Machinery performance defines the overall factory efficiency, reliability, and sustainability of every tire factory. Even well-maintained machines can limit output when controls, automation, or data integration are outdated. Keeping equipment running isn’t enough. Optimizing and modernizing it ensures competitiveness, energy efficiency, and production stability.

At Black Donuts, we specialize in upgrading, automating, and connecting tire manufacturing machinery, from individual machines to fully connected production lines. Our goal is to maximize performance and minimize downtime through mechanical, electrical, and digital upgrades that make every system work together as one.

TURNKEY SOLUTION

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Turnkey Solution

Every modernization project follows a structured, end-to-end process designed to guarantee measurable improvement in real production conditions:

Assessment & Audit – evaluate machine condition, OEE data, and process flow to identify performance gaps.
Modeling & Feasibility – use digital twin simulations and performance modeling to validate upgrade potential before implementation.
Design & Integration – implement mechanical, electrical, and control upgrades; connect machines to the Ontire® MES for full visibility and automation.
Implementation & Training – execute modernization projects with minimal disruption and provide operator training.
Verification & Support – measure improvements and provide ongoing technical support.

This integrated method eliminates the typical fragmentation between equipment suppliers and process consultants, delivering a single accountable partner and a single measurable outcome. Result: higher machine performance at every stage.

Optimization Areas

  • Information and material flow integration –synchronized communication between machines and systems (Ontire® MES).
  • Cycle time & changeover reduction – faster setups for multiple tire models and reduced downtime.
  • Performance upgrades – enhanced OEE, optimized curing cycle and stable quality.
  • Preventive maintenance optimization – scheduled interventions that reduce unplanned stops.
  • Transport and handling optimization – AGV and conveyor upgrades for smoother internal logistics.
  • Ergonomic automation – removal of manual handling tasks, improving  safety.
  • Traceability enhancements – real-time monitoring of process and material data.

By combining process expertise and automation engineering, Black Donuts helps manufacturers reach higher productivity, lower maintenance costs, and safer working conditions. Every modernization upgrade adds measurable factory value.

Measured Results

  • Increased machine utilization and reduced idle time
  • Optimized personnel allocation
  • Improved machinery layout and information flow
  • Increased throughput and shorter lead times
  • Better coordination between processes
  • Lower maintenance costs and waste levels
Each optimization project is validated through performance metrics, ensuring every improvement leads to faster output, less waste, and higher overall efficiency.

Where Optimization Delivers the Biggest Impact

Upgrading bottleneck equipment such as curing presses is the fastest way to increase capacity. By shortening cycle times and improving process consistency, total output rises without adding new machines.

Using pull-based systems such as Kanban keeps production flow steady and prevents overstocking between departments. By mapping each step of the process, unnecessary tasks and delays can be eliminated, while scheduled maintenance helps avoid downtime and keeps machines running longer.

Optimized production planning ensures all stages — from mixing and building to curing and inspection — work seamlessly together. Balancing workloads minimizes idle time and bottlenecks, while optimizing material movement reduces lead times and enhances overall plant efficiency.

We usually begin our machinery optimization projects by conducting a thorough factory audit. If you want to learn how our Tire Plant Auditing Services can identify areas for improvement and guide your modernization efforts, feel free to reach out to us.

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