I have a set of New Schwalbe Lugano tires on my bike. I bought them from an ebay seller some time ago, and haven't used them until now, but it is most likely to late to return them. One tire has a noticeable bulge, I have removed the tire and inspected the tube multiple times, I have mounted it on different wheels, I have mounted different tires on this wheel, I have used different tubes, every combination possible, yet this tire always looks like this :
The bulge is right were the joint is in the carcass of the tire, you can see from the inside of the tire, It almost looks like part of it pulled away, the dark residue is actually glue

Anyone have any experience with these tires? I thought I'd try something different than the Pasela I normally use, silly me.

It looks like a tire that's been used on the front wheel on a Tackx-trainer (don't know if it's called that in the US). I have a nice brand new rubino that was on a bike I once bought, with an incredible bulge kinda like yours only more dramatic. It nearly drags me off the road when riding it...

I guess anything's possible, they came from Bikewagon, had the Cardboard cards and protective plastic over the sidewall label.. Sure looked new

I should add I bought two, the other tire seems fine

I had Lugano's, and whilst these were the modern version with two colored stripes, I'm never buying them again. The casting is just so awful: there's a huge "wave" in the stripes, indicating that the compound was layed on indifferently at best. I noticed the same thing with the tires on a friends' bike. Yes, they are the cheapest in the Schwalbe line up, but you get what you pay for.

Its funny, these tires aren't skinwall, but just tan color rubber on the sides, like red or blue would be. And Yes, color is applied very inconsistently. One concern is that if I pump the tire to 75psi, the bulge is hard to see, but if I go to 100psi like I want to, it gets much bigger, as in photos.

Yes, mine were irregular too. Some parts expanded noticably more beyond 100 psi. Both tires had the same problems in the same spot, indicating some serious QC problems at Schwalbe...

"fortunately" I ran through a beer bottle on the first ride (after 3 km...) ruining both tires beyond repair.

I'm actually hesitant to ride on it, mostly because I don't want a problem 20 miles out...

Schwalbe North America has a warranty form online here: https://www.schwalbetires.com/company/warranty_policy

I guess I will try this route and see what they say, I will update later. Thanks!

Online Warranty ticket submitted! It also said "We will assess and report via email within two working days, however a heavy case load may delay your response" Too many warranty claims to handle? Anyway, I used to work for a tire company and most of the time we wanted the tire back for inspection (unless we knew a certain batch was defective already, then we just sent it), but they seem to do it via email pictures instead.

I have not purchased any Schwalbe tires except for their Milano tubulars (I have them on three of my five bikes). and I had very good luck with them. Their treads and base tapes had been very straight and no lumpiness at all at the base tape as one might encounter with cheaper tires like the Vittoria Rally. Valves have been problem-free too.
I suspect that Schwalbe, like other manufacturers have bargain tires made in the far East (usually Thialand) that can have spotty quality control and maybe you are experiencing this. I'd return the tire to where you bought it for a warranty exchange. Most dealers and internet retailers are pretty good with exchanging defective tires for good ones as they and the tire manufacturers see that it's worth avoiding any liability that may come up with a tire failure accident, as long as it's obvious that the damage was not caused by the user.....
JMOs

Chombi

I've mounted many sets of Luganos and found them to be pretty darn good tires, even given the price point.
Can't speak to the quality of the color casting, but many of those wander around a bit regardless of brand.
Not too many years ago we paid the same amount for hard, shiny, wired tires that rode like concrete. Times have changed for the better.
Looks like you got a lemon. As you said in your post, the other one seems fine.

I actually have other Schwalbe tires, Lugano Folding and the Milano tubulars, thats what prompted me to buy these instead of the Pasela. I agree, I must have gotten a Lemon, I suppose it happens from time to time. I know they weren't made in the hidden Jungle facility were they keep the genetically modified silkworms, but the quality of these tires is quite poor next to the (same price) Pasela.

Follow up - A few days after submitting my claim, I received an email from Schwalbe saying it was a bad tire and they would send a replacement; the tire arrived today. Good customer service

You're lucky, I've heard horror stories about their customer service. Passing the customer around from the office in Europe to the North American office, with neither wanting to own up.

Interesting. The two posts above, with two completely different results. Go figure. Anyway, glad you got lucky Zoku.

I'm on this thread because I just developed a major bubble in a 700 x 23 Schwalbe Lugano after about 300 miles, and wanted to find out if it is common. My max inflation was 120 and I think the rating is 110. I have the other one put aside, but after this I don't trust it enough to use it. It felt good, comfy for a 23c, but screw that. Thanks for reporting, Zoku260, maybe you saved somebody's face.

I had a problem with blowouts (4 in one day) on a new Legano. I found the casing had separated for about an inch, causing the tube to get in there and blow out. I contacted Schwalbe, followed their instructions, and they sent me a new one, plus 3 tubes. I mounted it and find them better than other tires at the same price point.

Because I appreciate customer service, I'll be getting some Schwalbe tires for a current build. Just because.

I have a set of Specialized S-Works tires, and the color stripe is so crooked, people behind me want me to stop and change tires. Then, they developed a bulge at the same location. These are not entry-level tires, these are the S-Works Mondo.