Founded in 2010, Black Donuts Engineering Inc. (BDE) is a leading independent tire research and development company (R&D). The company specializes in comprehensive tire technology solutions and are known for their turnkey solutions that facilitate the creation and operation of smart, sustainable tire factories.
Interview with Martti Päivinen, Quality and Risk Management at Black Donuts Engineering Inc.
A brief description of the company and its activities.
Martti Päivinen: Our team of over 70 expert engineers has collaborated with 20 of the world’s top 25 tire manufacturers and numerous emerging players over the past decade.
Our company provides solutions, covering everything from designing new greenfield tire plants to offering brownfield services and tire design. We handle every aspect of a project, ensuring seamless execution from start to finish.
What are the main areas of activity of the company?
M.P: BDE’s services encompass research and development, greenfield (plant design) and brownfield projects, feasibility studies, tire development, technical consulting, testing and certification, production optimization, and supply chain enhancement.
What are the ranges of products/services?
M.P: BDE offers end-to-end tire solutions for every phase of tire development, managing all aspects from raw material selection to tread pattern and sidewall design.
Services include:
Greenfield and Brownfield Projects: Planning and designing new smart tire factories and upgrading existing plants (brownfield) for maximum efficiency.
Tire Design: Designing new tires for various conditions, such as summer, winter, all-season, long haul, regional, on/off-road, and specialized tires for electric vehicles and other sectors.
Product Development and Improvement: Expanding size ranges, upgrading performance, and enhancing quality for existing tire lines.
R&D and Technical Expertise: Providing advanced tire testing, certification, and production optimization support.
Our services cater to passenger cars (PCR), trucks (TBR), off-road vehicles (OTR), electric vehicles (EV), and agricultural machinery, with expertise in stud technology and tread pattern development processes.
What’s the news about new products/services?
M.P: For newcomers, launching a tire factory in under 24 months may seem daunting. But at BDE, we make this ambitious vision a reality. BDE has introduced an all-in-one solution for building sustainable greenfield tire plants, simplifying the process for newcomers by providing comprehensive services from initial planning to full operation. This approach not only reduces construction time by 16 months compared to the industry standard but also minimizes the environmental footprint and material usage.
Further, our global network of suppliers and machine vendors enables seamless communication, helping us stay on schedule and perform effectively. This network also simplifies acquiring new machines and maintaining quality. We take on full project responsibility, overseeing on-site operations to ensure installations align with design specifications and readily adjusting changes if needed.
We plan and test required prototypes, develop compounds and constructions for new products, design production moulds, and ensure moulds are ready for use. From conceptualization to producing the first tire, clients can rely on Black Donuts as their dependable partner, helping them overcome challenges and achieve their goals. We are involved in every stage of a tyre’s life cycle, the manufacturing process, and the efficient use of materials to promote recyclability.
Therefore, we handle everything from equipment procurement to construction oversight, delivering fully operational tire factories within 24 months—16 months faster than the industry standard. Our approach reduces the footprint by 25-35% and makes tires 10% lighter prioritizing environmental responsibility by implementing eco-friendly practices.
Our proven track record includes completing over 50 tire factory projects, each with an average capacity of 4 million PCR and 400,000 TBR tires annually. Our focus is on quality and sustainability from start to finish. Customers who choose BDE’s greenfield solutions, customers contribute to a greener future without compromising quality or productivity.
What is the state of the market where you are currently active?
M.P: BDE operates on a global scale, addressing the diverse needs of clients across Europe, Asia, the Middle East, Africa, and the Americas.
What can you tell us about market trends?
M.P: The tire industry is evolving due to a focus of sustainability, technological advancements, and changing consumer demands. There is an increasing demand for eco-friendly materials and energy-efficient production processes. The rise of electric vehicles (EVs) has created a demand for specialized tires. BDE is leading these trends by integrating efficient, eco-friendly practices and developing bio-based raw materials and recycling processes. We are at the forefront of these changes.
What are the most innovative products/services marketed?
M.P: We design eco-friendly, lighter tires to reduce fuel consumption and carbon emissions, aligning with global sustainability trends and regulatory requirements, like the new EU Regulation for wet grip and rolling resistance.
Our R&D experts are incorporating biomaterials in producing synthetic styrene butadiene rubber (SBR). Similarly, silica, a common tire filler material, can be produced from the ash of rice husks, turning agricultural waste into a valuable resource. These technologies help reduce fossil fuel usage and energy consumption.
What estimations do you have for 2024?
M.P: Recognizing the environmental challenges associated with extracting raw materials like rubber and petroleum-based compounds, the tire industry is actively seeking ways to reduce its impact. Looking ahead to 2025, BDE anticipates continued growth in demand for sustainable tire solutions and smart factory technologies with lower energy consumption.
Renewable and recycled raw materials will be more prominent in efforts to lower the usage of fossil-based raw materials. We plan to expand our innovative product lines and smart factory solutions, maintaining our leadership in sustainability and technological advancements. By 2030, we aim to use only biobased and recycled raw materials in tire production.