After more than three decades in tyre recycling, Pliteq CEO Paul Downey argues that despite rising sustainability rhetoric, the industry’s core technologies and material flows have barely evolved. While perceptions of recycled materials have improved, real innovation, he said, has been slower, narrower and far more uneven than expected.

Paul Downey, Chief Executive Officer of Pliteq, has worked in end-of-life tyre recycling since 1990. In that time, he expected major breakthroughs in pyrolysis and tyre-to-tyre recycling. He says they never came.

“When you look at pyrolysis, that hasn’t really changed in 30 years,” Downey said in an exclusive interview with Tyre Trends. “When you look at the use of rubber back into tyres, still a very small percentage of waste tyres goes back into new tyres,” he added.

Despite more money, more participants and more attention on recycling, he describes the sector as remarkably static. These, he said, were the areas where he expected research and to unlock scale. “Frankly the needle hasn’t moved very far in all those years. I’ve only seen very, very small changes in the last 30 years,” Downey noted.

One reason is energy. “Tyres take a tremendous amount of energy to grind up. So, you still need a lot of energy. Energy challenges are going to be an ongoing issue,” he said, pointing to wider stress on energy infrastructure.

That energy intensity affects both mechanical recycling and pyrolysis, where tyres are broken into oil, gas and carbon black. While refining recovered carbon black has long been studied, Downey says progress has been limited.

“You can refine the carbon black to make it more useful by tyre companies in terms of not degrading the quality of the finished tyre,” he said, adding that this has been researched for decades without dramatic improvement.

Pyrolysis remains minor in North America with a significant share of tyres still used as tyre-derived fuel. Downey divides end-of-life tyre use roughly into thirds viz-a-viz moulded goods, tyre-derived fuel and applications such as rubber-modified asphalt, which he says has also seen limited uptake since 1990.

After university, Downey joined a company that was already working with tyre manufacturing waste with materials that could not be used in new tyres due to quality deviations.

“When you produce a tyre, about two to three percent of the materials are off-spec. These materials can’t be used to make a tyre, so that becomes waste. That waste, combined with ELTs, was processed into noise and vibration products, primarily for automotive, heavy truck, and off-the-road vehicle applications,” he explained.

“This was back in the early 1990s. The original use was non-tyre. It was mostly in the noise and vibration space for vehicles,” Downey said.

In 1998, after developing multiple patents in Canada and the United States, Downey founded his own company. Initially, the business model revolved around licensing those patents to manufacturers, largely in the US. Over time, that approach evolved. “When I formed Pliteq, I stopped doing the licensing. All of the patents are now being used by the company,” he said.

FROM PATENTS TO PLITEQ

Today, Pliteq focuses on manufacturing finished products rather than licensing technology. The company produces sound and vibration control materials, insulated floor mats and building products made from recycled ELT rubber. Its applications range from isolating vibration caused by subway and railway lines to managing noise and vibration from HVAC systems, pumps, compressors and mechanical rooms in buildings.

“We’re looking at all the places in or around a building under construction where rubber could be used,” Downey explained.

Asked what has changed in the tyre recycling industry over the last 30 to 35 years, Downey’s answer is candid. “Remarkably, little has changed,” he quipped.

While markets for recycled tyres have expanded, the underlying technologies and material flows remain largely the same. Pyrolysis, often cited as a future solution for ELTs, has not progressed as dramatically as expected. “That hasn’t really changed tremendously in 30 years,” Downey noted.

Similarly, efforts to put recycled rubber back into new tyres have seen limited success. “There have been some efforts by major tyre companies but still a very, very small percentage of waste tyres goes back into new tyres. Those were areas where I thought there was a lot of potential for research, but the needle hasn’t moved very far,” he said.

Where the industry has evolved more meaningfully is in moulded goods. “That’s where we’ve seen the most development,” Downey said, pointing to sound and vibration products, underlayments and recycled rubber flooring used in schools, hospitals, gyms and fitness facilities. In North America, he estimates that moulded goods account for roughly one-third of ELT usage.

Another third of ELTs is used as tyre-derived fuel, while the remainder goes into applications such as rubber-modified asphalt, an area Downey says existed in 1990 and has not seen significant market uptake despite ongoing research.

CHANGING PERCEPTIONS

One of the most significant shifts Downey has witnessed is not technological but cultural. “When I started, recycling was a bad word. People didn’t want to buy recycled products because they thought it was garbage,” he said.

That perception has changed substantially. Today, architects, builders and developers show strong interest in sustainable materials, particularly in construction. While Downey does not attribute this shift directly to regulation, he acknowledges a broader market preference for sustainability.

“Now people don’t view recycling as inferior. That attitude has definitely changed over the last 30 years,” he said.

Moreover, public scrutiny around recycled rubber has intensified in recent years, particularly regarding the use of crumb rubber in athletic fields. Downey addressed these concerns directly, referencing studies he has reviewed.

“I haven’t seen any research that shows a correlation between crumb rubber and health issues. The Synthetic Turf Council conducted a multi-year study that showed exactly the opposite,” he said.

In Downey’s view, the primary concern around crumb rubber is environmental rather than medical. “It’s a powder. Potentially, it can wash away into the water supply,” he said.

Pliteq, however, is not active in the turf infill market. “We don’t sell crumb into athletic fields. We strictly manufacture moulded goods for sound control, vibration isolation, flooring and building products,” Downey clarifies.

SCALE AND FOOTPRINT

Pliteq operates offices in seven countries and sells into approximately 50 markets worldwide. Its main manufacturing facility is located in Canada, supported by two smaller plants in United States. Collectively, these facilities produce about 44,000 metric tonnes of finished products annually.

To achieve this output, Pliteq consumes roughly 60,000 metric tonnes of ELTs. “We don’t use the steel or textile,” Downey explained, referring to the components removed during tyre processing.

The company sources tyres primarily from North America, tapping into a collection network that has been established over the past three decades. ELTs are categorised into three distinct groups viz-a-viz passenger and light truck tyres, heavy truck tyres and mining or off-the-road tyres, each with different rubber compositions and properties.

“We keep those three categories separate. The amount and type of rubber are quite distinct,” Downey said.

Pliteq’s patents focus on application and use rather than core processing technologies. Beyond patents, the company relies heavily on proprietary know-how. “We have a number of trade secret processes that we don’t disclose,” Downey said.

These include particle selection, tyre source selection, screening, cleaning, formulation, mixing and moulding. “We do things in a way that nobody else in the world is doing. That allows us to achieve certain quality levels, surface finishes and performance characteristics that aren’t generally available,” he says.

Quality control is embedded throughout the manufacturing process. Downey estimated that each product passes through around seven distinct quality checks, supported by machine operators, automated systems and visual inspections. Any waste generated during production is reprocessed and reused, reinforcing a closed-loop manufacturing approach.

Pliteq operates a hybrid business model. Technology development, product design and manufacturing are largely centralised, while sales, warehousing and distribution are managed regionally. This structure allows the company to adapt products to local market needs.

“Some markets have very distinct requirements. What’s needed in UK might not be required in Singapore, Australia or US,” Downey said.

THE ROAD AHEAD

Looking forward, Downey sees gradual rather than dramatic change. Energy consumption remains a major challenge as tyre grinding is energy-intensive. Broader issues such as energy infrastructure strain and shifting global trade patterns also weigh on the industry.

Despite these challenges, Pliteq continues to reinvest its earnings back into the business. “We’re on a growth curve. We reinvest all the money back into the company and into the markets,” Downey said.

The company is currently operating at around 80 percent capacity, a level Downey stated is close to optimal. Expansion will focus first on strengthening existing teams across its seven offices before opening new locations.

“We’ve built the manufacturing model so it can scale as demand grows. But we only put new facilities where the market can sustain them,” he said.

After more than three decades in the ELT space, Downey remains pragmatic. The industry may not have transformed as dramatically as once hoped, but in moulded products and building applications, Pliteq continues to carve out a space where recycled tyres deliver measurable performance and growing acceptance in the built environment.

Balkrishna Industries Ltd (BKT) reported record quarterly sales volumes in its core off-highway tyre (OHT) business in the first quarter of FY27, supported by robust demand across India, Europe and the Americas, even as rising raw material costs, freight inflation and geopolitical disruptions squeezed margins.

The company posted 16 percent year-on-year growth in OHT sales volumes to 93,770 metric tonnes, while standalone revenue rose 24 percent to INR 34.09 billion. EBITDA increased to INR 7.03 billion, representing an EBITDA margin of 20.61 percent, while profit after tax reached INR 4.32 billion.

"Q1 started on a positive note for us. We delivered our highest quarterly sales volume in the OHT segment," Rajiv Poddar, Joint Managing Director, said. He noted that the performance came "despite the challenges across many international geographies and end markets, as well as within the supply chain of the world", highlighting the resilience of demand across key markets.

Management said profitability was affected by higher raw material prices stemming from global supply chain disruptions and geopolitical tensions, although the impact was partly offset through price increases introduced during the quarter.

BKT accelerates investment programme

BKT continues to advance one of the largest expansion programmes in its history.

The company has already invested approximately INR 38 billion under its broader INR 68 billion capital expenditure programme, with around INR 30 billion yet to be deployed. Of the remaining investment, INR 15-20 billion is expected to be spent during FY27 after capital expenditure of about INR 10 billion in the first quarter.

Completed projects include:

• Commissioning the second phase of its carbon black facility at Bhuj, increasing annual capacity to 360,000 tonnes, with an investment of INR 8 billion.
• Expanding captive power generation capacity from 40 MW to 64 MW, involving an investment of INR 1.25 billion.

"All the balanced CapEx projects, which are amounting to approximately INR 30 billion, are progressing as per schedule,” added Poddar.

On-highway business begins commercial rollout

Beyond its dominant OHT franchise, BKT has formally entered India's truck and bus radial (TBR) and two-wheeler tyre markets.

The company began commercial supplies after establishing its distribution network during the quarter and reported encouraging initial customer response. Although management declined to disclose revenue or volume figures given the early stage of the business, it expects sales to begin ramping up from the second quarter. "Having seeded the business in Q1, we expect a gradual ramp-up starting in Q2," Poddar said.

The long-term target remains INR 50 billion in on-highway tyre revenue by 2030. Satish Sharma, Senior President and Director of Strategy and Business Development, said FY27 would focus on expanding the portfolio before accelerating growth. "The vision statement states that INR 50 billion revenue from on-highway tyres by 2030. We're standing on that figure... FY 2028 onwards will be serious business."

India becomes larger contributor

India accounted for 40 percent of total volumes during the quarter, driven by demand from agriculture, construction, mining and industrial applications. Management said infrastructure investment and market share gains continue to support domestic growth, although margins in India remain marginally below export markets.

BKT estimates its market share at 18-19 percent in India, 7-8 percent in Europe and 3-4 percent in the United States, with inventory levels across key markets remaining normal.

Management also expects the US business to recover to its historical contribution of 15-16 percent of revenue, supported by improved tariff clarity and stronger brand positioning.

Inflation remains the principal challenge

BKT introduced approximately 5 percent price increases during the first quarter, with the full benefit expected to be realised in Q2. "We have taken on a price hike of about 5%, scattered across the various parts of the quarter. You will see the full passthrough coming in this quarter," Poddar said.

However, management said raw material costs have also increased by around 5 percent, potentially reducing margins by roughly 2 percentage points despite the pricing action.

Freight costs currently represent about 5 percent of revenue, with executives warning that continuing geopolitical tensions could lead to further increases.

The company also identified supply chain disruptions, vessel availability, container shortages, weather conditions in Europe and monsoon variability in India among the principal risks for the coming quarters.

Cabot Corporation has announced a significant leadership transition, with President and Chief Executive Officer Sean Keohane set to retire from his roles and step down from the Board of Directors, effective 30 September 2026. The company has elected Executive Vice President, Chief Financial Officer and Head of Corporate Strategy Erica McLaughlin to succeed him. McLaughlin will assume the positions of President and CEO, in addition to joining the Board as a member of the class whose term concludes at the 2029 Annual Meeting of Stockholders, effective 1 October 2026.

To facilitate a seamless handover, Keohane will remain with Cabot in an advisory capacity through the end of the 2026 calendar year. Concurrent with McLaughlin’s elevation, the company has initiated a formal search process to identify her replacement as Chief Financial Officer.

McLaughlin brings over two decades of experience to her new role, having joined Cabot in 2002 and holding various senior leadership posts across finance, strategy and the Reinforcement Materials division. Since assuming her current position in 2018, she has been instrumental in shaping corporate strategy and driving operational discipline. Her prior roles included Vice President of Business Operations for Reinforcement Materials, General Manager of its tire business and Vice President of Investor Relations. Beyond Cabot, she contributes her expertise as a board member for Azenta Life Sciences and as an advisor to FM Global.

Keohane’s distinguished tenure spans nearly 25 years, with his service as President and CEO beginning in 2016. His leadership was marked by significant portfolio refinement, the strengthening of core businesses, and the successful expansion into battery materials. He also advanced the company’s sustainability agenda and commitment to operational excellence, delivering robust performance and sustained shareholder value throughout his career.

Board Chair Michael Morrow said, “Erica brings deep industry expertise and a strong understanding of Cabot’s businesses, markets and global operations. This experience, coupled with her commitment to the company’s long-term strategic priorities, positions her exceptionally well to lead Cabot. Our decision to appoint Erica as the next President and CEO reflects a thoughtful and deliberate succession planning process. Her deep knowledge of the organisation and commitment to the values and culture that have been integral to Cabot’s success will provide continuity as we execute this leadership transition. We believe she brings the leadership, discipline and strategic clarity needed to lead Cabot forward and deliver on our long-term vision.

“The Board is deeply appreciative of Sean’s exceptional leadership and distinguished career at Cabot. We extend our congratulations on a well-deserved retirement. During his tenure as CEO, Sean provided strong, steady and thoughtful leadership, focusing the company’s portfolio around its core businesses and advancing new strategic long-term growth priorities. His collaborative leadership style has strengthened our organisation and leadership team, leaving a strong foundation for continued success in the years ahead.”

McLaughlin said, “I am deeply honoured to succeed Sean as President and CEO and lead Cabot into our next chapter. Having been at Cabot for close to 25 years, I know firsthand the strength of our people and our businesses. I look forward to working with the Board and our global team to build on our success, grow the company by supporting our customers with innovative chemistry solutions to advance their businesses and create value for our stockholders.”

Keohane said, “It has been a tremendous privilege to lead Cabot and to work alongside such a talented and dedicated global team. I am incredibly proud of what we have accomplished together and the foundation we have created. I am confident Cabot is in excellent hands under Erica’s leadership. We have worked side by side for almost my entire tenure as CEO and I have seen first-hand her strong leadership, operational discipline and sharp strategic mind. Erica is a trusted and highly capable leader with deep knowledge of our business and a commitment to our people, the culture and the unique heritage of this great company. I look forward to supporting a seamless transition in the months ahead.”

Robin Wiener, President of the Recycled Materials Association (ReMA), has been appointed to the Board of Directors of the Tire Recycling Foundation (TRF). Her appointment recognises her leadership within both the recycled materials and tyre manufacturing sectors. In this new capacity, Wiener will support the Foundation's mission to enhance the tyre recycling supply chain and foster the growth of innovative markets for recycled tyre materials.

TRF, a joint initiative led by the U.S. Tire Manufacturers Association and the Tire Industry Association, aims to drive circularity and sustainability in the US tyre recycling industry. Wiener joins a board of global industry leaders dedicated to securing funding and allocating grants for critical research and demonstration projects.

Apollo Tyres Chairman Onkar S. Kanwar has said the company remains focused on disciplined execution, sustainability and long-term value creation as it navigates geopolitical uncertainty, changing trade dynamics and a challenging global business environment.

Addressing shareholders at the company's 53rd Annual General Meeting (AGM), Kanwar said FY26 had been a year that tested businesses worldwide, but Apollo Tyres had continued to strengthen its financial performance while investing for future growth.

"The future is not something we inherit. It is something we create through the choices we make every day," Kanwar told shareholders, quoting Mahatma Gandhi's observation that "The future depends on what we do in the present."

Apollo Tyres reported consolidated revenue of INR 284.71 billion for FY26, crossing the INR 280 billion milestone, while operating profit rose to INR 41.43 billion. Kanwar said the company's focus extended beyond financial performance to improving capital efficiency, operational discipline and profitable growth.

"Every important decision we take is driven by one simple question: Are we building a stronger company for tomorrow?" he said.

Kanwar also highlighted the company's efforts to strengthen the Apollo Tyres brand through its association with the Indian national cricket team, describing the partnership as one that reflected Apollo Tyres' values of resilience, determination and excellence rather than merely serving as a branding exercise.

Sustainability remained central to the company's strategy, he said, noting that Apollo Tyres' greenhouse gas emission reduction targets had been validated by the Science Based Targets initiative (SBTi), reinforcing its commitment to achieving net-zero emissions by 2050.

The company continued to expand the use of renewable energy while improving responsible sourcing and resource efficiency across its operations, Kanwar said. "Sustainability is no longer a separate agenda for Apollo Tyres; it has become an integral part of how we innovate, manufacture and grow."

Kanwar credited employees for the company's performance, describing their commitment and adaptability as the foundation of Apollo Tyres' continued progress. He also acknowledged the support of governments and institutions across the markets where the company operates.

He singled out Hungary as a key manufacturing base in Europe, saying Apollo Tyres' plant at Gyöngyöshalász reflected the benefits of long-term collaboration with the Hungarian government.

Looking ahead, Kanwar expressed confidence in the company's growth prospects, citing India's expanding market opportunities and Apollo Tyres' international manufacturing and distribution footprint.

"Uncertainty will always be a part of business, but organisations that remain true to their values, continue to innovate and invest responsibly will be best placed to succeed," he said.

Thanking shareholders, customers, dealers, suppliers, financial institutions and government partners for their continued support, Kanwar said Apollo Tyres remained committed to building "a company that is stronger, more resilient and more responsible with every passing year."