The pilot facility in Monterrey will initially convert 1 million end-of-life passenger tyres to recovered carbon black. Operations are slated to commence by the end of CY2024, while the company also has plans to add a second train in the future to double the capacity.

Northern Mexico has long struggled with the challenge of end-of-life tyre (ELT) disposal. Decades of improper waste management have led to an accumulation of over 20 million waste tyres, many of which are left in municipal dumpsites or landfills. These discarded tyres pose not only an environmental hazard but also a significant public health risk as they can become breeding grounds for mosquitoes and other disease-carrying pests.

Local governments have ramped up efforts to address this crisis, but the scale of the problem requires long-term, systemic solutions. Innovent Renewables’ new facility in Monterrey is poised to play a key role in this effort. The facility will transform waste tyres into valuable resources such as recovered carbon black and will help reduce landfill reliance, cut carbon emissions and provide a sustainable alternative to the traditional methods of carbon black production.

The pilot facility represents a significant milestone for the recycler as it sets out to address the growing environmental challenge of ELTs in the region. Initially slated to process 1 million waste passenger tyres annually, the facility will convert these tyres into high-quality recovered carbon black, oil and steel. With operations scheduled to begin by the end of calendar year 2024, the company is also looking ahead with plans to add a second processing train to double its capacity in the near future. This expansion marks a critical step in tackling the 20 million-plus tyres accumulated in Mexico’s northern areas while offering sustainable solutions for industries seeking to reduce their carbon footprints.

“This facility represents a vital step forward in addressing the enormous environmental burden posed by tyre waste in northern Mexico. We’re not only reducing waste but converting it into materials that industries can use in a circular and sustainable manner,” said Chief Executive Officer Vibhu Sharma.

Extracting value

The tyre recycling process based on pyrolysis begins with the shredding of end-of-life tyres, which are then fed into a main reactor where they undergo pyrolysis, a high-temperature process in the absence of oxygen.

This results in the breakdown of tyre material into pyrolysis gases, oil and recovered carbon black. The gases are recycled within the system for energy recovery or flared off, enhancing energy efficiency.

The pyrolysis oil is condensed and purified, followed by distillation into high-value chemicals for industrial applications. Meanwhile, recovered carbon black, a solid by-product, is processed through milling and polishing for reuse in manufacturing. This design demonstrates an energy-efficient method of converting waste tyres into valuable products such as fuel, chemicals and carbon black.

“Firstly, we have a proprietary continuous pyrolysis process that ramps up and cooks the tyres to decompose them in a particular way. We also use specially designed agitator to ensure uniform decomposition to oil and carbon black. This ensures higher surface area and quality of the RCB. We designed a proprietary polishing unit that crushes that RCB coming out of the reactor and then polishes it to remove metal oxides and silica. We have several equipment in place to capture steel particles in the RCB. The final product still has some amount of silica and metal oxides, but the purity and uniformity of the RCB is much higher,” said Sharma.

Addressing demand

As industries worldwide strive to meet decarbonisation goals, the demand for sustainable alternatives to carbon-intensive materials have surged. Recovered carbon black fits squarely into this trend, offering a viable option for companies looking to reduce environmental impact while maintaining performance characteristics.

Innovent Renewables’ order book reflects this growing interest. The company has secured letters-of-intent from several major tyre manufacturers as well as companies in the printing ink, rubber and paint sectors.

“Increasingly, companies are looking for sustainable solutions that allow them to reduce their carbon footprints without sacrificing the quality of the products. Our RCB gives them that opportunity. It’s a win-win for both industry and the environment,” said Sharma.

He added, “We see the Monterrey facility as just the beginning. As we prove the viability of our process and stabilise operations, we’ll be able to scale up production not just here in Mexico but potentially in other regions around the world that are dealing with tyre waste issues. There’s a huge global need for solutions like this.”

Sustainable vision

According to Sharma, the company’s goal is to provide a circular solution for industries that are serious about sustainability. “It’s not just about the recovered carbon black; we’re also helping companies reduce their reliance on virgin oil and steel by offering them high-quality, recycled alternatives. This allows them to achieve carbon credits and decarbonisation targets while contributing to a cleaner environment,” noted Sharma.

While tyres remain the primary focus, the company is already working to expand its applications into other industries by targeting sectors such as rubber gaskets, printing inks and paints to tap into new growth markets.

It is also finding ways to repurpose the other by-products of its pyrolysis process. The oil extracted from the tyres can be used as fuel or as a raw material for various industrial applications, while the recovered steel can be sold back to manufacturers, creating a fully circular model that maximises resource recovery and minimises waste.

“We’re proud to be part of the solution to one of Mexico’s most pressing environmental issues. But this is just the start. Our vision is to become a global leader in the circular economy, providing industries around the world with the materials they need to build a sustainable future,” Sharma concluded.

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In a significant expansion of their existing recycling partnership, Alcoa Australia and Tyrecycle have commenced a new programme to repurpose used conveyor belts from Alcoa’s mining operations. The first reel of used belt was successfully delivered to Tyrecycle’s East Rockingham processing plant, marking a pivotal step in addressing a major waste stream. This initiative builds upon the companies' established contract for recycling off-the-road tyres and forms a core component of Alcoa’s broader corporate strategy to minimise, recycle and reuse waste generated by its Western Australian activities.

The ambitious programme will see approximately 32 kilometres of used conveyor belt transported to the facility over several months. In its initial phase, the collaboration aims to recycle 80 reels of belting. Tyrecycle will process an estimated 100 tonnes of this material weekly, transforming it into rubber crumb. This output will supplement the more than 300 tonnes of Alcoa’s used tyres the company already recycles annually. The primary focus of the recycling process is to reclaim the steel wire embedded within the belts and to convert the rubber into a versatile crumb product.

This crumb is destined for a wide array of practical applications, serving as a valuable additive in road construction bitumen, and as a raw material for creating surfaces for sports fields and playgrounds, adhesives and various moulded rubber goods. Tyrecycle emphasises a circular economy vision, aiming not just for repurposing but for eventually integrating recycled material back into the manufacturing of new conveyor belts. Since its inauguration, the East Rockingham facility has been instrumental in providing Western Australian mining operators with solutions to decarbonise their supply chains. This partnership with Alcoa simultaneously supports regional employment and advances shared environmental goals by diverting substantial rubber waste from landfill and giving it a productive new life.

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KRAIBURG TPE has introduced a new series of thermoplastic elastomers engineered specifically for e-bike handles. This THERMOLAST R RC/UV/AP series is designed to merge sustainability with high performance and improved ergonomics. A central feature of this material is its composition, which incorporates between 15 percent and 40 percent recycled content, directly addressing the industry's push towards more eco-conscious manufacturing.

The compound provides a soft-touch grip for enhanced rider comfort and control, alongside resistance to chemicals and ultraviolet light. Its lightweight nature contributes significantly to the overall reduction of e-bike weight, with some modern models now being up to 50 percent lighter than traditional designs. From a production standpoint, the material is formulated for multi-component injection moulding and bonds reliably to polypropylene, facilitating complex and innovative handlebar designs. Manufacturers can also select from a wide hardness range to customise the grip feel without sacrificing the material’s inherent durability or safety.

The performance of this TPE series is validated by extensive testing, including a two-year outdoor exposure that confirmed its resilience against harsh weather. It also maintains stability in temperatures up to 90°C, ensuring reliable long-term use. This product launch is part of KRAIBURG TPE's broader sustainability commitment, which includes developing bio-based TPEs, holding certifications for recycled content and providing Product Carbon Footprint data. The company's efforts have been recognised with an EcoVadis Gold Medal, and it has reaffirmed its commitment to Science Based Targets initiative (SBTi). This new material series positions KRAIBURG TPE as a pivotal partner in creating greener and more functional e-bike designs for a rapidly growing market.

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Bekaert's Ultra & Mega Tensile steel cord solutions have received the prestigious 2025 China Green Point Award for their significant role in advancing the tyre industry's shift towards low-carbon manufacturing.

This innovative reinforcement technology utilises high-strength steel, which allows for the production of lighter and more durable tyres while using less raw material. A key environmental benefit is the substantial reduction in rolling resistance, which directly improves vehicle fuel efficiency and leads to lower CO₂ emissions. Furthermore, the technology supports circular economy principles by incorporating steel with a high recycled content.

With over seven decades of expertise, Bekaert empowers leading global tyre manufacturers to create high-performance, sustainable tyres, thereby accelerating the transition to greener mobility on a large scale.

The company shared the achievement in a social media post: “A big thank you to our teams for their leadership in driving this achievement, and to our partners across the industry for making sustainable mobility a reality. This award is more than recognition: it’s proof of how materials innovation, powered by people, can accelerate change from the ground up – literally.”

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Ecolomondo Corporation, a Canadian developer of sustainable technology for recycling scrap tyres, is reporting significant commercial progress at its Hawkesbury TDP facility. The company is experiencing a substantial rise in demand for its recycled products, leading to strong sales growth.

A key development involves a major customer who, since mid-July 2025, has purchased 12 truckloads of recovered carbon black (rCB), representing approximately 276 metric tonnes. This client has signalled its intention to increase order volumes further as it transitions its business from another supplier. In another positive step, a second US-based customer has formally approved Ecolomondo's recovered carbon black for use in its manufacturing supply chain and is anticipated to commence bulk orders imminently. Additionally, the company has successfully shipped its 26th tanker of tyre-derived oil, amounting to 520 metric tonnes with an estimated value of USD 416,000.

This upward trend is reflected in the financial results. For the period from 1 January to 31 August 2025, revenues reached USD 640,986, a 91 percent increase compared to the USD 336,078 recorded during the same timeframe in 2024. This growth is largely attributed to the rising sales of recovered carbon black. To support the escalating production needs, Ecolomondo plans to hire and train additional personnel for the Hawkesbury facility. The company notes that, as expected during this operational ramp-up phase, the facility is not yet generating gross margins and continues to operate at a loss.

Jean-François Labbé, Interim CEO, Ecolomondo Corporation, said, “These milestones demonstrate the reliability of our production and the repeated nature of revenues we are building.”

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