INNOVATION
Driven by innovative processes, design and technology.
We continue to invest in our purpose-built ContiLifeCycle facility, supporting the ongoing development of our retreading operations through process improvements and manufacturing innovations.
By combining hot retreading and rubber recycling activities at a single site, we operate an integrated production process designed to support efficient use of materials and resources. Over more than 50 years of UK manufacturing, we have continued to evolve our operations in response to changing industry requirements and technological developments.
Explore some of the projects and initiatives that form part of our ongoing commitment to the development of commercial tyre retreading.
AUTOMATED TYRE BUILDING
As part of an ongoing programme of investment in our ContiLifeCycle facility, the Automated Build Cell (ABC) project was introduced to support the development of our manufacturing processes and working practices. The project forms part of a multi-year programme focused on enhancing production operations and introducing automation within the retreading process.
Prior to the introduction of the ABC system, tyres were manually loaded and unloaded onto the building machines. The automated process now transfers tyres from indexed conveyors to the building machine, where a new rubber compound is applied to the prepared casing during the retreading process. The tyre then progresses to the curing stage before continuing through production.
The design, development and installation of the ABC system were carried out by our in-house engineering team as part of the ongoing development of manufacturing operations at the site.
REPAIR AND PREPARATION
Our tyre repair robot prepares casings for the tread application stage through a fully automated, conveyorised process. By reducing manual handling during casing preparation, the system provides a controlled and repeatable manufacturing method. The technology forms part of our production process at ContiLifeCycle, supporting consistent casing preparation prior to tread application.
Supporting production with automated tyre handling and process integration
Our latest Generation 5 Regiomaster tyre is now available
Published 2025/10/13 at 07:20 We are pleased to announce the expansion of our Regiomaster product line with the launch of the new BDR5, a next-generation drive axle tyre which is available in three key sizes – 295/80R22.5, 315/70R22.5 and 315/80R22.5. Bandvulc BDR5 Specifically developed to replace the current BDE1, the BDR5 is designed for national and regional fleet customers, delivering reliable performance for long-distance and regional transport operations. As the first directional tyre in the Regiomaster range, it offers enhanced handling, stability and efficiency in all driving conditions. Engineered for lasting mileage. BDR5 is built to maximise tyre life and…
Our latest Generation 5 Gripmaster products are now available
Published 2025/03/31 at 13:09 We have bolstered our Gripmaster construction tyre range, with the addition of two new Generation 5 products – the Bandvulc BDG5 for drive axles and the Bandvulc BTG5 for trailers. These latest products broaden our Generation 5 product line and have been specifically engineered for both on- and off-road construction vehicles. Bandvulc BDG5 Available in three key sizes, 295/80R22.5, 315/70R22.5 and 315/80R22.5, the tyre’s non-directional pattern design provides enhanced flexibility, handling and high traction. This is combined with a tough, durable compound which increases resistance to cuts and chunking, resulting in a longer service life. Bandvulc…
ContiLifeCycle Ivybridge champions Continental’s retreading innovation
Published 2023/10/24 at 13:42 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…
New investment in robotics drives efficiencies
Published 2022/11/28 at 10:23 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…
Bandvulc unveils next-generation BD5 drive tyre
Published 2022/06/29 at 07:00 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…
Quality Rubber: Setting the retread standard
Published 2022/02/15 at 13:40 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…
Bandvulc Launches Wastemaster 5
Published 2021/06/07 at 11:35 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…
50 Years of UK Manufacturing
BANDVULC HITS GOLD! Published 2021/05/15 at 12:27 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 Bandvulc producing a tyre almost 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 and we…
Creating a bespoke product
Published 2021/03/22 at 09:06Peter 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…
Bandvulc launches new Wastemaster II High Load
Published 2021/03/15 at 11:16 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…
Bandvulc Develops New Specialist Product
Published: 2016/06/15 at 12:41Bandvulc, 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…
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