Greenfield tire project
One engineering team across the project
Black Donuts is an independent tire factory engineering partner supporting greenfield projects for manufacturers and investors.
We help plan, design and build new tire factories. We assess technical and financial feasibility, develop the factory concept and support engineering, implementation, commissioning and production ramp-up.
Our team brings together expertise in factory engineering, tire development, materials and production. We stay involved through the first tire and the work needed to reach stable industrial production.
- 50+ tire factories designed worldwide
- Experience working with 20 of the world’s top 25 tire manufacturers
- Expertise across factory engineering, tire development, automation, materials and testing
- ISO 9001 and ISO 14001 certified management systems
Why manufacturers are investing in new tire factories
Manufacturers build new facilities to serve growing markets, bring production closer to customers and introduce new products or processes. The reason for investing shapes the factory’s location, capacity, equipment and long-term operating requirements.
| Investment driver | What it means for the factory |
|---|---|
| New tire products | Define the product range and the production processes needed to make it |
| Regional production | Evaluate locations, supply routes and access to customers |
| Capacity growth | Plan equipment, utilities and space for the required output |
| Automation | Decide where automated processes will improve production and material flow |
| Material changes | Account for new compounds, testing needs and process requirements |
| Investment performance | Compare capital costs, operating costs and production scenarios |
Technical and Financial Feasibility
Technical and financial feasibility
A new tire factory needs more than a building and a machinery list. Product range, production capacity, equipment, utilities, staffing and investment all affect how it will operate. These decisions need to fit together before detailed design begins.
Black Donuts helps manufacturers and investors assess the proposed factory from both a technical and financial perspective. Depending on the project, the study can cover:
- Target markets, product range and tire sizes
- Production capacity and product mix
- Site, utilities, staffing and production requirements
- Preliminary factory concept and material flow
- Capital and operating cost estimates
- Profitability and cash flow projections
- Payback period, net present value (NPV) and internal rate of return (IRR)
- Sensitivity analysis and alternative scenarios
The study gives the project team a basis for comparing options and deciding which factory concept to develop further.
Greenfield Tire Factory Project Phases
Technical Study & Market Study +
We develop the initial factory concept and rough layouts, plan production capacity, and prepare preliminary budget and schedule estimates. The study also includes energy and staffing calculations and an estimate of manufacturing cost per kilogram.
Pre-Design +
We develop detailed layouts and floor plans, process machinery specifications, utility calculations, material and information flows, and the site layout. This phase also includes capacity calculations, a 3D layout and project planning.
Realization +
We support product design, bidding and procurement, utility and construction design, permitting, site supervision, installation, industrialization and project management. Our team provides technical support throughout this phase.
Ramp-Up & Industrialization +
We adjust tire manufacturing specifications, support manufacturing quality assurance and fleet testing, train personnel, and work with the production team towards stable production.
Long-Term Support +
We provide ongoing technical support according to the customer’s needs.
Engineering Priorities
A factory’s location, capacity, machinery, layout, utilities and material flow affect one another. We evaluate them together so that the planned production processes work in practice.
Modern tire factories must balance efficiency, product quality, operational safety, sustainability and long-term flexibility. Black Donuts brings together factory engineering, layout development, production technology, automation, utilities, tire R&D and testing. Each factory concept is developed around the project’s tire portfolio, production targets, investment requirements, market needs and operating conditions.
Quality, safety, energy use and room for future development are considered as the factory concept takes shape.
Discuss Your Greenfield Project
Planning a new tire factory or evaluating an investment?
Tell us about the proposed products, capacity, location and project stage.
Our engineering team can help identify the decisions needed to move forward.
