Reflecting on current and future trends in the tyre industry, Andre Lanning, Global Business Director, Synthetic Rubber, Trinseo Europe GmbH, sees the need for much closer collaborations - not only between tyre companies and suppliers but among suppliers themselves. “If we really want to address the big issues in the industry, reduce rolling resistance, improve fuel efficiency, and get better at recycling and re-using materials and chemicals, we need to have a paradigm shift in how we approach innovation.”

According to Dr. Sandra Hofmann, Director, Technology & Innovation, Synthetic Rubber, Trinseo Deutschland GmbH, speed (response time to market) and sustainability are the main trends that will dominate the global tyre industry compared to other industries.

 “The tyre industry, traditionally, has been conservative on knowledge-sharing and collaborating on innovation. Going forward, collaborations are key to moving forward as the complexity in the segment we are focusing on is very high. Every stakeholder in the tyre industry is driving hard for innovations, and, on the co-suppliers’ side, we are keen on collaborations. And, of course, working together with customers is always part of the development,” said Dr. Hofmann.

In recent times, Trinseo has been focusing on close relationships with other stakeholders for developing new products. Trinseo fosters deep engagement with partners through its centralised synthetic rubber site located in Schkopau, Germany, where technology & innovation, mini-plant, pilot plant, and expanded production assets are located. To reduce product development time from lab sample to commercialisation, Trinseo started a state-of-the-art S-SBR pilot plant in Schkopau, for its synthetic rubber business, which makes it more agile and flexible than ever before in its ability to turn around S-SBR product testing. The company says the S-SBR pilot plant allows for more efficient use of Trinseo’s production facilities and helps speed up innovation in the performance tyres market. As part of its efforts, the company introduces the early development process to its customers. “We have invested substantially in R&D. In 2018, we started the pilot plant where we can make several hundred kilograms of materials, and that is enough for our development partners and customers to build a tyre already in the product development process,” said Dr. Hofmann.

Dr. Hofmann added, “The capabilities we are bringing to the table, in combination with our openness and willingness for collaborations, are major enablers towards shortening of the product development process.”

Major tyre companies are betting high on recycled and bio-mass materials, aiming to eliminate materials derived from fossil fuels, to make tyres in the future. However, the ‘industrialisation’ of recycled and bio-mass materials to obtain synthetic rubber will be a more significant threshold. “It is nice to have targets, but the main challenge is to implement these targets through technology. Making synthetic rubber from recycled and bio-mass materials will be a gradual process, and we see it as an opportunity and want to be a front runner for sustainability”, said Lanning.

Sustainability

Trinseo, according to the executive, is already contributing to tyre companies’ sustainability efforts by supplying solutions that reduce rolling resistance, CO2 emissions and improve fuel efficiency. 

“Sustainability has many dimensions. It could be recycled and bio-based materials. As a company, we are very much active in the recycling of polystyrene back into styrene monomer which can be introduced as recycled feedstock for packaging applications. As for butadiene, for a long time, it has been made of biomass like sugar and others. As a company, we are exploring sources of sustainable feedstocks, not only looking at how we can contribute to our customers’ sustainability efforts, but to the raw materials that go into our own products,” explained Dr Hofmann.

When asked about having a common platform for all stakeholders to develop products, Lanning, said “if tyre manufacturers are serious about sustainability, there needs to be closer and more open collaboration around innovation between tyre and rubber producers. And that is not the case today. Working together we can tackle the challenges, whereas pursuing innovation completely separately will make it harder to reach the sustainability targets”.

Trinseo has an excellent technical community, called Technical Service & Development Group, that works with its customers around the world. This way, the company educates them on its products and their usages. “Irrespective of where we operate, Trinseo focuses on high-end technologies in functionalised S-SBR,” said Lanning. Dr Hofmann added “We are investing heavily in local markets to provide our products and services more efficiently and improve communications between our customers and the company”.

Synthetic rubber is now being used for passenger car tyres, owing to properties that make it suitable for high-end tyres. Trinseo is expanding its portfolio by also focusing on truck and bus tyres (the company’s low Tg polymers like SPRINTAN SLR 3402 are already used in truck and bus tyres as a partial replacement for natural rubber; they improve energy efficiency and performance, predominantly balancing rolling resistance and wear).

“We need to increase the use of synthetic rubber in truck and bus tyres to further impact global sustainability goals. To achieve these goals, we are looking for customers that plan to have SR in tyres for heavy commercial vehicles as well, but we are also using this opportunity to educate the end customers about the advantage of using functionalised S-SBR” said Lanning.

Another challenge for material suppliers is to keep its product development strategies aligned with the fast-changing trends in the automotive industry. Fundamental requirements of low rolling resistance in tyres are not changing in any types of new mobility, believes the company executive. “We also see a shift of focus on wear improvement,” added Dr Hofmann.

Optimising all three aspects of the magic triangle has always been a challenge. The latest functionalised SPRINTAN™ S-SBR grades are proven to reduce lab indicators for rolling resistance by 30 percent compared to nonfunctionalised synthetic rubber grades. This allows for at least three to five percent less fuel consumption in passenger cars. Trinseo’s recently launched SPRINTAN 918S displaying multi-functionalisation technology to reduce rolling resistance and improve wet grip for ultra-high-performance tyres used on premium cars and SUVs.

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Zeon Corporation has announced the development of Nipol BR1300, a novel hydrophilic styrene butadiene rubber (SBR) for winter tyres. Synthesised with a polybutadiene rubber base, the material delivers unprecedented hydrophilicity for tyre applications. Commercial production began in May 2025 at Zeon’s Tokuyama plant in Yamaguchi Prefecture.

As part of its strategic portfolio optimization, Zeon plans to phase out low-profitability products like ESBR-1 and NBR latex by 2026. However, it will continue manufacturing high-margin products, including ESBR-2, nitrile butadiene rubber and solution SBR. This shift underscores Zeon’s focus on advanced, value-driven rubber solutions.

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Covestro India has entered into a strategic collaboration with CSIR-National Chemical Laboratory (NCL) through an innovative CSR initiative focused on developing sustainable upcycling technologies for polyurethane waste. This partnership aims to overcome existing recycling limitations by transforming discarded polyurethane materials into valuable chemical feedstocks, potentially revolutionising the material's circular economy.

This collaboration underscores both organisations' commitment to environmental innovation, leveraging NCL's advanced research infrastructure and Covestro's market leadership to address critical gaps in plastic circularity. Current polyurethane recycling methods, predominantly mechanical with some emerging chemical processes, face substantial challenges including material degradation, high energy consumption and hazardous byproduct generation. The project seeks to develop commercially viable chemical recycling solutions that maintain material integrity while minimising environmental impact.

Polyurethanes, widely used in furniture, automotive parts and insulation, present unique recycling difficulties due to their complex molecular structure. Most end up in landfills after use, creating significant sustainability challenges. By combining Covestro's industrial expertise with NCL's seven decades of chemical research excellence, the partnership aims to create breakthrough upcycling technologies.

Avinash Bagdi, Director & Head of Sales & MD Solutions India & Projects – Tailored Urethanes, said, "This partnership strengthens our commitment to finding innovative solutions for polyurethane waste and directly supports Covestro's vision of becoming fully circular. By developing effective methods to upcycle polyurethanes, we're taking concrete steps towards creating a more sustainable future in line with our corporate vision of driving the transition to a circular economy."

Dr Ashish Lele, Director of NCL, said, "CSIR-National Chemical Laboratory is excited to partner with Covestro (India) in this groundbreaking initiative to develop novel chemical upcycling methods for polyurethane waste. The conventional and electrochemical strategies we're developing address the critical limitations of current recycling technologies and align perfectly with our shared vision of a circular economy. This collaboration represents a significant step towards sustainable plastic management in India and globally, with potential to transform polyurethane waste into valuable chemical resources."

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Zeon Corporation has begun building a pilot facility at its Tokuyama Plant in Shunan City, Yamaguchi Prefecture, to test a new method for efficiently producing butadiene from plant-derived ethanol. The demonstration plant, expected to start operations in 2026, will supply butadiene for manufacturing trial batches of polybutadiene rubber, bringing the company closer to commercialising this sustainable production process.

This project is a key part of a joint initiative between Zeon and The Yokohama Rubber Co., Ltd. to develop eco-friendly methods for producing butadiene and isoprene from renewable sources, with full-scale adoption targeted for the 2030s. Under the collaboration, Zeon will produce butadiene rubber at the new facility, while Yokohama Rubber will use the material to create experimental tyres and conduct performance testing. The data collected will help refine the technology ahead of larger-scale trials. The companies aim to finalise the production process by 2030 using an expanded pilot plant, with plans for industrial-scale commercialisation by 2034.

A ceremonial groundbreaking event took place on 10 July 2025, with 33 attendees, including local government officials from Yamaguchi Prefecture and Shunan City, construction partners and Zeon executives such as Chairman Kimiaki Tanaka and Tokuyama Plant Manager Akira Honma. The gathering included traditional safety prayers for the construction phase, marking the official start of this sustainability-focused industrial project.

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Continental is increasing its use of renewable and recycled materials in tyre production, aiming to exceed 40 percent by 2030 while maintaining high safety and performance standards. In 2024, these materials accounted for 26 percent of tyre composition, with a projected 2-3 percent increase in 2025. Key to this shift are carbon black and silica – essential fillers that enhance durability, grip and braking performance.

Silica, a critical component for optimising grip and minimising rolling resistance, is traditionally derived from quartz sand. However, Continental now obtains silica from rice husks, an agricultural by-product of risotto rice production. This innovative approach not only repurposes waste but also requires less energy than conventional methods. Partnering with manufacturers like Solvay in Italy, Continental integrates rice husk-derived silica across its entire tyre portfolio. Silica has been a game-changer in tyre technology for decades, significantly improving safety and energy efficiency. Its use in tread compounds has contributed to a nearly 50 percent reduction in braking distances while also lowering rolling resistance, thereby reducing fuel consumption and CO₂ emissions.

Carbon black, another vital material making up to 20 percent of a passenger car tyre's weight, is being sourced through sustainable alternatives. Continental employs three innovative methods: bio-based carbon black from tall oil (a paper industry by-product), recycled carbon black from pyrolysis oil derived from end-of-life tyres and a direct recovery process that extracts carbon black from used tyres via pyrolysis. The company collaborates with suppliers like Orion Engineered Carbons and Tokai Carbon, utilising different carbon black variants tailored to specific tyre components, such as sidewalls and treads. Through the mass balance approach, Continental substitutes fossil-based raw materials with bio-based or recycled alternatives without altering existing production processes.

Additionally, Continental has partnered with Pyrum Innovations to advance tyre recycling through pyrolysis, a process that recovers carbon black from end-of-life tyres for reuse. While currently applied in forklift tyres, efforts are underway to adapt this recycled carbon black for broader tyre applications, ensuring compliance with performance and safety standards. These initiatives underscore Continental’s dedication to sustainable innovation, demonstrating how eco-friendly materials can enhance both tyre performance and environmental responsibility across the value chain.

Jorge Almeida, head of Sustainability at Continental Tire, said, “Innovation and sustainability go hand in hand at Continental. Using silica from the ashes of rice husks in our tyres shows that we are breaking completely new ground – without compromising on safety, quality or performance.”

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