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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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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In a significant development for environmental science and the rubber industry, Perpetuus Advanced Materials has announced a viable solution for eliminating 6PPD-quinone, a highly toxic byproduct of 6PPD, a chemical commonly used in tyres and synthetic rubbers. This breakthrough is particularly urgent given the established link between 6PPD-quinone and acute mortality in coho salmon, a crisis identified in 2020 that has since spurred global regulatory concern. The company’s innovation provides both a direct manufacturing replacement and a method for environmental remediation.

The core of the solution is an amine functionalised graphene masterbatch, engineered using the company's proprietary plasma-functionalised graphene nanoplatelets. This advanced material operates through a novel mechanism where the amine groups act as radical scavengers, effectively stabilising the rubber and rendering the use of 6PPD entirely obsolete. By preventing the formation of the toxic 6PPD-quinone at its source, this technology addresses the root cause of the pollution. The masterbatches are supplied as pre-mixed sheets or blocks, allowing for straightforward integration into existing manufacturing processes for tyres and a wide array of other synthetic rubber products, including hoses, seals and industrial belts, without requiring any operational changes.

To tackle the existing environmental contamination, Perpetuus has concurrently developed a suite of modular filtration systems designed for stormwater management. These units, which include drain cartridges and bioreactor modules, utilise graphene nanoplatelets to capture pollutants. They are enhanced by a proprietary artificial intelligence platform that provides real-time monitoring of filter saturation and pollutant levels, offering a critical tool for protecting vulnerable waterways and urban runoff zones during the transition to reformed tyres.

Produced on a continuous plasma platform ensuring consistent quality, the masterbatch not only replaces 6PPD but also consolidates numerous other mix ingredients and additives, thereby simplifying production and improving workplace air quality. With over 10 years of specialisation in graphene-enhanced elastomers, Perpetuus is now actively pursuing regulatory approvals and industrial partnerships to accelerate the widespread adoption of this comprehensive environmental solution.

John Buckland, CEO, Perpetuus, said, “This is no longer about mitigation. We’ve replaced 6PPD. Our amine functionalised GNPs deliver the same anti-degradant function as 6PPD but with zero toxic quinone by-products. This isn’t theory. It works in formulation and scales now. This isn't a patch; it’s a permanent replacement. By removing 6PPD at the source, we remove the risk of 6PPD-Q entirely. The science is proven. The solution is scalable. The environmental need is urgent. The only question left is whether regulators and manufacturers are ready to act. This is the moment to eliminate 6PPD for good and replace it with something better.”

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Bekaert and EMSTEEL have forged a strategic partnership centred on the manufacturing and commercialisation of high-value, sustainable steel products utilising steel produced within the UAE by EMSTEEL. The agreement was formally signed at the Middle East Iron & Steel Conference & Exhibition in Dubai, with senior leadership from both organisations in attendance, including Group CEOs Engineer Saeed Ghumran Al Remeithi of EMSTEEL and Yves Kerstens of Bekaert.

The alliance will see the two companies extend their cooperation into several key areas. A major component involves technical collaboration, where Bekaert will provide its expertise and offtake intention to support EMSTEEL's strategic initiative to upgrade and substantially expand its wire rod product portfolio in the near future. Furthermore, the partners will jointly assess opportunities for downstream investments. These potential investments are designed to allow EMSTEEL to diversify its offerings with more advanced, value-added products. For Bekaert, this creates a pathway to manufacture its renowned Dramix steel fibre reinforced concrete solutions using locally sourced UAE steel.

A shared objective of this partnership is to actively promote the advantages of sustainable construction materials and solutions throughout the Gulf Cooperation Council markets, leveraging EMSTEEL's position as the UAE's largest steel manufacturer and Bekaert's global leadership in steel wire transformation and coating technologies.

Yves Kerstens, Group CEO, Bekaert, said, “Today’s MoU is intended to serve various ambitions we have in common with EMSTEEL. This includes focused strategy execution in a region with vast growth opportunities, a strong innovation drive and explicit sustainability excellence.”

Engineer Saeed Ghumran Al Remeithi, Group CEO, EMSTEEL, said “This agreement reflects EMSTEEL’s commitment to advancing the capabilities and global reach of UAE-made steel. By combining our manufacturing strength and sustainability leadership with Bekaert’s world-class expertise in material science and advanced steel solutions, we are creating new pathways for innovation, value creation and low-carbon growth.”

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In a long-term strategic partnership, Solvay and Sapio have committed to a 10-year agreement to advance renewable hydrogen production at Solvay's Rosignano plant. This collaboration – a central pillar of the Hydrogen Valley Rosignano Project aimed at cutting CO2 emissions from Solvay’s peroxides operations – will see Sapio responsible for building and managing a 5 MW electrolysis unit. The required power will be sourced from a new 10 MW photovoltaic installation that Solvay will construct on-site.

With operations scheduled to commence by mid-2026, the project is expected to yield up to 756 tonnes of renewable hydrogen annually. This green hydrogen will be directly used in Solvay's manufacturing of peroxides, essential chemicals for the electronics, water treatment, and solar panel industries. The initiative has secured EUR 16 million in funding allocated by the Tuscan Region through Italy's National Recovery and Resilience Plan (PNRR). This decade-long effort is projected to reduce the site's carbon dioxide emissions by as much as 15 percent, marking a substantial step towards more sustainable industrial processes. The partnership's launch was officially celebrated with a groundbreaking ceremony on 18 November 2025.

Carlos Silveira, President of Solvay’s Peroxides business, said, “Our partnership with Sapio represents a good example in how we enhance our global peroxide operations. This project is a key part of our broader strategy to support essential industries – from electronics and water treatment to energy and food safety – with more sustainable solutions.”

Alberto Dossi, President of the Sapio Group and H2IT, said, "The launch of this important project for the production of renewable hydrogen represents a major step forward in the development of the entire hydrogen value chain. With H2IT, we have set ourselves the goal of creating a collaborative ecosystem in which industry, research, policy and local communities work together for a cleaner and more sustainable future. With this collaboration, Sapio is actively contributing to building a cleaner and more sustainable world."

Mario Paterlini, CEO, Sapio Group, said, "We are extremely proud of our collaboration with Solvay: this project, funded by the National Recovery and Resilience Plan (NRRP), is concrete proof that companies can truly contribute to the decarbonisation of the planet and the growth of our country. In a world of great uncertainty like the current one, it is essential to join forces and be a point of reference for the entire ecosystem."

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