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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Nynas has played a pivotal role in a landmark achievement for Croatia's energy sector by supplying its advanced NYTRO BIO 300X insulating liquid. This fully renewable fluid has been used for the first time in the Croatian market to fill a 630 kVA distribution transformer. The unit, manufactured by KONČAR – Distribution & Special Transformers, was recently installed in Zagreb for HEP ODS, the national Distribution System Operator.

This collaboration marks the inaugural deployment of a ‘Green Transformer’ in Croatia, representing a significant advancement for the country's distribution network. The project underscores a unified drive towards greater sustainability and a reduced environmental footprint for critical power infrastructure. For Nynas, this milestone highlights the practical application and reliability of its bio-based product portfolio.

NYTRO BIO 300X is engineered to provide a drop-in solution that combines high oxidation stability and superior cooling performance, allowing operators to enhance their ecological standards without compromising on operational reliability or transformer longevity. The successful installation stands as a testament to how industry partnerships are actively accelerating the transition to a more sustainable energy future.

Ivanka Radić, responsible for transformer oils at KONČAR - D&ST, said, “The thermal and dielectric tests on the transformer filled with NYTRO BIO 300X were successfully completed, and the unit is now fully operational. As expected, all test results were within the required limits, confirming the reliability and stability of this innovative fluid.”

Daniele Frustagli, General Manager Italy & the Balkans at Nynas, said, “We are very proud to have been entrusted with this project by KONČAR - D&ST and HEP ODS Zagreb, allowing us to showcase to them and the entire electrical industry the advantages of this fully renewable, bio-based hydrocarbon liquid. In addition to meeting and exceeding the IEC 60296 ed. 5 (2020) specification, the product is readily biodegradable, fully bio-based and has ultra-low viscosity.”

Vanja Burul, President of the Management Board at KONČAR - D&ST, said, “This project reflects our ongoing efforts to explore more sustainable insulating fluids. We see great potential for further use of NYTRO BIO 300X in future applications.”

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Rhodia, the Latin American polyamide leader and a Solvay Group company, has unveiled a major new multi-year investment initiative for its Santo André industrial facility in São Paulo. This strategic programme, valued at BRL 100 million (USD 18.56 million approximately) and scheduled from 2025 to 2028, is designed to drive modernisation, enhance energy efficiency and foster innovation. The funds are allocated for the creation of advanced technologies and an increase in production capacity, with a particular emphasis on high-value-added products. These include smart wires and sustainable solutions that position the national industry at the global forefront.

This substantial investment underscores Rhodia's confidence in the Brazilian market's potential, which is supported by a business environment moving toward greater competitive balance. The company highlights that predictable market rules and effective trade defence measures are crucial for enabling such long-term commitments. By expanding its operations, Rhodia will not only solidify its leadership in polyamide 6.6 production but also advance the spinning processes for polyamide 6. This move is a fundamental step in securing a reliable supply chain and strengthening Brazilian sovereignty, spanning from raw chemical materials to finished part manufacturing. Ultimately, the initiative reaffirms Rhodia's enduring commitment to the national chemical and textile sectors, ensuring enhanced competitiveness and sustained value generation for the local industry.

Daniela Manique, President – Latin America, Rhodia, said, “These investments reflect our confidence in the Brazilian market and its capacity for innovation. We are prepared to offer advanced and sustainable solutions that meet the demands of the dynamic textile sector. We believe that a fair and predictable competitive environment is the main factor for growth, the preservation of skilled jobs and technological development in Brazil.”

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At the recent Reuters Events – Sustainability Europe 2025 conference in London, Birla Carbon’s President and CEO, John Loudermilk, outlined ambitious plans for the company’s circular product, Continua Sustainable Carbonaceous Material. He revealed a strategic vision to significantly expand its availability, with a target for it to eventually comprise up to 10 percent of the company’s global product portfolio. Sourced from end-of-life tyres, Continua SCM is an industrially-produced material designed to offer the same quality, consistency and technical performance as traditional carbon black.

This innovative material allows manufacturers to integrate greater sustainability and circularity into diverse applications such as tyres, plastics and coatings without sacrificing product performance. Loudermilk emphasised that accelerating this transition requires a multi-faceted approach, including supportive regulatory frameworks, deeper collaboration with tyre pyrolysis technology partners and strengthened customer engagement.

Beyond its circular offering, Birla Carbon is also progressing other sustainability initiatives. These include developing carbon black derived from bio-based feedstocks and exploring advanced carbon capture and conversion technologies. These combined efforts support the company’s overarching aspiration to achieve net-zero carbon emissions by 2050, alongside ongoing work to enhance process efficiency and resource utilisation.

Loudermilk said, “While global carbon black consumption typically grows in line with GDP, the demand for sustainable and circular products is increasing at a much faster pace. At Birla Carbon, we see an opportunity to displace up to 10 percent of the carbon black consumption in the world with circular materials like Continua™ SCM, our brand that is derived from end-of-life tyres.”

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Continental has initiated a strategic consolidation of its operations in the United States, which includes the planned closure of its Aldora Mills textile plant in Barnesville, Georgia, by the conclusion of 2026. This decision, impacting approximately 230 employees, follows an extensive review of the company's long-term competitiveness in the Americas. The facility, which produces textile reinforcement materials, including tyre cord fabric, hose yarn and knitted fabric, for exclusive use within Continental’s Tires and ContiTech group sectors, had faced persistent cost challenges for years, with shifting global market conditions ultimately making its continued operation unviable. The company's immediate priority is to provide comprehensive support to the affected staff through career counselling and local employment resources.

Despite this specific closure, Continental is reinforcing its substantial commitment to the US market through continued and significant capital investment. In the past decade alone, the company has directed around USD 1.5 billion into its American manufacturing footprint. This is evidenced by recent projects, such as a major expansion of the ContiTech plant in Mount Pleasant, Iowa and the construction of a new, company-owned tyre distribution centre in the Dallas-Fort Worth area scheduled to open in early 2026.

The company's enduring presence in the country remains robust, with a workforce of over 8,800 people spread across its Tires and ContiTech sectors. Its tyre manufacturing plants located in Illinois, Indiana, Mississippi and South Carolina possess a combined annual production capacity of more than 16 million tyres. The closure of the Aldora Mills facility is therefore presented as a necessary step to safeguard the overall health and future performance of Continental's broader operations across the Americas.

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