Germany. Continental is taking a decisive step towards intelligent automation at its ContiLifeCycle (CLC) plant in Hanover-Stöcken, where seven autonomous mobile robots (AMRs) responsible for the internal transport of tires have been operating since March 2025. The company thus seeks to optimize processes, improve work ergonomics and advance in its transition to Industry 4.0.
AMRs are responsible for moving green tires between different stations in the retreading process, freeing up personnel to dedicate themselves to specialized tasks such as machinery adjustment and quality control.
"Autonomous robots have been supporting our production flow for six months... They are a valuable addition to our daily operations and help to create a safe, efficient and ergonomically optimized production environment," said Felix Hantelmann, ContiLifeCycle Plant Manager.
The robots circulate autonomously through the industrial hall thanks to advanced sensors, 360° cameras and control technology based on artificial intelligence. At a speed of up to two meters per second, they transport tires from the assembly machine to the vulcanizing presses and then to the quality control area.
This automated flow accompanies a hot retreading process that involves:
- Transfer of the sanded housing to the construction machine.
- Application of up to 18 kg of fresh rubber heated to 100 °C.
- Tire transfer by AMR to presses or storage areas.
- Vulcanized at 160 °C and subsequent inspection.
- Reducing physical exertion is one of the main benefits. Previously, operators manually moved trolleys and cranes weighing up to 250 kg loaded with two tires, making multiple journeys between stations.
Technology with the support of the human team
The implementation process included a comprehensive training program for employees, which reinforced the rapid acceptance of the technology. They even participated in the choice of the names of the robots, including Cargo Knight, Rubber Ranger, Iron Tread and LifeCycle Commander, a gesture that strengthened the integration of these solutions into the daily routine.
The success at Hanover-Stöcken has led to the adoption of similar solutions at other Continental plants around the world, including sites in North America, Europe and Asia. This approach is part of the company's overall strategy to strengthen efficiency, sustainability and digitalization in tire manufacturing.
Since 2013, the ContiLifeCycle plant has retreaded more than one million truck and bus tires. The process allows up to 70% of the original structure to be reused, achieving products comparable to a new one in safety and performance, but with less use of resources. Globally, Continental has produced around eight million retreaded tyres at its various facilities.
