The Tamil Nadu-based company’s greenfield expansion will propel its rCB capacity from 5,000-20,000 metric tonnes. Director Ravi Rathi explained that there has been a change in attitude towards rCB within tyre companies, leading to heightened demand.

Tamil Nadu-based Capital Carbon is expanding its recovered carbon black (rCB) capacity by 15,000 metric tonnes with a new greenfield project at Gummidipoondi. The plant is slated to become operational by January 2025 and boost the capacity from 5,000 metric tonnes to 20,000 metric tonnes, annually.

Speaking to Tyre Trends, Director Ravi Rathi explained, “The decision to pursue a greenfield expansion in the rCB sector stemmed from the rapid development of this innovative product over the past four to five years. Given our background in the pyrolysis business, expanding into rCB felt like a natural progression. rCB is still a relatively new product and both manufacturers and users are in the process of learning about its applications. When we first began exploring this market, around four years ago, it was challenging. Many tyre manufacturers would dismiss our proposals even before we could present our case as they were hesitant to incorporate recycled materials into their mainstream formulations.”

“However, in recent years, attitudes have shifted significantly due to increasing emphasis on sustainability and circular economy principles. The industry is now more open to integrating green products. We started with a modest capacity of 5,000 metric tonnes per annum, which allowed us to gain insights into customer needs. Gradually, we scaled our operations from small quantities to commercial sales. The key driver for our recent expansion is customer demand. We have obtained product approval, and customers are eager to purchase rCB,” he added.

He also noted that companies wanted assurance that the demands could be met consistently, which was also a factor behind the expansion. Furthermore, having multiple units also allows the company to manage any potential supply chain issues, effectively. “If a minor problem arises in one unit, we can still supply material from another, minimising disruptions for our customers,” said Rathi.

The entire CAPEX for the greenfield plant is set at INR 20 crore.

Pyrolysis to rCB

Capital Carbon commenced operations in 2012 with a modest pyrolysis capacity of 10 tonnes per day. Over the years, it has consistently expanded its capacity, increasing to 150 metric tonnes per day. The company has also bolstered its backend operations, enhancing sourcing capabilities and adding substantial shredding and crumbing capacity.

Additionally, Capital Carbon has focused on value-added products including pyrolysis oil distillation and rCB. As of now, it operates a shredding capacity of 120,000 metric tonnes per annum for captive consumption. This capacity is supplemented by sourcing contaminated tyre bales, which typically have 20-30 percent rubber contamination. This material is cleaned to yield 98 percent pure steel, with the remaining rubber used for pyrolysis, creating a separate business vertical.

Currently, the company processes approximately 50,000 to 52,000 metric tonnes of tyres per annum through its pyrolysis operations. In terms of value addition, Capital Carbon produces between 20,000 to 24,000 tonnes of pyrolysis oil, annually.

When asked about the motivation behind establishing a pyrolysis plant, Rathi noted, “My father worked at Birla Carbon and retired in 2019. Although we lacked prior business experience, we were inspired by the industrial upbringing and the promising potential of the pyrolysis sector. Following the completion of my chartered accountancy studies, I decided to pursue this opportunity.”

He acknowledged that pyrolysis often has a negative reputation in India, where it is sometimes viewed as a ‘dirty business’. To combat this perception, Capital Carbon prioritises quality management and environmental responsibility in its operations. IT employs fuel-based heating methods in its pyrolysis process as electric heating is generally not feasible due to the high volumes involved in tyre pyrolysis. The initial heating requires some fuel, which can include biomass or pyrolysis oil, but the system becomes self-sufficient once it reaches a certain temperature.

The primary outputs from the pyrolysis process include fuel oil, carbon char (used as raw material for rCB or as an alternative energy source for cement plants), steel wires and pyrolysis gases, which are utilised for heating purposes.

He highlighted that the pyrolysis oil produced is of high quality with low sulfur and carbon content, making it cleaner than many conventional heating fuels used in India.

Quality control

The company’s sourcing strategy primarily focuses on domestic suppliers. It procures rejected tyres and dealer returns from various companies, which constitute a substantial portion of the feedstock. This local sourcing approach ensures that it maintains a steady supply of raw materials

Following sourcing, the production of recovered carbon black involves several critical steps. Initially, tyres are shredded to extract carbon black, steel and other components. The distinction in product application necessitates tailored processing methods.

For instance, producing carbon char for energy requires less stringent technical specifications compared to producing carbon black intended for high-performance applications, such as tyre manufacturing or footwear.

“The quality of the final product begins with meticulous sorting of tyres to determine suitability for pyrolysis. This initial step is vital for ensuring consistent output quality. Following sorting, the tyres are shredded into steel-free rubber chips of 15-20 millimetres. During pyrolysis, we focus on maintaining specific quality parameters for the pyrochar produced. This includes stringent controls to limit ash content, which must remain below 20-22 percent to ensure product consistency. The handling of impurities such as wires and stones in the pyrochar is essential. Post-processing, the pyrochar is milled to fine particle sizes (10-15 microns), enhancing its surface area for better compatibility with rubber compounds,” explained Rathi.

Once the recovered carbon black is processed, palletisation becomes the next step. This method streamlines handling and ensures that the product meets industry standards. While the equipment resembles that used for traditional carbon black, adaptations are necessary to accommodate the unique characteristics of recovered carbon black.

“To facilitate customer adoption, we offer tailored packaging solutions including 25kg paper bags, EVA / LDPE bags and FIBC bags, allowing clients to integrate our products seamlessly into their existing production processes,” he added. 

As the industry evolves, the need for standardised quality benchmarks for recovered carbon black has become increasingly clear. Major corporations have driven this change, leading ASTM to establish a dedicated committee (D36) focused on developing specific standards for recovered carbon black. Unlike conventional carbon black, which adheres to existing standards, recovered carbon black requires new metrics to account for its varied origins and compositions.

The committee is currently validating a series of standards including moisture content, pallet hardness and particle size analysis, specifically for rCB. This ongoing development is slated to enhance product credibility and facilitate broader market acceptance.

Commenting on the same lines, Rathi mentioned, “We maintain a dedicated quality lab to refine our production processes continually. Our focus on evolving our offerings has resulted in the introduction of two new grades of recovered carbon black, aimed at meeting diverse market needs. Our commitment to leveraging advanced machinery and improved grinding techniques reflects our proactive approach to quality enhancement and capacity expansion.”

Optimistic market outlook

The demand for recovered carbon black in India is poised for significant growth, driven by a strong shift toward sustainability. Customers are increasingly seeking high-quality suppliers, indicating a burgeoning market for rCB.

“Globally, rCB production currently accounts for less than one percent of total carbon black production, underscoring a substantial opportunity for expansion. As customer awareness and demand for sustainable products increase, we anticipate a corresponding rise in rCB consumption,” informed Rathi.

He added, “Many major corporations have committed to achieving carbon neutrality by 2050, necessitating immediate action to integrate green and circular products into their supply chains. As these companies strive to meet their net-zero targets, they are turning to recovered materials such as rCB to fulfil sustainability mandates. Our role is crucial in assisting these customers to achieve their goals through the production of eco-friendly and circular products derived from end-of-life tyres.”

Speaking on market opportunities, he said, “India remains our largest market, but we are also making significant inroads into Sri Lanka. The European market is particularly promising, though it presents challenges related to certifications and distribution. We are currently working on obtaining the necessary certifications, including ISCC Plus, to unlock this market potential.”

“Our immediate focus is on completing our current expansion project, after which we will enhance our pyrolysis capacity to align with the growing demand from our customers. As the volumes of recovered carbon black usage increase, we aim to be ready with sufficient supply,” he added.

He expects to penetrate the European market by the first half of FY26, following the completion of the current plant expansion.

Challenges in scaling production

“One of the primary challenges in scaling rCB production is the scarcity of raw materials. The supply of suitable feedstock is diverse and scattered, making it difficult to source consistently. In the past, customers struggled to understand the differences between recovered carbon black and virgin carbon black grades, often asking if we could produce specific grades like L550 or L660. However, as knowledge in the market has matured, customers are increasingly recognising that rCB is a distinct material requiring tailored processing approaches,” informed Rathi.

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Yokohama Rubber has reported new findings from an international research programme aimed at combating leaf fall disease, a fungal infection that has disrupted natural rubber production in Indonesia, the world’s second-largest supplier.

The results were presented on 9 December at the fifth Joint Coordinating Committee Meeting held at Universitas Indonesia. The initiative, formally titled “Development of Complex Technologies for Prevention and Control of Rubber Tree Leaf Fall Diseases”, forms part of the Science and Technology Research Partnership for Sustainable Development, a scheme run by the Japan Science and Technology Agency and the Japan International Cooperation Agency with support from Japan’s foreign and education ministries.

The project brings together Japanese industry, government and academic institutions, including the national research agency RIKEN, with Indonesian partners. Its objective is to maintain output from smallholders, who account for more than 90 per cent of Indonesia’s natural rubber production. The programme is pursuing several approaches: pesticide-based disease control; the development of disease-resistant clones; and early detection using satellite and drone imagery.

Yokohama Rubber, which uses natural rubber as a principal raw material for tyres, has been involved since the project’s launch in 2020. The company began assessing pesticide effects on rubber quality in 2024, following a screening process. Field tests on large plantations have shown that correctly applied pesticides do not impair the properties of raw or vulcanised rubber. Yokohama Rubber is now contributing to research on how such treatments may affect smallholders.

The group said its “Procurement Policy for Sustainable Natural Rubber” incorporates support for participants across the supply chain, including small-scale farmers. It expects its role in the project to aid the sustainable production of natural rubber and help stabilise smallholder incomes. Yokohama Rubber is also an official partner in a separate SATREPS initiative on using rubber seeds to develop environmentally focused products intended to mitigate global warming and plastic pollution.

Under its sustainability theme, “Caring for the Future”, the company has emphasised links between its commercial activities and broader environmental and social objectives.

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Australia has released its first national specification for the use of crumb rubber asphalt on local roads, a move intended to give councils clearer guidance on designing and maintaining light-to-medium-duty networks and to strengthen domestic recycling demand for end-of-life tyres.

The Crumb Rubber Modified Dense Graded Asphalt (CRM DGA) Model Specification for light to medium duty roads was published by the Australian Flexible Pavement Association (AsPA) following collaboration with Tyre Stewardship Australia. The document offers standardised technical requirements for councils, which manage about 75 percent of the national road network — roughly 675,000km of streets and community-level infrastructure.

Existing asphalt standards were largely developed for higher-order state roads, leaving local governments to interpret specifications that did not reflect lower traffic loads or the environmental conditions typical of suburban and regional networks. The new model specification aims to close that gap by setting guidance aligned with the factors that most influence degradation on council roads, such as surface ageing and weather exposure.

The specification promotes the use of crumb rubber modified binders, which can extend pavement life under light-to-medium-duty conditions. Incorporating recycled rubber also aligns with broader circular-economy policies across Australia’s states and municipalities, which are seeking to reduce landfill and illegal dumping while supporting domestic tyre-recycling capacity.

AfPA said the CRM DGA Model Specification V1.0, dated October 2025, is publicly available. It includes requirements for mix design and materials, construction processes such as compaction and temperature control, and performance testing suited to council networks. It also offers practical guidance on integrating reclaimed asphalt pavement content.

Local governments seeking case studies and procurement tools on crumb rubber applications can access Tyre Stewardship Australia’s Crumb Rubber Resource Centre for further technical and project information.

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Flexsys has created what it says is the tyre industry’s first practical and scalable alternative to 6PPD, marking a major step toward replacing a chemical used for decades but now under regulatory pressure.

The company said the new antidegradant is the result of several years of research and testing with federal laboratories, independent scientific groups and tyre makers. Early results show the material could match the performance and safety of 6PPD while avoiding the environmental risks linked to 6PPD-quinone, a transformation product identified in 2020.

Flexsys said the new chemistry provides the short- and long-term protection needed to stop tyres cracking or ageing. It is also designed to fit into existing rubber compounds with minimal changes, which could help manufacturers adopt it quickly. The company added that the product meets environmental and regulatory benchmarks, including criteria set by the Washington State Department of Ecology.

Importantly, the new molecule is not part of the “PPD” family, meaning it does not form quinone during use. Flexsys said this would remove the environmental impact associated with 6PPD-quinone. The company is also using many of the same intermediate chemicals already used in 6PPD production. This could allow manufacturers to rely on existing factory assets and speed the shift to the new technology.

“This achievement reflects our unwavering commitment to responsible innovation, built on decades of expertise in tire protection chemistry,” said Carl Brech, Chief Executive Officer of Flexsys. “Our solution is formulated to deliver the performance and reliability that tire makers expect and is designed for future environmental and regulatory standards.”

6PPD has been essential to tyre durability for 50 years. But studies published in 2020 showed that 6PPD-quinone could harm aquatic species, including coho salmon. Regulators and tyre producers have been looking for a safer option since then. Flexsys said its new antidegradant meets this challenge without reducing tyre safety.

“Our team set out to develop a next-generation antidegradant that meets the tire industry’s highest performance standards without compromising tire safety, while also reducing toxicity,” said Neil Smith, Chief Technology and Sustainability Officer. “I could not be more proud of the perseverance and dedication of the Flexsys R&D team. Our group has been highly motivated by both the technical challenges of this project as well as the positive societal impact that this work will ultimately have.”

Flexsys acknowledged support from the Sustainable Polymers Tech Hub in Akron, Ohio, part of the U.S. EDA Tech Hubs programme.

The company is now working on process optimisation to allow large-scale production. It is also in discussions with regulators around the world to secure approvals for commercial use. Testing with tyre makers is continuing.

“Flexsys is helping set the direction of the tire industry for the coming decades with this development,” Brech said. “We will continue to work tirelessly to bring this breakthrough to the market as soon as possible.”

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Wacker Chemie AG has strengthened its position in China’s fast-growing market for silicone specialities by opening a new application development centre with joint-venture partner SICO Performance Material in the eastern city of Jining.

The 2,300-square-metre facility brings together several laboratories focused on organofunctional silanes, which are used as high-performance additives in plastics, coatings and adhesives. By locating the centre next to SICO’s production and scale-up lines, Wacker aims to shorten development cycles and move new products into the market more quickly. The companies said investment in the site is in the mid-six-figure euro range.

Tom Koini, who leads Wacker’s silicones division, said the opening marks an important step in its China strategy. “As a provider of innovative silicone specialties and solutions, we can use this development center to achieve a key milestone for our business in China. Our focus is on high-margin specialty silanes, for which demand in China is rising continuously. This investment together with our partner SICO strengthens our presence and commitment to the region,” he said.

Wacker, which took a majority stake in SICO in 2022, is seeking to build a larger share of China’s specialty chemicals market, where demand for hybrid polymers has increased for years. These materials help improve the mechanical and chemical properties of adhesives, sealants, coatings and engineered plastics, all of which are used in sectors such as electric mobility, electronics and power equipment.

At the opening ceremony, SICO General Manager Kevin Qu called the centre an investment in the long term. “We can now pool all of our silane expertise here at our application development centre. This know-how ranges from chemical product properties and supply chain matters through to questions of process engineering and current marketing trends. We will leverage this in-depth knowledge to develop forward-looking innovations for our customers. This marks a new chapter of success in the history of our joint venture,” he said.

The companies said the centre will act as a link between research, technical service and manufacturing teams. Scientists will focus on developing additives, adhesion promoters and stabilisers based on organofunctional silanes and functional silicone fluids.

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