KORBACH (Germany) – It is in Korbach, a town in western Hesse, that beats the productive heart of Shelf, a giant founded in 1871 and today a world leader in the tire sector. This plant employs over 3.500 people. It's here that some of the world's most advanced tires are developed and produced, from car tires to those fitted to the bikes of WorldTour professionals. Here are two examples: Tadej pogacar ed Elisa Longo Borghini.
We had the pleasure of visiting the Korbach plant and following the production process step by step. It was a fascinating journey through safety, precision, innovation and above all performance. These are the four pillars of a brand that makes quality a matter of industrial culture. In an area where almost every family has a direct or indirect connection with Continental, the factory is not just a place of production, but the social and economic engine of an entire community.
The entrance to the factory
This is where our tour begins, between ancient brick and steel buildings and the more modern ones that line the perimeter of the plant. Before entering, each visitor must pass a series of checks: personalized badge, specific clothing, safety shoes, and a briefing on safety and respect for industrial secrecy. Smartphones are sealed, at least in some areas.
The production of Continental tires is in fact a process covered by patents and proprietary formulas, the result of years of research and development.
In the first department the raw materials are found, the basis of everything. Therefore: natural rubber, synthetic rubber, carbon black, silica, sulfur, and a long list of additives that determine the final properties of the product. The large silos and industrial mixers are almost reminiscent of a giant-scale kitchen, where every ingredient is measured to the nearest millimetre. Engineers explain how each type of tire is designed to meet specific conditions: rolling resistance, grip, durability, or puncture resistance. Thus begins the long journey that transforms a shapeless material into a perfect tire.
After a long process, we've reached this point. The tire is almost finished (here's the placement of the rings, which, however, don't go on folding models), but it's not yet a single piece.
After a long process, we've reached this point. The tire is almost finished (here's the placement of the rings, which, however, don't go on folding models), but it's not yet a single piece.
From mother rubber to special compounds
This is where Continental's technology shows itself in all its complexity. The so-called "mother gum", almost like a giant insulating tape, a centimeter or even more thick, is loaded into huge mixers, where temperature and pressure are controlled in real time. This is how the mixes, the true technological but also material heart of tires. Their composition varies depending on their use: a time trial tire will never have the same structure as a cyclocross or endurance tire, for example.
During the process, they are added synthetic or cotton fabrics, which act as a carcass, providing more or less rigidity or lightness, puncture resistance or smoothness… Each layer is laminated with millimetric precision.
The technicians explain how the materials are sourced through partnerships with top-notch companies. But above all, they show us how every step is carefully monitored. These large rubber belts are occasionally perforated. They explain that these are "core samples" for quality control, to avoid even the slightest defect.
In this controlled environment, the scent of rubber mixes with the constant noise of the machinery, which works 24 hours a day in a constant and perfectly synchronized rhythm. The goal is clear: to transform matter into performance, inch by inch.
The key moment: vulcanization
After kneading and rolling, theThe tire moves on to the first cutting stage. Each section is cut based on the tire model and wheel diameter. In some cases the circlet, that metal ring that allows the tire to adhere perfectly to the rim. Folding models, on the other hand, do without it to reduce weight or adapt to tubeless specifications.
The decisive step is vulcanization, the moment when the rubber is truly “born”. At temperatures exceeding 170 degrees and under controlled pressure (about 50 bar), the compound is transformed into a solid and elastic structure, ready to face the asphalt. Here the tread patterns and the Continental brand. As soon as they come out of the machine, the tires are stretched out and left to cool. As good Italians, the image of a pasta factory making spaghetti came to mind!
Here, however, the delicacies are called GP 5000, Aero 111, Magnotal, Terra Adventure… Each model has its own dedicated mold: both for the tread design and its section. Once cooled, each tire is tested on machines that simulate thousands of kilometers of rollingOnly products that pass all checks move on to the final packaging stage.
From the laboratory to the WorldTour
It's in the final department that the tires become "official," ready to be mounted on the team's bikes. The technicians show us the customized versions intended for Continental's partner teams: laid down by the UAE Team Emirates from XDS-Astana, from Bahrain-Victorious to Ineos Grenadiers… It serves 31 UCI teams, both men and women, across all categories. The tires are sent directly to service centers or to team mechanics, where they are mounted and tested. For example, we've seen prototypes that will be released for sale next year.
Pogacar is very attentive to the general development of everything related to technique and technology that surrounds it and he is no different with tyres.
Let us conclude with a reminder of the environment. Tires, as is well known, are among the biggest polluters. Yet Continental is working like perhaps no other in the industry to minimize their impact. The Korbach plant itself is an example of sustainable industry. Over 90 percent of waste is recycled and much of the energy comes from renewable sources.The goal is to produce the least polluting tires possible, whether for bicycles, trucks, cars, or work vehicles. Visiting Korbach means understanding that behind every tire lies a culture, made of German precision and a passion for the road.
