Continental has deployed seven autonomous mobile robots at its ContiLifeCycle retreading plant in Hanover-Stöcken, Germany. Operational since March 2025, the AMRs manage internal transport of green tires in the hot retreading process.
This automation reduces physical strain on workers and aligns with Industry 4.0 principles in tire production.
Highlights
- Seven AMRs in service: Handle repetitive transport tasks with digital system integration.
- Navigation technology: Sensors, 360-degree cameras, and AI enable safe movement at 2 m/s.
- Ergonomic gains: Replace manual handling of loads up to 250 kg.
- Proven workflow: Supports retreading of truck and bus tires with up to 70% material reuse.
AMR Role in Plant Operations
The robots transport tires between tire-building machines, curing presses, and quality control stations.
They connect directly to the plant’s digital order system for routing and coordination.
Felix Hantelmann, plant manager, states the AMRs free operators for higher-value tasks like machine setup and inspections.
Previous methods required manual crane and trolley use for heavy loads.
Hot Retreading Process Flow
Automation integrates at multiple stages of the ContiLifeCycle hot retreading workflow.
- Buffed carcasses receive up to 18 kg of new rubber at 100°C for tread and sidewalls.
- Handling robot loads completed green tire onto trolley.
- AMR transports trolley to curing press or storage based on capacity.
- Vulcanization at 160°C shapes the 75 kg tire; conveyor moves it to final checks.
This sequence minimizes manual intervention and optimizes production sequencing.
Employee Training and Integration
Continental provided structured training during implementation.
Workers named the robots, including Cargo Knight and Rubber Ranger, to build acceptance.
The AMRs now function as standard team components after initial deployment.
Sustainability and Production Scale
Retreading reuses up to 70% of the original tire while matching new-tire performance and safety.
The Hanover plant has processed over one million tires since 2013.
Global Continental retreading volume reaches approximately eight million truck and bus tires.
Similar AMR systems operate at plants in North America, Europe, and Asia.
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