Upgrade your tire plant without unnecessary downtime

Modernizing a running tire plant is never easy. Production must continue, even as regulations tighten, and customers expect higher performance. At Black Donuts, we make modernization manageable. Our brownfield tire plant modernization services deliver upgrades with minimum downtime, helping you expand capacity, optimize performance, and future-proof your factory. Our brownfield projects cover:

Process​ optimization​
Machinery modernization​ & integration​
Tire design & quality​ improvement​

You don’t need to upgrade everything at once. With a modular approach, an existing tire plant can begin by upgrading one or two areas that deliver the strongest ROI — such as automation in high-impact sections- and expand step by step as your priorities evolve and budget allow.

A STEP-BY-STEP APPROACH

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”Black Donuts brought in the know-how of all the latest technologies and raw materials for low rolling resistance EV tire.”

How We Manage Brownfield Projects

Check We conduct a full production audit,

from auditing the current production level capabilities, from raw material reception to dispatch, evaluating quality level, inventory management, and overall process performance. We also redesign machine layouts, refine workflows, and improve team coordination to eliminate inefficiencies, unlocking your factory’s full potential. Unlike other engineering or testing partners,

Check OUR TEAM offers comprehensive end-to-end expertise under one roof,

encompassing design, simulation, automation, testing, and sustainability. With InTire Labs, we integrate bio-based and recycled materials directly into factory upgrades, providing you with a future-ready, competitive advantage.

Check You’ll receive a detailed report with clear recommendations

the final report outlines long-term brownfield improvements as well as short-term measures that can be implemented immediately.

Our Brownfield Roadmap

Check AUDIT – Plant assessment, equipment inventory, production flow study

Check Report – Gap analysis, risk mapping, and investment options

Check Modular Solution – Scalable upgrades that integrate with existing assets

Check Checklist – Clear action plan with timelines, costs, and KPIs

This structured approach reduces risk, accelerates upgrades, and keeps your production running smoothly, so you achieve efficiency, sustainability, and long-term competitiveness without costly disruption.

How We Help Modernize Tire Plants

Our experts start with an independent audit of your layout, machinery, and processes. We then identify efficiency gaps and create a phased development plan aligned with your budget and production goals—so you gain measurable improvements without unnecessary risk.

We build a virtual model of your plant to test changes before implementation. This allows us to detect bottlenecks, optimize layouts, and validate workflows—giving you data-driven confidence while avoiding costly trial-and-error.

We redesign your production lines with modular, flexible layouts that integrate new machinery smoothly. The result is a smarter, energy-efficient factory that reduces downtime and lowers operating costs.

We integrate MES (Ontire) and digital tools to give you full production visibility. By improving information and material flow, and applying AI-driven optimization, we help you streamline operations and maximize resource efficiency.

We support the introduction of next-generation tire designs directly in your plant. With InTire Labs’ compound development, raw material testing, and full tire benchmarking—including competitor analysis—you stay ahead in product innovation.

We help you minimize your CO₂ footprint through bio-based and recycled materials, lighter tire solutions, and greener processes. Every upgrade ensures compliance with ISO 14001, REACH, and international environmental standards.

Why Choose Black Donuts for Brownfield Services

Meticulous planning avoids disruption to your production schedule.​

Meet the latest industry regulations and environmental standards with confidence.​

Our team manages every aspect of your brownfield project, from initial audit to final implementation.​

Design, simulation, factory and testing under one roof.

Digital twin validation before implementation
Maximize existing equipment and resources.
Greener materials and processes through InTire Labs

Trusted by leading tire manufacturers worldwide.

Outdated layouts and legacy systems shouldn’t slow your business. With Black Donuts, you can turn your current factory into a smarter, greener, and more profitable tire plant, without stopping production. Unlike general engineering providers, Black Donuts is dedicated exclusively to the tire industry. We offer end-to-end expertise under one roof, delivering upgrades faster, with less risk, and future-ready sustainability.

Start with an audit. Contact us today to schedule your brownfield assessment.

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Brownfield Projects Q&A

Brownfield services involve upgrading and modernizing an existing tire plant while production continues, avoiding costly shutdowns.

Through phased planning, Digital Twin simulation, and modular integration, we implement upgrades while keeping production lines active.

A virtual model of your factory that allows testing of layouts, workflows, and machinery changes before real-world execution—reducing risk.

Brownfield is faster, more cost-effective, and less resource-intensive since it leverages existing infrastructure. Greenfield is for entirely new plants.

Reduced CO₂ emissions, bio-based and recycled material integration, lighter tire designs, and compliance with ISO 14001 and REACH.

Every project is tailored, but most upgrades are completed in significantly less time than greenfield builds, thanks to modular solutions and simulation.