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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Following the formal approval of its foundational design, Sinopec has announced the construction of a new green, high-end rubber materials facility in Tianjin, China. The project, which was initially revealed in 2023, represents a total investment of CNY 2.452 billion (approximately USD 344.65 million). Its production output will include 100 kilotonne per annum (ktpa) of solution styrene butadiene rubber and an equal volume of nickel-based butadiene rubber.

Operated by Sinopec’s Beijing Yanshan branch, the venture will be funded through a combination of 70 percent bank loans and 30 percent company capital. The initial construction phase, focused on piling work for processing units, storage areas and auxiliary facilities, is valued at CNY 28 million (approximately USD 3.94 million) and scheduled for completion within 31 days.

This new rubber plant is an integral component of the larger Sinopec Nangang high-end materials industrial cluster, which also features a recently completed 1.2 million tonne-per-year ethylene complex. Encompassing a 277,004 sqm site with a built area of 43,522 sqm, the facility is projected to become operational in 2027.

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Elkem ASA, a global leader in advanced silicon-based materials, has announced a significant advancement in silicone sustainability with the successful validation of a new mechanical recycling process for High Consistency Rubbers (HCR). This innovation provides a scalable method for recycling crosslinked HCR waste and reintroducing it into new product formulations. The process achieves re-incorporation rates of over 50 percent while maintaining the excellent mechanical properties required for high-performance applications. This breakthrough demonstrates how material engineering can enable a more circular economy for silicones, helping to reduce waste and the carbon footprint while meeting rising market demand for sustainable solutions.

This mechanical recycling process expands Elkem's comprehensive silicone recycling strategy, which now encompasses both chemical and mechanical pathways. The ability to integrate multiple recycling technologies allows the company to tailor its approach based on the type of waste material, specific carbon reduction goals and the performance needs of the final product.

The development is a key outcome of the open innovation project ‘RENOV’ (Recycling & Reincorporation of Elastomer Materials), focused on creating technologies for recycling and reincorporating crosslinked elastomer waste. The project, supported by the French environment agency ADEME, unites Elkem with industrial partners Hutchinson and Nexans, as well as several CNRS-affiliated laboratories. A primary objective is to evaluate market acceptance and identify the most promising commercial and environmental applications for mechanically recycled HCR.

High Consistency Rubbers are valued for their exceptional strength, thermal stability and electrical insulation properties, making them critical components in industries ranging from electric vehicles and aerospace to medical devices and electronics. Elkem will present samples of the recycled material and detail this new technology at the K 2025 trade fair in Düsseldorf, Germany, from 7–14 October 2025.

Joséphine Munsch, R&T sustainability leader at Elkem, said, “This breakthrough demonstrates the power of purpose-driven innovation aligned with market expectations. After two years of development, we are proud to present a first proof of concept for mechanical recycling of HCR, opening the door to new industrial applications and reinforcing our ambition to leverage pragmatic, science-driven solutions to lead and accelerate the transition to a circular economy for silicones.”

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ContiTech, a group sector of Continental, has officially launched production at its new USD 90-million hydraulic hose manufacturing facility in Aguascalientes, Mexico. This significant investment is a strategic move to reinforce local supply chains, boost regional production capacity and position innovative fluid power solutions closer to its customer base across North America.

The new 900,000-square-foot plant will produce high-performance hoses for numerous industrial and mobile applications, serving vital sectors such as construction, agriculture, mining and energy. It has been designed to operate in a tightly coordinated network with ContiTech’s existing facility in Norfolk, Nebraska. This dual-plant strategy enhances production flexibility, improves operational efficiency and allows the company to be more responsive to evolving customer demands by strategically balancing technology, volume and lead times.

This expansion underscores ContiTech's long-term commitment to growth in key markets through substantial investment in local infrastructure and talent. Production at the Aguascalientes site will be gradually increased, with the first customer deliveries anticipated to commence in the fourth quarter of 2025.

Philip Nelles, Member of the Continental Executive Board and CEO of the ContiTech group sector, said, “The start of production in Aguascalientes marks a key milestone in ContiTech’s journey towards being a more agile, regionalised partner to our customers. At ContiTech, we build on 150 years of materials expertise. While our portfolio is broad and diverse, all our solutions are grounded in the same strength: high-performance materials that are mission critical, innovative and engineered to perform. Whether they connect, convey or cover, our products play essential roles across industries and applications.”

Andreas Gerstenberger, CEO of ContiTech USA and Head of Business Area Industrial Solutions Americas, said, “We are ready to lead in this segment. This new plant reflects our commitment to both innovation and proximity. With our customers increasingly looking for responsive and innovative solutions, we are proud to deliver with local production, advanced technology and a skilled workforce. More than just expanding our footprint, this investment is about creating mutual value with our customers, partnering closely to help them succeed in their own markets. By placing customer needs at the centre of everything we do, we aim to be their first choice for material-driven solutions, now and in the future.”

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Vipal Rubber, a leading global producer of retreading rubber, has reaffirmed its commitment to innovation with the launch of its new V SUPER HYBRID technology. Available from 1 March 2025, this new compound is designed to redefine performance standards for mixed-terrain applications, offering enhanced mileage, durability and resistance for retreaded tyres across various fleet sizes.

The V SUPER HYBRID achieves a superior balance between on-road and off-road performance. It has proven effective in demanding sectors such as logging, grain and livestock transport, demonstrating robust capabilities across diverse operating conditions. Key advantages of the innovation include improved resistance to chipping and punctures, enhanced casing protection that extends tyre service life, lower environmental impact through increased tread utilisation and significant operational cost savings for fleet operators.

Field tests substantiate these claims. In one trial involving a high-torque truck on steep, unpaved terrain, tyres with V SUPER HYBRID technology showed an 11.5 percent increase in mileage over a standard market compound while maintaining structural integrity with no signs of breakage. Furthermore, the same technology demonstrated the potential for up to a 140 percent mileage increase over conventional compounds in continued testing. The tread's regular wear pattern also allowed for better depth utilisation, enabling tyres to remain in operation down to 5-6 mm, compared to the previous limit of 12 mm. Another test with a grain and livestock truck confirmed these results, documenting a 12.5 percent performance gain across different tread designs.

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