Each year, over 300 million tyres are replaced across Europe, with approximately 45 million changes occurring in Germany alone. These replacements represent a significant environmental and financial cost, but REMA TIP TOP, based near Munich, is aiming to change that. Through advanced repair and retreading solutions for car, truck, agricultural, and industrial tyres, the company is promoting a sustainable tyre cycle that cuts both costs and raw material consumption.
"Retreading worn tyres and repairing defective ones is an ecologically and financially unparalleled alternative to new tyres," says Gerhard Hieber, Product Manager at REMA TIP TOP and network partner of Allianz Zukunft Reifen (AZuR). Hieber explains that through AZuR’s initiatives, REMA TIP TOP aims to reuse or recycle 100% of tyres after their first life cycle.
In Germany alone, about four million drivers experience tyre damage each year, typically caused by road debris or minor accidents. According to Hieber, in over 1.5 million cases, the tyre could be repaired safely and economically, saving consumers from replacing the entire tyre prematurely. He states: "Repaired tyres offer the same level of safety as new tyres, even at high speeds and torques. This is ensured if the damage is properly assessed and the repair is carried out in a specialised workshop."
REMA TIP TOP’s TÜV-certified MINICOMBI system offers a quick and cost-effective solution for typical damage like tread punctures between 3-6 mm. For larger punctures of up to 10 mm, the company uses a hot vulcanisation process. The cost savings are significant; replacing a defective tyre on both axles can add an extra €100 to €200 per vehicle, depending on the tyre size and performance class.
As the demand for sustainability grows, so too do innovations in tyre repair technology. REMA TIP TOP recently launched a world-first: a tyre repair patch featuring a bimodal bonding layer. This new patch improves both initial adhesion and structural integrity, increasing the long-term reliability of repairs.
Additionally, the company is shifting towards solvent-free tyre repair, further reducing environmental impact. "According to our calculations, the manufacture and disposal of a single tyre produces 44 kg of CO2. In Germany alone, tyre repairs could save over 32,000 tonnes of CO2 emissions every year," Hieber notes.
Retreading goes beyond simple repair. It gives tyres a second or even third life, significantly reducing the carbon footprint compared to manufacturing new ones. A study by the Fraunhofer Institute for Environmental, Safety and Energy Technology (UMSICHT) found that retreaded tyres generate 63% less CO2 during production compared to new high-quality tyres.
Many drivers are sceptical of retreaded tyres, believing they are less safe. However, as Hieber clarifies, retreaded tyres have been subject to the same stringent quality standards as new tyres for decades, meeting UN-ECE Regulations 108 and 109. These ensure that retreads meet the same safety, speed, and load requirements as new tyres.
While car tyres can only be retreaded once, truck tyres can be retreaded up to three times, and in aviation, where safety standards are especially strict, tyres can be retreaded over six times.
REMA TIP TOP also invests in education and training to promote sustainable tyre practices. Through the REMA TIP TOP Academy in Poing, the company trains workshops and technicians in advanced tyre repair systems, helping to ensure that repairs are performed safely and effectively.
