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Pyrolysis has long been associated with pollution and inefficiency, particularly in developing markets where outdated methods dominate.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

Arkema has launched its next-generation solution for polymer curing called Luperox NeatCure. Unveiled at the K 2025 Show, this innovative product is a formulated organic peroxide in granular form, specifically created to accelerate curing times across various processes, including extrusion and injection moulding.

A primary benefit of its dust-free composition is a significant enhancement in workplace safety, minimising the risks associated with handling powdered substances. Developed in response to evolving regulatory demands, this technology enables manufacturers to achieve greater productivity and efficiency. The company says the new solution ensures rapid curing while fully maintaining the performance integrity of the final elastomers and polymers.

Tilo QUINK, Senior Vice President Performance Additives, said, “The launch of Luperox® NeatCure® illustrates our ability to bring responsible innovation to the market, combining safer handling with superior efficiency. We are proud to support our customers with solutions that help them meet both their productivity goals and sustainability commitments.”

Romuald DE HAUT DE SIGY, Global Group President Functional Additives, said, “Luperox® NeatCure® is more than a new product; it’s the breakthrough that will set a new standard in the Cross-linking Organic Peroxides market. Thanks to our advanced formulation expertise, we can deliver a solution that not only optimises curing performance but also ensures the highest level of safety and compliance. This is a decisive step forward to our customers in elastomers and polymers processing.

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

According to the report, a number of reasons, including limited supply and rising demand, contributed to the volatile pattern in natural rubber prices this month. Consumption was increased by seasonal considerations, especially in China, where stronger demand was evidenced by inventory reductions at key ports. However, tapping efforts were restricted due to manpower shortages and rains in producing regions, which tightened supplies.

Global natural rubber (NR) output is expected to increase slightly by 0.5 percent in 2025 compared to 2024, according to recent data from ANRPC member countries. At the same time, a 1.3 percent increase in demand for natural rubber is anticipated in 2025. As buying demand increased, the market sentiment got more positive, especially when the customary peak season for natural rubber, notably for heavy-duty vehicles and all-steel tyres, began.

Tokai Carbon Co., Ltd. has finalised the strategic acquisition of Bridgestone Carbon Black (Thailand) Co., Ltd. from Bridgestone Corporation and Asahi Carbon Co., Ltd. The transaction, valued at roughly THB 2.05 billion (USD 56 million approximately), was officially completed on 30 September 2025. This move represents a significant expansion of Tokai Carbon's carbon black operations within the key Southeast Asian market.

Subsequent to the deal's closure, the newly acquired entity has been rebranded as Thai Tokai Carbon Product Rojana Co., Ltd. The company's ownership is now held by Thai Tokai Carbon Product Co., Ltd. at 99 percent and Tokai Carbon Co., Ltd. at one percent, making it a consolidated subsidiary. Tokai Carbon has appointed its Executive Officer, Tatsuhiko Yamazaki, as the new Managing Director to lead the organisation.

This acquisition is a calculated step in Tokai Carbon's wider plan to bolster its global presence and reinforce its production and supply chain capabilities. The company anticipates that this will solidify its standing in the international carbon black sector, which serves the tyre, rubber and various industrial markets. While the specific financial effect on its 2025 results is still being assessed, the move is a clear part of its ongoing growth strategy across Asia.

Hana Technologies Inc., a manufacturer of radio-frequency identification inlays, has joined the board of Auburn University’s RFID Lab, marking its deeper engagement in setting industry standards for the technology.

The appointment positions the California-based company, which holds ARC Quality certification, alongside other industry participants in shaping research and standards development at the Alabama-based laboratory, which is recognised as a leading academic centre for RFID testing and certification.

RFID technology uses electromagnetic fields to identify and track tags attached to objects automatically and has seen growing adoption in the retail, logistics, and manufacturing sectors for inventory management and supply chain tracking.

“I am excited and honoured to once again collaborate with the Auburn RFID Lab Board, representing Hana RFID,” said Jeremy Liu, chief technology officer of Hana RFID. “This opportunity allows us to contribute to the future of RFID by ensuring quality remains a top priority. Hana is proud of its strong position in the RFID world, and we are committed to supporting our partners with the finest, smartest products available. Together, we will keep moving the industry forward.”

John Erdmann, president and chief executive of Hana RFID, said: “The Auburn RFID Lab has been a key contributor since the very beginning, helping to create a strong and trustworthy RFID ecosystem. We are grateful for this foundation and see our board membership as a chance to give back to the community. Hana will be a fully engaged member – providing continuous feedback, and sharing our knowledge to ensure RFID adoption continues to grow on a solid, reliable base.”

The company, which operates manufacturing facilities globally, did not disclose the term of the board appointment or specific initiatives it plans to pursue in the role.