Paul Lloyd: “Farrel Pomini’s core business lies in supplying processing equipment for the plastics and petrochemical industries."

Pyrolysis has long been associated with pollution and inefficiency, particularly in developing markets where outdated methods dominate. However, technological advancements and a stronger push for circularity are transforming this perception. HF Group, through its subsidiary Farrel Pomini and WF Recycle-Tech, is at the forefront of this shift, introducing a continuous pyrolysis system that promises cleaner and more efficient tyre recycling. Unlike traditional batch processing, its technology ensures consistent output, better resource recovery and reduced emissions.

Pyrolysis has always been considered to be a dirty business. However, with the changes in technology and the increasing hunt for circularity across the tyre industry, businesses are attempting to redefine the age-old tyre recycling process and remove the malice associated with it.

Farrel Pomini is one such entity with the HF Group that is attempting to make pyrolysis cleaner. WF Recycle-Tech, established in 2013, started commercial operations in 2022 with selling its first pyrolysis unit in 2024, slated to be operational in 2026.

Speaking to Tyre Trends, President Paul Lloyd said, “Farrel Pomini’s core business lies in supplying processing equipment for the plastics and petrochemical industries. While its continuous mixer can be used for rubber applications, it is primarily designed for plastic masterbatches and compounds. The company operates across multiple divisions with its plastics compounding equipment focusing on niche applications for highly filled and temperature-sensitive materials. Although the plastics market is significantly larger than the rubber sector, Farrel Pomini targets specialised segments within it. Expanding its footprint in sustainability, the company has developed recycling systems for both plastics and rubber. The end-of-life tyre recycling solution was developed in collaboration with its group company, WF Recycle-Tech.”

Tyre pyrolysis has long been regarded as a polluting industry, particularly in developing countries where unregulated plants often operate at night to evade environmental scrutiny. In markets like India, many such facilities shut down due to non-compliance, reinforcing the industry’s reputation as a ‘dirty business’.

Lloyd further explained, “In Europe, the focus is shifting towards sustainability, driving innovation in pyrolysis technology. Traditional methods relied on large kilns, where tyres were burned with external heat over extended periods. The process was inefficient, labour-intensive and environmentally damaging, requiring extensive manual cleanup.

HF Group has taken a different approach, developing a continuous pyrolysis system that eliminates these challenges.”

Instead of batch processing, the system ensures a constant flow of material, allowing for the controlled capture of gases, liquids and solid outputs. The process begins with pre-grinding tyres into metal-free rubber crumb (6–20 mm), which is then fed into the machine via a hopper. Operating at a capacity of 1,500 kilogrammes per hour, the system requires only continuous material input while automatically managing output streams including recovered oil and gas.

Apropos to the pain points that the company wanted to address, he noted, “Over the past decade of developing this solution, several key learnings and priorities emerged. First and foremost, the goal was to create an efficient pyrolysis system that could consistently process tyre waste at an industrial scale. Second, the decision to develop a continuous rather than batch-based system was fundamental as continuous pyrolysis offers greater consistency, scalability and efficiency. Third, integrating a continuous mixer in the pre-processing stage became a major focus as it significantly improved the homogeneity and quality of the output materials. Finally, optimising the recovered output, particularly recovered carbon black, became the primary objective. Initially, the project was focused on tyre-derived oil (TDO), but as the market evolved, the emphasis shifted to producing the highest-quality rCB, aligning with upcoming ASTM standards and stringent industry requirements.”

By integrating advanced processing controls, the solution ensures cleaner, more efficient pyrolysis, positioning itself at the forefront of sustainable and cleaner tyre recycling.

THE OUTPUT

HF Group’s expertise in mixing technology creates a natural synergy between its traditional business and its expansion into tyre recycling. While the company is known for its tyre curing and rubber mixing solutions, it also has a plastics mixing division; this same mixing technology plays a crucial role in its pyrolysis process.

The recycling system starts with tyre crumb, which is fed into a high-shear Farrel Continuous Mixer originally designed for plastics processing. The mechanical shear heating raises the temperature of the material to 330 degrees Celsius. This ensures uniform heating before the material enters the pyrolysis chamber, where temperatures increase to between 520 degrees Celsius and 580 degrees Celsius. The continuous system eliminates inefficiencies seen in traditional batch pyrolysis, where prolonged heating cycles lead to higher energy consumption and inconsistent output.

Material recovery is a key advantage of the system. For every tonne of tyre crumb processed, approximately 50 percent is converted into pyrolysis oil, yielding 550–570 litres. Around 40 percent becomes recovered carbon black (rCB), a critical raw material that can replace virgin carbon black in industrial applications. The remaining 10 percent is gas, which can be used to power the system, further improving energy efficiency.

Beyond throughput, the system’s design significantly reduces overall energy demand. Mechanical shear heating minimises reliance on external thermal energy, while the continuous process prevents heat loss and optimises fuel efficiency.

Additionally, rCB from the pyrolysis process requires 60–70 percent less energy to refine, further enhancing sustainability.

“Pyrolysis fundamentally relies on heat and time in the absence of oxygen. Under these conditions, tyres thermally degrade, breaking down into vapour, which is condensed into oil and a solid residue, which is now widely used as recovered carbon black (rCB). This output can be further refined for industrial applications, creating a circular economy within the rubber industry,” explained Lloyd.

CHALLENGING INTEGRATION

The primary challenge for tyre manufacturers in adopting rCB is achieving performance characteristics comparable to virgin carbon black. Similarly, tyre pyrolysis oil must meet stringent quality standards to serve as a feedstock for high-value applications beyond just fuel. The company’s continuous pyrolysis system addresses these concerns by enhancing the quality and usability of both outputs.

“In the case of tyre pyrolysis oil, if used as a fuel, the calorific value may vary slightly, but it remains a viable option. However, its greater potential lies in serving as a feedstock for sustainable carbon black or even virgin carbon black production. The consistency of the oil’s composition determines its suitability for high-end applications, making process control a critical factor,” noted Lloyd.

He added, “For rCB, higher quality directly translates into increased usability across different applications. While rCB will never completely replicate virgin carbon black, superior grades enable a higher substitution rate. In some cases, a high-quality rCB can replace up to 30 percent of virgin carbon black, whereas lower-quality alternatives may only allow a 15 percent substitution. This increased usability not only enhances sustainability but also raises the material’s commercial value.”

HF Group’s rCB, produced through its WF Recycle-Tech process, has been extensively tested across multiple industries. It has demonstrated strong performance in plastics masterbatch applications, technical rubber goods and even tyre manufacturing. One major tyre producer has already validated its suitability for substitution in new tyres, underscoring its industry acceptance.

A key differentiator of the process lies in its patented two-stage pyrolysis system. While continuous pyrolysis itself is well established, HF Group’s innovation stems from its integration of a high-shear Farrel Continuous Mixer in the first stage.

This approach ensures uniform heating, eliminates direct heat exposure and optimises the pyrolysis reaction in the second stage. The result is a more efficient process that yields higher-quality recovered carbon black and cleaner tyre pyrolysis oil.

PERSEVERING THROUGH LIMITATIONS

The primary limitations of the system, Lloyd noted, revolve around scalability, operational efficiency and material consistency. The current processing capacity of 1,500 kilogrammes per hour is relatively low. Scaling up production rates while maintaining efficiency and reliability is an ongoing challenge. The key challenge is ensuring long-term operational stability and optimising run times.

Another significant factor is feedstock variability, particularly in markets like India, where used tyres from different sources such as passenger cars, trucks and buses are often mixed without segregation. The ideal scenario would involve processing a uniform type of tyre with a consistent rubber composition, but in reality, recycling operations must work with what is available.

“There are two main approaches to addressing this viz-a-viz meticulous sorting, which ensures consistency but is time-consuming and costly, or strategic blending, which creates a stable output by balancing material variations. The current system has been designed to handle diverse feedstocks without sorting, using a consistent blend of tyres to produce a predictable output,” said Lloyd.

In the long term, technological advancements such as artificial intelligence or tracking mechanisms for tyres could enhance sorting processes, making recycling operations more efficient. However, for now, the focus remains on refining the system to handle real-world feedstock conditions while delivering high-quality outputs. The continuous processing system also provides flexibility to adjust parameters and optimise results, making it a robust solution even in environments where feedstock quality is unpredictable.

MARKET TALK

The return on investment for pyrolysis systems is quite favourable, but it carries risks, especially in the early stages. A well-managed system operating efficiently for 6,000–7,000 hours per year, with a stable feedstock supply and consistent product quality, can generate strong financial returns, explained the executive.

However, challenges arise if there are interruptions in material supply, equipment downtime or fluctuations in product quality. These factors introduce uncertainty, which can make securing financing more difficult. That said, the market for TDO and rCB is growing, providing ample opportunities for revenue. Companies that can differentiate its output and meet quality standards can command premium prices, further improving ROI.

The market focus for HF Group’s advanced pyrolysis solutions primarily includes recyclers looking to add more value to their processes, material users such as tyre manufacturers and technical rubber companies seeking sustainable raw materials and new businesses emerging in response to industry needs.

“In the US and Europe, there is a growing entrepreneurial push to bridge the gap between traditional recycling and the sustainability requirements of the tyre industry. However, in markets like India and other parts of Asia, the challenge lies in shifting perceptions. Many existing pyrolysis operations use older-generation systems. The transition to modern, cleaner and more efficient systems requires education, proof of performance and financial support. Despite these challenges, India remains a strong market for HF, as the industry values high-quality technology and is willing to invest in the best solutions once the benefits are clearly demonstrated,” informed Lloyd.

Over the next five years, the company’s primary goal is to establish a proven track record with the first full-scale pyrolysis system, demonstrating its performance, reliability and efficiency. Once this is achieved, the focus will shift to helping potential customers secure financing by reducing perceived risks, making it easier for them to invest in the technology.

Alluding to the next phase of development, Lloyd informed, “The next phase of development focuses on three main areas. The first priority is industrialising the system to ensure it operates efficiently, consistently and reliably over long production cycles. This transition from pilot-scale to full-scale manufacturing is where HF Group’s expertise in engineering advanced processing equipment comes into play. Secondly, efforts are underway to further refine the pyrolysis reaction to enhance output quality and efficiency. Lastly, ongoing research and development is focused on post-processing improvements, particularly the removal of ash from recovered carbon black to increase its usability in high-performance applications.” n

Kraton Corporation, a leading global producer of speciality polymers and high-value bio-based chemicals derived from pine wood pulping co-products, has achieved International Sustainability and Carbon Certification (ISCC) PLUS for its manufacturing facility in Panama City, Florida, United States. This independent certification tracks sustainable materials via a mass balance approach. The achievement allows Kraton to issue a formal ISCC PLUS Sustainability Declaration with shipments of its biobased polyterpene resins, providing its customers with the documentation needed to validate the renewable content in their own products.

The Panama City site becomes the company’s fourth production plant to gain this certification, building upon a commitment that started with the certification of its Sandarne, Sweden, facility in 2021. By securing these certifications across its network, Kraton strengthens its leadership in supplying circular and renewable solutions. This effort supports broader industry shifts, as customers can now more seamlessly integrate verified, sustainable materials into their supply chains and end products.

Ultimately, the company’s pursuit of such certifications aligns with a larger transition towards a more sustainable and circular economy, demonstrating how specialised chemical producers can enable tangible environmental progress through verified chain-of-custody systems.

Lana Culbert, Kraton Pine Chemicals VP of Marketing, said, “Our SYLVARES™ and SYLVATRAXX™ brands feature a portfolio of high-performance polyterpene resins. They are widely recognised for their use in adhesives and tyre applications, yet their versatility extends to other industries, like agriculture, with more opportunities ahead. While we can measure bio-based content of our pine chemicals using Carbon-14 analysis, certifying our Panama City facility under ISCC PLUS strengthens supply chain transparency, supporting the growth of the circular economy.”

Solvay has inaugurated its new bio-circular silica facility at its plant in Livorno, Italy, a strategic investment that underscores Italy’s industrial leadership in green innovation. The facility directly anticipates evolving EU sustainability rules for tyres and supports the ambitious environmental goals of Solvay’s customers. By establishing this operation, Solvay positions itself as a proactive partner in achieving the objectives of the European Green Deal and upcoming product regulations.

The site manufactures highly dispersible silica using an innovative process that transforms rice husk ash, an agricultural byproduct, into a valuable bio-based raw material. This method creates a local circular economy, benefits the agricultural sector, and reduces associated CO₂ emissions by 35 percent compared to conventional production.

This initiative is a cornerstone of Solvay's global strategy to transition all its silica production to certified circular raw materials by 2026. While the Livorno site is the first to use rice husk ash, other global plants will utilise different local waste streams. For the tyre industry, adopting this circular silica already enables tyres to contain up to 15 percent recycled or renewable content, providing significant progress towards the sector’s 2030 material targets.

Beyond compliance, the silica produced is essential for developing energy-efficient tyres that lower rolling resistance, thereby reducing fuel consumption and extending electric vehicle range. The Livorno facility thus reinforces Solvay's market leadership in sustainable silica and highlights Italy’s vital role in the company’s broader portfolio of green investments, including projects in green hydrogen and circular soda ash.

Philippe Kehren, CEO, Solvay, said, “By acting now, Solvay is helping tyre manufacturers prepare for future EU requirements and meet their own sustainability goals. Livorno is a tangible example of how we turn circular economy principles into industrial reality, enabling progress for generations.”

Jana Striezel, Head of Purchasing at Continental Tyres, said, "Solvay has managed to transform an agricultural byproduct into a high-performance material on an industrial scale. We are looking forward to integrating more and more rice husk ash silica as a recycled material in our tyre production and are very satisfied with its performance. We are keen on innovative, renewable and recycled materials because they support our ambitious sustainability roadmap.”

An Nuyttens, President of Solvay’s Silica business, said, “Livorno sets a benchmark for circular innovation in Europe and beyond. Our goal is clear: wherever Solvay produces silica, we will integrate circular materials to reduce environmental impact and support our customers’ sustainability objectives.”

Ecolomondo Corporation, a Canadian developer of sustainable technology for recycling scrap tyres, has announced that its Hawkesbury facility reached a key operational milestone during the week of 12 January 2026, by successfully completing a record five double processing batches. This progress signifies a major step forward as the company advances towards full commercial production at the plant. Utilising its proprietary Thermal Decomposition Process (TDP) and a new automated Human-Machine Interface system, the facility maintained consistent operations and produced high-quality recovered materials.

The week’s activity led to the recycling of an estimated 9,375 scrap tyres, processing a total of 150,000 pounds (approximately 68,038 kg) of rubber feedstock. From this, approximately 60,000 pounds (approximately 27,215 kg) of recovered carbon black and 75,000 pounds (approximately 34,019 kg) of tyre-derived oil were generated, alongside syngas used to power the process itself.

As a Canadian leader in tyre recycling technology, Ecolomondo views these results as a strong validation of the scalability and reliability of its proprietary TDP system, underscoring the ongoing ramp-up at its Hawkesbury TDP facility. This consistent performance enhances the company's position in the circular economy, turning a challenging waste stream into valuable industrial commodities and demonstrating the commercial viability of its innovative approach.

The Association of Natural Rubber Producing Countries (ANRPC) has released its Monthly NR Statistical Report for December 2025, providing an overview of key developments in the global natural rubber sector.

As per the report, the natural rubber market is positioned in a strategic accumulation phase that belies superficial price indicators. A critical analysis reveals that while US Dollar-denominated prices showed a slight pullback, this was overwhelmingly due to the appreciation of the Thai Baht rather than a decline in intrinsic value. In Thailand, a key producing nation, local currency (THB) prices remained fundamentally firm, underscoring a resilient domestic price floor that continues to support the long-term upward trend.

This underlying market strength is concretely evidenced by price movements in Malaysia. During the reported period of consolidation, Malaysian SMR-20 prices increased by 2.08 percent and latex prices rose by 2.35 percent. These gains in a major producing hub directly contradict a bearish narrative and confirm that underlying global demand continues to outpace available supply. The current market behaviour is therefore characterized as a ‘cumulation pullback’, a necessary corrective foundation following earlier strong gains, designed to build liquidity before the next advance.

Fundamental data supports this outlook. Global natural rubber production for 2025 is anticipated to grow by a modest 1.4 percent. Although the latest demand figures show a marginal adjustment of -0.7 percent, overall market sentiment remains resilient, bolstered by clear recovery signals from the tyre industry. Critically, the market is now entering the seasonally tight ‘wintering’ period from February to May, when latex production naturally declines. The consolidation and strategic accumulation observed in December 2025 have thus established a solid platform. With supply set to contract and demand holding firm, all conditions are aligned for a sustained price rally as the market moves into early 2026.