INNOVATION

Industry leading processes, design and technology.

We continually invest in the future of our purpose-built LifeCycle plant by taking full advantage of technical advancements and the latest technology available throughout the retreading operation.

Our pioneering approach allows us to combine hot retreading and rubber recycling under one roof in a closed production cycle enabling us to set new standards in sustainability. Below are some insights into the day-to-day projects and innovations which have kept Bandvulc at the forefront of retreading technology for 50 years.

AUTOMATED TYRE BUILDING

Our latest innovation in robotics has already seen an increase in efficiency across the plant.  The Automated Build Cell (ABC) project is part of Bandvulc’s three-year development plan to ensure the manufacturing plant continues to develop innovative retreading technologies and drives further efficiencies both for our plant and to improve the working conditions for our people. 

Prior to the introduction of the ABC robot, the loading and unloading of the tyres onto the building machines was a completely manual process for our operatives. Now, the robot automatically loads the tyres onto the building machine from indexed conveyors and the state-of-the-art extrusion technology applies the new compound onto the tread and sidewall of the prepared casing before it is cured in the press. The design and installation of the ABC robot has been carried out in house by our own engineering team.

REPAIR AND PREPARATION

Our tyre repair robot makes quick work of preparing tyres for the next stage of production, which is applying the new tread.  This fully conveyorized system has dramatically reduced the manual handling effort for our workforce, increasing efficiency and reducing rubber waste since it’s introduction.  

SAFETY AND EFFICIENCY

To keep our plant running in the most efficient way possible, our pick and place robots are programmed to select the next tyre required in the process according to our production plans and demands.  The Plant’s production seamlessly controls the whereabouts of each tyre on its journey to become a ‘new’ retread. 

INNOVATION FACTS

ContiLifeCycle Ivybridge champions Continental’s retreading innovation

All News | Continental | Innovation | Expertise | Sustainability | Retreading
Following our relaunch as a ContiLifeCycle facility in March, our retread plant in Ivybridge has assumed the role of a technical innovation hub for Continental’s tyre retreading programme. The move supports the brand’s ongoing sustainability strategy. As one of the UK’s most advanced tyre recycling and hot retreading facility, our Ivybridge operation will play a significant role in the development of future ContiLifeCycle products and initiatives. Prior to the rebrand, the site was the main premises for leading Continental-owned retreader, Bandvulc. New Bandvulc products continue to be developed and manufactured alongside ContiRe tyres in Ivybridge. Tony Mailling, Head of Hot…
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New investment in robotics drives efficiencies

Bandvulc | All News | Innovation | Expertise
Innovation is as simple as ABC at Bandvulc, thanks in part to the installation of the ABC (Automated Build Cell) Robot at the Ivybridge plant. Our Head of Hot Retread Production at Bandvulc, Tony Mailling, explains more about how innovation and teamwork has progressed this exciting project: “Prior to the introduction of the ABC robot, the loading and unloading of the tyres onto the building machines was a completely manual process for our operatives.  Now, the robot automatically loads the tyres onto the building machine from indexed conveyors and the state-of-the-art extrusion technology applies the new compound onto the tread…
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Bandvulc unveils next-generation BD5 drive tyre

All News | Tyres | Innovation | Retreading
Bandvulc launches all-new BD5 drive tyre to replace BD08 in the Fleetmaster range Independent tests show BD5 delivers a 20% + increase in lifetime mileage over BD08 Revised directional tread pattern provides greater grip and superior handling in wet and dry conditions Tyre retreading expert, Bandvulc, has unveiled its all new BD5 tyre at the inaugural Road Transport Expo 2022 in Stoneleigh. Engineered to deliver exceptional high-mileage performance in all conditions, the innovative new BD5 will replace the BD08 in the Bandvulc Fleetmaster range later this year. Operators of the new BD5 tyre will benefit from enhanced driving dynamics thanks…
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Quality Rubber: Setting the retread standard

All News | Innovation | Expertise | Quality
Quality, reliability and safety are of paramount importance during our tyre production process. At the forefront of retread technology in the UK for more than 50 years, Bandvulc has built an enviable reputation for producing retread tyres of the highest standard. From initial design and development work to casing recycling and tread application on the factory floor, our team of experts implement critical measures that ensure our tyres offer exceptional performance across a range of applications. This is supported with the knowledge and expertise shared by our parent company, Continental Tyres. In our latest FOCUS case study our Director of…
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Rubber Recycling: the core of tyre sustainability

All News | Innovation | Sustainability
Bandvulc began operating 50 years ago at our home in Devon, primarily recycling rubber for our local community. Now we are the UK’s leading commercial tyre retreader and part of Continental, yet despite significant expansion in capabilities and product offerings over the years, we remain true to our founding principles and commitment to the environment, putting in place a myriad of efficient manufacturing processes to make sure our retread tyres produced are as sustainable as possible. In our latest FOCUS case study, Tony Mailling, our Operations Director focuses on rubber recycling at our Ivybridge plant and the important role it…
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Bandvulc Launches Wastemaster 5

All News | Tyres | Innovation
Devon-based Bandvulc are preparing to roll out the latest state-of-the-art tyre in their Wastemaster range after extensive testing and field trials. The launch of the Wastemaster 5 marks the 5th generation of the Wastemaster tyre product which has been developed, tested and produced at Bandvulc’s Ivybridge factory.  The Wastemaster 5 will replace the Wastemaster III, a proven product in the waste sector that has been around for more than 20 years. Tony Mailling, Operations Director at Bandvulc comments; “Over the past 2 years we have seen strong growth in the waste and construction market, which is buoyant at the moment…
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50 Years of UK Manufacturing

Bandvulc | All News | Innovation | Expertise | Sustainability | Quality
BANDVULC HITS GOLD! This year South Devon company Bandvulc is marking its 50th anniversary. It was established in 1971 when the import of rubber from Malaysia began and the retreading of tyres started, turning out around 30 a week. Today they are Britain’s biggest commercial retread tyre company, producing a tyre every 3 minutes, from their facility in Lee Mill, near Ivybridge. Acquired by the Continental Tyre Group in 2016, Bandvulc are market leaders because they continually develop more and more advanced products which respond to customers’ needs with in-house facilities. “We find out what our customer needs from a tyre…
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Creating a bespoke product

All News | Innovation | Expertise
Peter Pritchard thinks he has the best job in the world. He’s a Rubber Technician. He joined Bandvulc, Britain’s largest commercial tyre retreader, in 1992 as a laboratory technician at the company’s headquarters at Lee Mill, near Ivybridge. “I was working in quality control and I was just fascinated,” he says. “I was mainly self-taught and I became interested in everything that was going on in the factory and so I worked hard to get qualifications to become a rubber technologist.” When he takes customers on factory tours, they are often taken aback at the efforts Bandvulc go to in…
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Bandvulc launches new Wastemaster II High Load

All News | Tyres | Innovation | Expertise
Bandvulc, the UK’s leading manufacturer of retreaded tyres has launched a new 295/80R22.5 High Load version of its Wastemaster II tyre, to better meet its customers’ needs in the waste management sector. .  The new Wastemaster II HL is purpose-designed to fit on the latest generation of original equipment. Sporting the same robust urban features and bespoke compound advantages as the existing Wastemaster II product, the new tyre comes to the market in a 154/149 J load/speed rating. Wastemaster II HL benefits from Bandvulc’s ‘Armorband’ technology, which provides additional protection around the tyre sidewall as an extra safety barrier against kerbing.…
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Fowler Welch puts Bandvulc to the test

All News | Tyres | Innovation | Expertise
After years of fitting Bandvulc and Continental tyres to its fleet, leading supply chain logistics provider, Fowler Welch, has now put the two manufacturers’ low rolling resistance (LRR) offerings to the test. In a joint-trial at Millbrook Proving Ground, Fowler Welch and Bandvulc arranged an evaluation of the performance and efficiency benefits of low rolling resistance tyres, with support from Continental and its ContiPressureCheck™ TPMS system.   Low rolling resistance tyres are designed to reduce friction and resistance to improve fuel economy without compromising on critical factors such as safety and braking distance. These products would therefore support Fowler Welch…
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How retreading reduces environmental impact

All News | Innovation | Sustainability
With environmental consciousness front of mind across the transport industry and society as a whole, commercial fleet operators work hard to reduce fuel consumption, to meet strict legal requirements and help lower overall driving costs. When it comes to tyres, one of the most effective ways operators can lessen environmental impact is by choosing retreads for their fleets. Bandvulc, the UK’s leading commercial retreader and now part of the Continental Tyre Group, has over 40 years of experience in retreading and casing management and offers high-quality retreads in both ContiRe and Bandvulc brands. A sustainable product and process The positive…
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Bandvulc Develops New Specialist Product

All News | Bandvulc | Tyres | Innovation
Bandvulc, the leading innovator of specialist tyre products and originator of the WASTEMASTER concept tyre, has recently added a new unique tyre to its portfolio - The Tugmaster, an all positions yard tyre featuring ARMORBAND technology to protect against sidewall damage and a HIGH POLYMER rubber compound to provide higher resistance to punctures. As with the WASTEMASTER range, the innovative ARMORBAND technology is unique to Bandvulc’s products and offers protection around the sidewall of the tyre, providing an extra safety barrier against curbing and a coloured strip on one side provides early warning in the event the barrier is compromised.…
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