Zeppelin Systems has been awarded the engineering contract for constructing a second ReOil pyrolysis plant, with construction slated to commence in February 2024. 

By establishing this new pyrolysis plant, ReOil has significantly expanded its annual recycling capacity, now capable of processing approximately 60,000 tons per year. This state-of-the-art facility, covering roughly 27 acres, is a testament to the ingenuity and engineering expertise provided by Zeppelin Systems.

Having already supplied the initial engineering groundwork for the new plant in 2019, Zeppelin Systems has been awarded the completion contract, underscoring the high level of customer satisfaction. As the primary engineering partner, Zeppelin Systems delivers comprehensive turnkey solutions, encompassing plant technology, process engineering, and final plant planning, all from a single source.

“A flagship project for Zeppelin Systems with a signalling effect. Only a few companies can implement such complex and extensive projects virtually anywhere in the world,” says Dr Markus Vöge, CEO of Zeppelin Systems GmbH, adding: “The aim is to offer process solutions in the future that can be provided as part of license models. For example, the ELT pyrolysis plant as a turnkey product from Zeppelin Systems.” Guido Veit, Vice President of Sales, Plastic and Rubber at Zeppelin Systems GmbH, adds: “ReOil’s engineering contract is the first project as part of the Zeppelin Sustainable Tyre Alliance. This makes us proud and demonstrates the strength of the alliance. In addition, we will continue to work hard to bring additional processes to technological maturity and strengthen the network in terms of the circular economy.”

ReOil Managing Director Paweł Mikuśkiewicz is also delighted with the very successful partnership between Zeppelin Systems and ReOil: “We knew that this major project could only be planned and built with the help of an experienced and internationally active plant engineering partner. That’s why we chose Zeppelin Systems, and we really appreciate our long-standing, trusting business relationship.”                                                          

Zeppelin Systems, a trusted partner in plant engineering for the rubber and tyre industry, has taken a significant step towards a more sustainable future by launching the Zeppelin Sustainable Tire Alliance in March 2023. This collaborative initiative aims to work alongside global partners in reshaping the tyre production and recycling process in a more environmentally conscious manner.

Among the esteemed members of this technology alliance is the Polish firm ReOil, known for establishing Europe’s largest pyrolysis plant dedicated to recycling old tyres in 2015. Over the years, ReOil has successfully recycled approximately 20,000 tonnes of old tyres annually. Once operational, this colossal plant is expected to reintegrate about 60,000 tonnes of old tyres into the sustainable circular economy annually.

ReOil, a leading operator in raw material recycling, employs continuous pyrolysis to break down rubber from discarded tyres into valuable substances like gas, oil and recovered Carbon Black (rCB). These recycled materials find application in various industries, including textiles, tyre manufacturing, rubber components, plastics, steel production, and even aviation fuel. Since its commissioning in 2015, ReOil has effectively recycled around 70,000 tonnes of old tyres, reaching a stable and profitable operational state in 2020.

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Solvay is expanding its global circular economy strategy by converting its Asian production of highly dispersible silica (HDS) to use certified circular raw materials. Beginning in 2026, its plants in Qingdao, China, and Gunsan, South Korea, will transition to using ISCC+ certified waste sand. This major initiative is projected to make over half of the region’s HDS output circular, directly aiding tyre makers in their goal of incorporating over 40 percent sustainable materials by 2030.

This transition provides tyre manufacturers with a cost-effective, high-volume circular Zeosil silica that integrates seamlessly into existing processes without the need for reformulation. The move builds on the successful conversion of Solvay’s Livorno, Italy, facility to using rice husk ash and reflects a coordinated, global shift towards circular sourcing. It also supports the broader sustainability goals of Solvay Silica, including the adoption of low-emission technologies like electric furnaces to minimise the carbon footprint of its products worldwide.

By pioneering circular silica from diverse feedstocks and regions, Solvay is fostering more resilient and sustainable supply chains through innovative partnerships across the entire value chain.

An Nuyttens, President of Solvay’s Silica Business unit, said, “Solvay’s circular silica helps improve fuel efficiency and EV range, offers long-lasting wear benefits, improves safety, while advancing sustainability. This is more than innovation - it’s a reinvention of how we source, produce and collaborate across the value chain.”

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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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