have been a pioneer in retreading truck and bus tyres for more than 120 years. Our tyre retreading saves raw materials and costs – a real win-win situation for fleet operators and the environment.”
said Jorge Almeida, Head of Sustainability at Continental Tires.
Turning old into new: hot and cold retreading
Among other things, tyres consist of a casing and tread. However, the casing may still be completely intact, while the tread has reached the end of its service life. Approximately 70 percent of truck and bus tyres were considered retreadable in 2022, based on industry reports and studies of tyre manufacturing practices.
As part of the retreading process, the remaining tread rubber and, in the case of hot retreading, the sidewall of the tyre are buffed and restored. This prepares the casing for a second and third tyre life. Continental uses state-of-the-art analysis processes, production methods and recycling technologies in its hot and cold retreading. In hot retreading, the casing is restored from bead to bead in a hot vulcanisation process. A new rubber compound is applied to the used casing. In cold retreading, known as ContiTread in Continental’s product range, a profiled and pre-vulcanised tread material is applied to the buffed casing. Cold retreading is carried out at lower temperatures and with pre-vulcanised treads. Generally, around 85 percent of the material from the original tyre can be reused in both hot and cold retreading.
From recovering reclaimed rubber to the fully integrated ContiLifeCycle plant
The origins of Continental’s tyre retreading activities can be found in Hanover. Tyres could already be retreaded at the Continental plant in Hannover-Vahrenwald more than 120 years ago. In 1903, the company also bought a factory building in Seelze, in the Hanover region, and set up a plant on the site for reclaiming, processing and recycling old rubber. Even back then, nine to 13 tonnes of used rubber were processed every day. That is equivalent to the average weight of around eight cars. Continental thus laid the foundations for circular and sustainable business practices more than 120 years ago.
Continental set another important milestone in the retreading of truck tyres in 2013 when it opened the ContiLifeCycle plant in the Stöcken district of Hanover. The distinctive feature of this plant is its combination of a retreading and a recycling plant. With an integrated approach consisting of hot retreading for truck and bus tyres as well as a rubber recycling system developed specifically for the ContiLifeCycle plant, the company has been actively promoting the sustainable use of raw materials, water and energy for a decade. Since 2013, around 900,000 truck and bus tyres have been given an extended service life through retreading at the plant in Hanover-Stöcken.
In 2016, Continental acquired leading British retreading firm, Bandvulc. Earlier this year, the Bandvulc production facility in Ivybridge, Devon, became the second ContiLifeCycle plant, sitting alongside Stöcken. Producing both Bandvulc and ContiRe tyres, Ivybridge has assumed the role of a technical innovation hub for the ContiLifeCycle programme and continues to be highly regarded for the work it has done to push the envelope of retread innovation in the UK and Europe. Bandvulc-branded retread tyres are available in more than 100 different patterns and sizes, including those for more specialist applications.
Added value for fleet customers
Retreaded tyres also contribute to Continental’s LODC-concept, which is specially designed for vehicle fleets.
“LODC stands for Lowest Overall Driving Costs, which is our comprehensive consultancy approach that seeks to help fleet customers to reduce their tyre-related operational costs. The sustainable ContiLifeCycle concept is an integral part of our LODC approach, offering fleet customers hot and cold retreaded tyres, service-oriented casing management as well as durable and fuel-saving new tyres. With our ContiRe and ContiTread retreads, fleets can reduce their tyre costs by up to 35 percent, with a significantly lower environmental impact.”
said Tansu Isik, Head of Region South, Channels Fleet and OE Trailer at Continental Tires.
Expanding the Circular Economy
The retreading activities are an example of Continental’s intelligent circular economy solutions. The environment benefits from retreading, as the use of valuable resources such as crude oil, natural rubber and water can be significantly reduced. In addition, retreading helps to save CO2 emissions, as it requires up to 70 percent less energy compared to the production of a new tyre. The fact that a large proportion of the casing can be reused contributes to the cost efficiency.
Continental is working tirelessly to advance innovative technologies and sustainable products and services throughout its entire value chain, from sourcing sustainable materials to recycling end-of-life tyres. The company also relies on the pyrolysis of used tyres. The overall goal is to recover 60 percent of the materials used in tyre construction from used tyres by 2050 at the latest.
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