Continuous investment in advanced automation, rubber compound development and environmentally conscious processes helps us enhance quality, efficiency and workplace safety across our operations. Our modern production facilities are designed with sustainability and ergonomics in mind, supporting a productive and comfortable environment for our employees.
In 2016, we strengthened our European hot retreading operations with the acquisition of Bandvulc Tyres. With over 50 years of retreading excellence, Bandvulc brought a rich heritage and deep expertise that perfectly complements Continental’s commitment to innovation. This strategic move reinforces our vision for the future of hot retreading—combining decades of proven craftsmanship with cutting-edge technology and resource efficiency.
We continually invest in the future of our purpose-built LifeCycle plant, leveraging technical advances and the latest technologies throughout the retreading process. By combining hot and cold retreading under one roof within a closed production cycle, we can utilise synergies between retreading and rubber recycling to support efficient resource use and help reduce material waste.
Our latest robotics investment, the Automated Build Cell (ABC), has helped improve efficiency across the plant. Developed as part of a three-year programme, the ABC project supports the continued development of advanced retreading processes while also contributing to improved workplace ergonomics for employees.
Prior to the introduction of the ABC, operatives manually loaded and unloaded tyres onto building machines. The automated system now transfers tyres from indexed conveyors to the building machine, where extrusion technology applies compound to the tread and sidewall in a controlled and consistent manner. Following curing, the retreading process is completed. Designed and installed by our in-house engineering team, the ABC system reflects the technical capabilities and expertise within our organisation.
Our advanced tyre repair robot streamlines casing preparation for the tread application stage. This fully automated, conveyor-based system has dramatically reduced manual intervention, ensuring consistent processes, boosting throughput, and minimising rubber waste. Since its introduction, the system has delivered greater process control and significantly improved overall production efficiency.
At our Stocken plant, autonomous robots navigate the production hall using sensor technology, 360-degree cameras and AI-supported control systems. By transporting tyres between different stages of the retreading process, the system helps support operational efficiency, process consistency and workplace ergonomics, allowing employees to focus on value-adding activities such as quality control.
“Continental, Bandvulc and the Ivybridge site have long been recognised for their contribution to retread tyre development in the UK and across Europe. While the name above the door may have changed, Ivybridge continues to play an important role in our retreading operations and ongoing innovation efforts.
The Ivybridge site's role reflects the skill, experience and commitment of the team, which has helped increase awareness and understanding of modern retread tyres. Advances in materials, manufacturing processes and engineering have contributed to the development of retread products that are designed to meet demanding operational requirements. Today, retreading incorporates a range of technologies and technical expertise that support consistent product quality and performance.”
Tony Mailling, Plant Manager of ContiLifeCycle Ivybridge
Our retread manufacturing process is supported by ongoing investment in research, development and engineering, helping us maintain high standards throughout tyre production.
This commitment is supported by regulatory requirements that help promote consistency across the industry. To help ensure performance, dimensions and tyre sidewall markings meet defined quality criteria, our processes comply with UN ECE Regulation 109.
Both of our ContiLifeCycle retreading plants, producing ContiRe and Bandvulc tyres, operate in line with ISO-certified quality management standards, supporting consistent production processes across all stages of manufacturing.
*Source: British Tyre Manufacturers’ Association (BTMA), Retreading Benefits: btmauk.com/retreading/benefits/
In our latest video, our UK retreading plant evaluates used tyres from our customers’ fleets and determines their potential for a new life as retread tyres. By combining the expertise of our people with our advanced retreading technology, we ensure every tyre receives the most thorough assessment before going on to serve another life.
See the magic for yourself! This video shows you the hot-retreading process from assessing the casings suitability through to final inspection.
.jpg/jcr:content/renditions/cq5dam.web.1280.1280.jpeg)