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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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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Kuraray Asia Pacific Pte. Ltd., a subsidiary of Kuraray Co., Ltd., has inaugurated the Kuraray Asia Pacific Centre in Singapore's Science Park. This new facility will function as a dedicated technical support hub for the Asian market. Its primary focus will be on providing specialised expertise for growing regional demand in PVOH resin, EVAL EVOH resin and activated carbon products.

Equipped with advanced material evaluation and analysis laboratories, the centre is designed to deliver prompt and tailored solutions to meet specific local customer requirements. It will also act as a platform for open innovation, fostering collaborative development and product demonstrations to generate new value.

By establishing itself within the concentrated research environment of the Singapore Science Park, the centre aims to accelerate market development and attract global talent through strategic partnerships. This initiative is a key part of the Kuraray Group's strategy to address emerging customer needs, explore new applications and strengthen its overall business expansion throughout the region.

Lim Wey-Len, Executive Vice President, Singapore Economic Development Board, said during the opening ceremony on 1 September: “We welcome Kuraray and other like-minded companies to leverage Singapore’s innovation ecosystem, talent pool, and regional connectivity to scale impactful and sustainable solutions from here.”

Tomoyuki Watanabe, Director and Managing Executive Officer, and President of the Vinyl Acetate Resin Company at Kuraray, said, “By offering a place for co-creation with our customers, we hope to drive the rapid market growth in the region.”

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

According to the report, natural rubber prices exhibited significant volatility in July. This instability was driven by a combination of adverse weather conditions impacting production, ongoing geopolitical tensions and international trade tariffs. After an initial phase of ample supply and muted demand, market sentiment shifted as concerns over potential supply disruptions prompted a notable increase in purchasing activity.

The report further projects a modest global production increase of 0.5 percent for 2025, while demand is anticipated to grow by a slightly higher 1.3 percent. However, this growth is expected against a challenging backdrop of a potential global economic slowdown. Complex US tariff policies and their widespread ripple effects are primary factors contributing to what may become one of the most subdued years for economic expansion since the pandemic.

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Continental is establishing a groundbreaking industrial process for recycling complex rubber waste through a strategic acquisition of key patents and the launch of a new pilot facility. This initiative, led by its ContiTech division, leverages advanced pyrolysis technology to transform end-of-life rubber products into valuable raw materials, creating a sustainable alternative to fossil resources.

The core of this innovation is a thermal decomposition process where waste rubber is heated in a low-oxygen environment. This breaks the material down into its core chemical constituents, one of which is a high-quality oil with properties mirroring traditional crude oil. This output is particularly significant as it can be directly used in the manufacture of new plastics and rubber goods, effectively closing the material loop.

A major historical obstacle for the industry has been the difficulty of recycling vulcanised rubber, whose altered chemical structure resists conventional separation methods. Pyrolysis successfully circumvents this challenge, cleanly decomposing the material to recover not only oil but also carbon black and other energy sources. The widespread adoption of pyrolysis has been hindered until now by the complexity of purifying its outputs to meet industrial standards. Continental’s new facility, originally developed by British start-up LowSulphurFuels, directly addresses this hurdle with a specialised purification process, making large-scale rubber recycling both technically feasible and economically attractive.

This advancement is especially critical for complex rubber products like composite hoses and specialised seals, which were previously nearly impossible to recycle efficiently. By converting this challenging waste stream into a high-grade resource, Continental is driving progress towards a circular economy. This move also reinforces the company's position as a leader in sustainable innovation, complementing its extensive patent portfolio and ongoing projects focused on material recovery and developing eco-friendly solutions for the automotive and industrial sectors.

Dr Michael Hofmann, Chief Technology Officer, ContiTech, said, “With this technology, we’re closing a crucial gap in the circular materials economy: we’re able to recover high-quality raw materials from rubber waste, which we can then feed back into the chemical material cycle to create new products without relying on crude oil. We’re thus demonstrating how innovation can become the driving force behind sustainable industrial processes – and how a previously untapped raw material cycle can be made economically viable.”

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