The Tamil Nadu-based company’s greenfield expansion will propel its rCB capacity from 5,000-20,000 metric tonnes. Director Ravi Rathi explained that there has been a change in attitude towards rCB within tyre companies, leading to heightened demand.

Tamil Nadu-based Capital Carbon is expanding its recovered carbon black (rCB) capacity by 15,000 metric tonnes with a new greenfield project at Gummidipoondi. The plant is slated to become operational by January 2025 and boost the capacity from 5,000 metric tonnes to 20,000 metric tonnes, annually.

Speaking to Tyre Trends, Director Ravi Rathi explained, “The decision to pursue a greenfield expansion in the rCB sector stemmed from the rapid development of this innovative product over the past four to five years. Given our background in the pyrolysis business, expanding into rCB felt like a natural progression. rCB is still a relatively new product and both manufacturers and users are in the process of learning about its applications. When we first began exploring this market, around four years ago, it was challenging. Many tyre manufacturers would dismiss our proposals even before we could present our case as they were hesitant to incorporate recycled materials into their mainstream formulations.”

“However, in recent years, attitudes have shifted significantly due to increasing emphasis on sustainability and circular economy principles. The industry is now more open to integrating green products. We started with a modest capacity of 5,000 metric tonnes per annum, which allowed us to gain insights into customer needs. Gradually, we scaled our operations from small quantities to commercial sales. The key driver for our recent expansion is customer demand. We have obtained product approval, and customers are eager to purchase rCB,” he added.

He also noted that companies wanted assurance that the demands could be met consistently, which was also a factor behind the expansion. Furthermore, having multiple units also allows the company to manage any potential supply chain issues, effectively. “If a minor problem arises in one unit, we can still supply material from another, minimising disruptions for our customers,” said Rathi.

The entire CAPEX for the greenfield plant is set at INR 20 crore.

Pyrolysis to rCB

Capital Carbon commenced operations in 2012 with a modest pyrolysis capacity of 10 tonnes per day. Over the years, it has consistently expanded its capacity, increasing to 150 metric tonnes per day. The company has also bolstered its backend operations, enhancing sourcing capabilities and adding substantial shredding and crumbing capacity.

Additionally, Capital Carbon has focused on value-added products including pyrolysis oil distillation and rCB. As of now, it operates a shredding capacity of 120,000 metric tonnes per annum for captive consumption. This capacity is supplemented by sourcing contaminated tyre bales, which typically have 20-30 percent rubber contamination. This material is cleaned to yield 98 percent pure steel, with the remaining rubber used for pyrolysis, creating a separate business vertical.

Currently, the company processes approximately 50,000 to 52,000 metric tonnes of tyres per annum through its pyrolysis operations. In terms of value addition, Capital Carbon produces between 20,000 to 24,000 tonnes of pyrolysis oil, annually.

When asked about the motivation behind establishing a pyrolysis plant, Rathi noted, “My father worked at Birla Carbon and retired in 2019. Although we lacked prior business experience, we were inspired by the industrial upbringing and the promising potential of the pyrolysis sector. Following the completion of my chartered accountancy studies, I decided to pursue this opportunity.”

He acknowledged that pyrolysis often has a negative reputation in India, where it is sometimes viewed as a ‘dirty business’. To combat this perception, Capital Carbon prioritises quality management and environmental responsibility in its operations. IT employs fuel-based heating methods in its pyrolysis process as electric heating is generally not feasible due to the high volumes involved in tyre pyrolysis. The initial heating requires some fuel, which can include biomass or pyrolysis oil, but the system becomes self-sufficient once it reaches a certain temperature.

The primary outputs from the pyrolysis process include fuel oil, carbon char (used as raw material for rCB or as an alternative energy source for cement plants), steel wires and pyrolysis gases, which are utilised for heating purposes.

He highlighted that the pyrolysis oil produced is of high quality with low sulfur and carbon content, making it cleaner than many conventional heating fuels used in India.

Quality control

The company’s sourcing strategy primarily focuses on domestic suppliers. It procures rejected tyres and dealer returns from various companies, which constitute a substantial portion of the feedstock. This local sourcing approach ensures that it maintains a steady supply of raw materials

Following sourcing, the production of recovered carbon black involves several critical steps. Initially, tyres are shredded to extract carbon black, steel and other components. The distinction in product application necessitates tailored processing methods.

For instance, producing carbon char for energy requires less stringent technical specifications compared to producing carbon black intended for high-performance applications, such as tyre manufacturing or footwear.

“The quality of the final product begins with meticulous sorting of tyres to determine suitability for pyrolysis. This initial step is vital for ensuring consistent output quality. Following sorting, the tyres are shredded into steel-free rubber chips of 15-20 millimetres. During pyrolysis, we focus on maintaining specific quality parameters for the pyrochar produced. This includes stringent controls to limit ash content, which must remain below 20-22 percent to ensure product consistency. The handling of impurities such as wires and stones in the pyrochar is essential. Post-processing, the pyrochar is milled to fine particle sizes (10-15 microns), enhancing its surface area for better compatibility with rubber compounds,” explained Rathi.

Once the recovered carbon black is processed, palletisation becomes the next step. This method streamlines handling and ensures that the product meets industry standards. While the equipment resembles that used for traditional carbon black, adaptations are necessary to accommodate the unique characteristics of recovered carbon black.

“To facilitate customer adoption, we offer tailored packaging solutions including 25kg paper bags, EVA / LDPE bags and FIBC bags, allowing clients to integrate our products seamlessly into their existing production processes,” he added. 

As the industry evolves, the need for standardised quality benchmarks for recovered carbon black has become increasingly clear. Major corporations have driven this change, leading ASTM to establish a dedicated committee (D36) focused on developing specific standards for recovered carbon black. Unlike conventional carbon black, which adheres to existing standards, recovered carbon black requires new metrics to account for its varied origins and compositions.

The committee is currently validating a series of standards including moisture content, pallet hardness and particle size analysis, specifically for rCB. This ongoing development is slated to enhance product credibility and facilitate broader market acceptance.

Commenting on the same lines, Rathi mentioned, “We maintain a dedicated quality lab to refine our production processes continually. Our focus on evolving our offerings has resulted in the introduction of two new grades of recovered carbon black, aimed at meeting diverse market needs. Our commitment to leveraging advanced machinery and improved grinding techniques reflects our proactive approach to quality enhancement and capacity expansion.”

Optimistic market outlook

The demand for recovered carbon black in India is poised for significant growth, driven by a strong shift toward sustainability. Customers are increasingly seeking high-quality suppliers, indicating a burgeoning market for rCB.

“Globally, rCB production currently accounts for less than one percent of total carbon black production, underscoring a substantial opportunity for expansion. As customer awareness and demand for sustainable products increase, we anticipate a corresponding rise in rCB consumption,” informed Rathi.

He added, “Many major corporations have committed to achieving carbon neutrality by 2050, necessitating immediate action to integrate green and circular products into their supply chains. As these companies strive to meet their net-zero targets, they are turning to recovered materials such as rCB to fulfil sustainability mandates. Our role is crucial in assisting these customers to achieve their goals through the production of eco-friendly and circular products derived from end-of-life tyres.”

Speaking on market opportunities, he said, “India remains our largest market, but we are also making significant inroads into Sri Lanka. The European market is particularly promising, though it presents challenges related to certifications and distribution. We are currently working on obtaining the necessary certifications, including ISCC Plus, to unlock this market potential.”

“Our immediate focus is on completing our current expansion project, after which we will enhance our pyrolysis capacity to align with the growing demand from our customers. As the volumes of recovered carbon black usage increase, we aim to be ready with sufficient supply,” he added.

He expects to penetrate the European market by the first half of FY26, following the completion of the current plant expansion.

Challenges in scaling production

“One of the primary challenges in scaling rCB production is the scarcity of raw materials. The supply of suitable feedstock is diverse and scattered, making it difficult to source consistently. In the past, customers struggled to understand the differences between recovered carbon black and virgin carbon black grades, often asking if we could produce specific grades like L550 or L660. However, as knowledge in the market has matured, customers are increasingly recognising that rCB is a distinct material requiring tailored processing approaches,” informed Rathi.

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As Extended Producer Responsibility (EPR) frameworks expand globally, the tyre industry is undergoing a structural transformation. Collection systems are improving, traceability is increasing and investments in recycling technologies are accelerating. However, one critical tension remains insufficiently addressed: the speed of industry evolution is outpacing the agility of public policy. And within that gap, one key question emerges: where does retreading fit in this new circular economy architecture?

A STRUCTURAL PARADOX

Retreading represents one of the most efficient forms of resource optimisation in the tyre lifecycle. It extends product life, reduces raw material consumption and lowers emissions. Yet, in many regulatory frameworks, it is still treated ambiguously – often grouped with recycling rather than recognised as prevention or preparation for reuse. This distinction is not semantic. It is strategic. Because when policy fails to differentiate, markets fail to prioritise.

A FAST-MOVING INDUSTRY, A SLOW-MOVING FRAMEWORK

The tyre market is evolving in real time:

1. Increasing penetration of low-cost imports.
2. Growing variability in product quality.
3. Accelerated turnover cycles.

Retreading, in this context, becomes more than a circular solution. It becomes a filter of industrial quality. Not all tyres are equally retreadable. And that difference defines their real contribution to circularity. Yet most EPR systems continue to operate with uniform economic signals, failing to distinguish between products that enable multiple lifecycles and those that exit the system after a single use.

SIGNALS FROM EUROPE

Recent developments in countries like Portugal – where eco-fees applied to retreaded tyres approach those of low-cost, non-differentiated new tyres – highlight a concerning trend. Similarly, in Spain, industry representatives continue to advocate for a clearer institutional recognition of retreading within EPR systems. These cases illustrate a broader issue: circular policies can unintentionally undermine higher-value circular strategies.

THE MISSING LINK: PERFORMANCE-BASED POLICY

What is missing is not regulation. It is regulatory precision. EPR systems have successfully organised waste flows. But they have not yet evolved to reward performance within the lifecycle. This is where eco-modulation becomes critical.

ECO-MODULATION AS A STRATEGIC LEVER

Eco-modulation should not be a marginal adjustment. It should be a core industrial policy tool. Properly designed, it can:

• Differentiate tyres based on real circular
• performance.
• Incentivise durability and retreadability.
• Penalise short-lifecycle, non-recoverable products.
• Align market behaviour with system objectives.
• To operationalise this, we need new metrics.

FROM COMPLIANCE TO PERFORMANCE: A PROPOSED FRAMEWORK

The next step for EPR systems is to move towards performance-based differentiation. This could be implemented through instruments such as:

• Retreadability Index (RI)
• Performance Score (CPS)

These would measure:

• Number of effective retreading cycles per tyre.
• Structural durability and casing quality.
• Real contribution to lifecycle extension.

Under such a system:

• Tyres with higher retreadability would receive lower eco-fees.
• Products that systematically fail to re-enter the cycle
• would face higher costs.
• This is not just a technical refinement. It is a shift from:
• Generic compliance.
• To intelligent market shaping.

THE LATIN AMERICAN PERSPECTIVE

In Latin America, the stakes are even higher.

The region faces:

• Structural dependence on imported tyres.
• Strong presence of low-cost, low-durability products.
• Emerging EPR frameworks (Chile, Costa Rica, Peru, Ecuador)

Chile, for example, through its EPR law (Ley REP), has made significant progress in structuring collection and recovery targets. However, like many systems, it still faces the challenge of fully integrating reuse strategies into its economic logic. Under these conditions, retreading is not just an environmental solution. It is a strategic industrial capability.

BEYOND WASTE MANAGEMENT

Latin America has a unique opportunity to design EPR systems not only to manage waste

but to govern resources and shape markets.

This means:

• Incentivising retreadable tyres
• Strengthening local retreading industries
• Reducing dependence on short-lifecycle imports
• Building resilience into supply chains

But this requires something critical: policy agility. Because if regulation lags behind market dynamics, it will not transform the system – it will merely formalise its inefficiencies.

A STRATEGIC CONCLUSION

If EPR systems are designed without properly integrating retreading – and without differentiating based on actual circular performance – they risk reinforcing a linear logic under a circular narrative. For emerging regions, this would be a critical mistake

The discussion around repair, reuse and retreading can no longer be treated merely as a waste management issue. It is increasingly becoming a matter of industrial resilience, strategic autonomy and economic security.

As global supply chains face growing pressure from geopolitical fragmentation, logistics disruptions and volatility in raw material markets, extending the useful life of products is emerging as a strategic capability for nations and industries alike.

In this context, Right to Repair should not be understood only as a consumer right but also as an industrial policy tool capable of strengthening local economies, reducing external dependency, preserving technical capabilities and supporting more resilient production systems.

Retreading, remanufacturing and reuse are part of a broader transition where value creation is no longer based exclusively on extraction and disposal but increasingly on intelligence, efficiency and lifecycle management.

CIRCULARITY WITHOUT HIERARCHY BECOMES INEFFICIENCY. REGULATION WITHOUT DIFFERENTIATION BECOMES DISTORTION.

Final note

The future of the tyre industry will not be defined only by how we recycle, but by how intelligently we extend the life of what we already produce. And that requires alignment between:

• Industry dynamics.
• Policy design.
• And strategic vision.

In that equation, retreading must move from the margins to the centre. Because properly understood, it is not just a process. It is a strategic filter, an industrial policy tool and a geopolitical lever.

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The Association of Natural Rubber Producing Countries (ANRPC) has released its market report for May 2026, depicting a sector characterised by sustained price strength and firm fundamentals. The global natural rubber market received additional upward momentum from a decline in Brent crude oil prices, which averaged USD 107.14 per barrel during the month. This represented a month-on-month decrease of 8.65 percent, attributed to easing geopolitical tensions in the Middle East and the temporary reopening of the Strait of Hormuz, which collectively bolstered the commodity's outlook.

Global production projections for 2026 stand at 15.337 million tonnes, marking a 2.4 percent increase from the previous year, with growth driven by Thailand, China, India and Malaysia, even as output moderates in Indonesia and Vietnam. Monthly production, however, fell to 997,000 tonnes in May, a year-on-year decline of 4.7 percent, due to seasonal wintering and dry weather conditions across South and Southeast Asia. Concurrently, worldwide consumption is forecast to rise by 1.3 percent to 15.550 million tonnes for the year, with May's consumption reaching 1.310 million tonnes, a 4.6 percent annual increase. This demand was underpinned by steady tyre manufacturing, electric vehicle-related consumption and resilient purchasing managers' indices in China and India, alongside record auto retail sales in India.

Physical prices for all major grades recorded broad-based gains throughout May, with SMR-20, STR-20, RSS-3, RSS-4 and latex all experiencing increases. Trade flows showed a mixed pattern, as imports from China and India contracted month-on-month, while Malaysia and Vietnam registered significant gains. On the export front, Cambodia, Vietnam and Thailand recorded increases, whereas Indonesia and Malaysia saw declines. Currency movements saw the Malaysian ringgit ease slightly, while the Thai baht traded within a stable range, and both nations reported decelerating GDP growth for the first quarter of 2026. Futures contracts on the SHFE and SGX reflected tightening supply and firm demand, posting notable month-on-month gains.

The market outlook remains cautiously balanced against a backdrop of several macroeconomic factors. Elevated trade tensions between United States and China, ongoing geopolitical conflicts and a steady United States Federal Reserve interest rate policy present potential headwinds. However, these are being offset by supportive elements, including the accelerating adoption of electric vehicles, tight feedstock supply due to adverse weather and the positive market sentiment generated by the European Union's decision to lower anti-dumping duties on Chinese tyres.

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Zeon Corporation has introduced a novel data management system specifically designed for elastomer research and development, marking the company’s first foray into a subscription-based service model. The platform is engineered to centralise and streamline R&D data pertaining to rubber products, with the primary goal of enhancing operational efficiency and accelerating developmental processes for its clientele. The initial phase of the rollout will concentrate on the Japanese market, with a strategic plan to broaden access to other regions in the future.

The elastomer industry frequently grapples with the fragmentation of data across disparate systems, which complicates the effective utilisation of historical information. Through extensive experience in elastomer supply and sustained client engagement, Zeon has identified this operational hurdle as a pervasive issue affecting the entire sector. This recognition has been the catalyst for developing a solution that directly confronts these data management deficiencies.

The newly launched system incorporates specialised functionalities that are finely attuned to the nuances of rubber product R&D. It integrates a comprehensive database that combines master data for key compounding agents available in Japan with extensive catalogue information, facilitating rapid and efficient data access for daily research tasks. The platform’s intuitive interface and user experience are meticulously crafted to optimise usability and data visualisation, with a commitment to ongoing enhancements based on evolving customer requirements.

Zeon has formally designated this data management solution as a growth driver for its strategic initiatives, extending beyond the Phase 3 objectives of its STAGE30 medium-term plan. The company envisions this business becoming a cornerstone of its strategy to augment the value proposition of its elastomer operations. By synergising its deep-seated elastomer expertise with advanced data utilisation technologies, Zeon is poised to foster innovation in client R&D and propel the overall advancement of the elastomer industry.

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A new bio-based cut & chip resin for the most demanding applications.

NaugaShield BIO-TR 30 is SI Group’s latest advancement in bio-based performance resins designed to significantly improve cut and chip resistance in high-severity rubber applications. With approximately 75 percent bio-based content, this innovative material delivers on sustainability targets while exceeding the performance typically associated with petroleum-derived resins, making it a strong choice for applications such as OTR tyres in mining, construction and agriculture, mining conveyor belts, rubber tracks and mill linings.

Cut and chip resistance is a complex set of material behaviours, including static mechanical strength, dynamic response under deformation and ability to withstand sharp impacts and abrasive environments. In demanding applications such as mining or agriculture, materials must tolerate repeated high-strain loading and resist the initiation and propagation of tears. NaugaShield™ BIO-TR 30 was developed precisely to meet these conditions, demonstrating notably low dynamic heat buildup and excellent tear strength – characteristics closely tied to enhanced cut and chip resistance and long-term durability under cyclical loads.

To evaluate its performance, NaugaShield BIO-TR 30 was benchmarked in an Off-road Rib Tread formulation against two widely used industry references: a gum rosin/semi-aromatic C5/C9 resin combination and a styrenated DCPD resin. All materials were tested at an equal loading of 10 phr to provide a direct and unbiased comparison. Under these conditions, the bio-based resin consistently outperformed both alternatives, offering a stronger balance of reinforcing behaviour, improved tear propagation resistance and superior resistance to thermal degradation during dynamic flexing. Further improvements were achievable by reducing the amount of free extender oil in the compound, underscoring the resin’s adaptability in formulation design and its ability to unlock even greater performance when optimised.

These laboratory indicators were corroborated through extended Coesfeld Cut & Chip testing (see chart), in which compounds were subjected to up to 3,000 cycles at 200 rpm under a 200N applied force. Formulations containing NaugaShield BIO-TR 30 exhibited substantially lower mass loss and maintained tread surface integrity more effectively than the hydrocarbon and gum rosin-based-benchmarks. The performance advantage was even more pronounced in compounds adjusted for lower free oil content, confirming that the resin can be tailored to meet the durability requirements of the most challenging operating conditions.

The strong performance of NaugaShield BIO-TR 30 in OTR tread compounds can be readily transferred to other rubber goods that encounter similar wear mechanisms. Applications such as mining belts, agricultural and construction tracks or mill linings benefit from the resin’s ability to reinforce the rubber matrix, reduce crack growth under repeated impact and maintain structural cohesion under high-strain deformation. This versatility allows manufacturers to integrate a 75 percent bio-based resin that supports sustainability by reducing fossil-based content and helping end products last longer while maintaining – and often improving – operational performance across multiple product lines.

NaugaShield BIO-TR 30 is currently available in commercial quantities, enabling compounders and manufacturers to move directly from laboratory evaluation to pilot- and production-scale trials.

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