Markets now demand advanced solutions that deliver performance, sustainability and total cost reduction. Bekaert is raising the bar with holistic solutions and no compromises.

Establishing the new possible in tire reinforcement

Tire industry dynamics are changing

Historically innovation within the tire industry was either performance, sustainability or cost focused. External dynamics (mobility changes, electrification, legislation) and internal dynamics (competitive intensity) demand that innovative solutions must holistically combine performance improvements such as rolling resistance reduction with use of recovered or recycled materials and (crucially) overall tire cost reduction. Without meeting all criteria, the adoption of new technologies will be severely restricted going forward.

Taking the challenge to deliver holistic solutions

At Bekaert, we have been driving tire reinforcement innovation for decades, including the recent launch of advanced reinforcement technologies within the Elyta® range including Ultra Tensile (UT) and Mega Tensile (MT) solutions; essentially finer / stronger steel cords with optimized geometrical design, leading to significant reduction of steel and rubber used on the reinforcement package. However, recent industry dynamics have created the need to “dial innovation up a notch”.

Meeting these evolving expectations for performance, sustainability and cost, however, requires much more than stronger steel alone. Meeting evolving vehicle performance requirements, including handling and efficiency needs, has required careful optimization of cord designs in close collaboration with tire manufacturers.

At the same time, sustainability expectations are increasing. Today, Bekaert is already supplying Ultra Tensile solutions containing a minimum of 50% recycled content in mass production and is actively developing further circular solutions for future applications.

On the cost side, developing processes capable of economically producing such advanced cords has been a major challenge. By setting tough targets and deploying process expertise built up over decades together with our in-house machine design, Bekaert has achieved several breakthroughs.

These efforts allow to progressively meet the challenges ahead by upgrading the portfolio offering with solutions that simultaneously deliver performance, sustainability and total cost benefits.

Passenger Car Reinforcement for the needs of tomorrow

Bekaert Ultra Tensile cords are growing rapidly in adoption in multiple markets – including in China where they accounted for more than 30% of our sales in 2025 – demonstrating that higher tensile reinforcement has moved well beyond the early adoption stage

The next evolution will be Mega Tensile cords, which can either succeed Ultra Tensile solutions or provide a direct upgrade path from conventional High and Super Tensile constructions. To illustrate the benefits with a specific case, a 2+2 High Tensile Passenger car cord can be replaced by a 4x1 Mega Tensile finer filament solution from Bekaert, typically resulting in a up to 15% ply weight reduction, approximately 2~3% rolling resistance improvement and >13kg of CO₂/tire¹ reduction in the tire use phase (not including the additional upstream value chain reductions).

Importantly, Bekaert's sustained focus on manufacturing and process innovation has made these advanced reinforcement technologies economically viable at scale. As a result, tire manufacturers can typically achieve 10% lower total ply cost, creating a compelling business case that complements the performance and sustainability advantages of the technology.

This combination of lower weight, improved rolling resistance, reduced environmental impact and lower total ply cost illustrates how next-generation reinforcement technologies can help address the increasingly holistic demands of modern tire development.

A compelling proposition for Truck & Bus tires

Historically characterized by a more careful adoption of innovative products, the commercial vehicle tires segment is also showing growth of interest and adoption of Ultra tensile cords. The reason is clear: the value creation potential can be even greater in all steel radial truck and bus tires, where higher material content, longer operating lifetimes and fuel efficiency considerations amplify the economic and sustainability impact.

To illustrate the commercial vehicle case we took 315/R22.5 tires; a popular configuration for long haul drive & steer axles, typically reinforced with High or Super Tensile steel cords today. A Bekaert future-ready reinforcement package (see infographic) combines Ultra Tensile technology in the carcass and Mega Tensile technology in the belt package, demonstrating the significant potential of higher tensile reinforcement.

The result is a compelling combination of benefits: up to 17-20% reduced steel consumption, around 15 to 21% lower rubber usage, approximately 4-5% improved rolling resistance and at least 14% lower total ply cost contribute simultaneously to performance, sustainability and total cost of ownership objectives. In other words, a single reinforcement-package upgrade can create value across multiple dimensions of tire performance and economics.

Importantly, this potential extends beyond the gains achievable today. Future developments, including the integration of higher recycled steel content within advanced reinforcement solutions, offer additional opportunities to increase the share of sustainable materials while further improving the overall value proposition.

An exciting journey ahead

The industry's new reality is here to stay. Tire manufacturers are increasingly challenged to deliver higher performance, improved sustainability and greater cost competitiveness simultaneously. Meeting these expectations and realizing the value opportunities will require continued innovation and closer collaboration across the tire value chain.

At Bekaert, we believe tire reinforcement has a critical role to play and we are fully committed to leading this transformation by continuously pushing the boundaries of steel reinforcement technology.

Our ambition is clear: co-developing the reinforcement solutions of tomorrow that enable tire makers to achieve the optimal balance between performance, sustainability and total cost of ownership. From Ultra Tensile to Mega Tensile and beyond, we remain committed to establishing the new possible in tire reinforcement.

The opportunities are significant, but every tire architecture is unique. The question is no longer whether advanced reinforcement can create value, but how much value can be unlocked in your specific application.

To explore what Bekaert's reinforcement package of the future could look like for your tires, reach out to your Bekaert team or visit Bekaert.com.

Disclaimer:

The data and examples presented in this article are derived from aggregated internal analyses, engineering studies and application-development activities. Results may vary depending on tire architecture, operating conditions and design assumptions. Specific customer projects and proprietary design information have been excluded from this publication.

¹ Estimated savings based on a reference tire milage of 30.000Km and considering 86% impact of usage phase of a PCR life cycle CO₂emission.

² Estimated savings based on a reference tire milage of 120.000Km and considering 90% impact of usage phase of a TBR life cycle CO₂ emission.

Sources used:

1. JATMA Tyre LCCO2 Calculation Guidelines Ver 3.0.1

2. DEFRA GHG Conversion Factors 2025 Full Set (Diesel Average Biofuel Blend)

The calculation assumes a generic diesel truck fitted with 10 tires, a tire life of 120,000 km, and the defined fuel-consumption and rolling-resistance parameters. Actual results may vary materially depending on the vehicle and tire configuration, axle position, load, duty cycle, driving behaviour, road and weather conditions, tire pressure, maintenance, fuel efficiency, mileage and achieved rolling-resistance performance. The estimate should not be interpreted as a guaranteed product performance or environmental claim. This result is an internal screening estimate and has not been independently reviewed or third-party verified

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Markets now demand advanced solutions that deliver performance, sustainability and total cost reduction. Bekaert is raising the bar with holistic solutions and no compromises.