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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Birla Carbon is set to participate in the upcoming Tire Technology Expo 2026, scheduled to take place in Hannover, Germany, from 3 to 5 March 2026. Attendees can find the company at Stand C 224, where it will present its latest innovations in carbon black and sustainable materials. The focus will be on solutions specifically designed to meet the evolving demands of the tyre industry, particularly in enhancing performance while aligning with broader environmental objectives.

The exhibition will serve as a platform to demonstrate how Birla Carbon’s advanced materials contribute to greater tyre durability and fuel efficiency. These developments are especially pertinent for next-generation mobility, including the specific requirements of electric vehicles. The company aims to show tire manufacturers how performance enhancements can be achieved without sacrificing sustainability commitments.

A key theme of their presence will be the strength and agility of their supply network across the EMEA region. By emphasising its robust local manufacturing and distribution framework, Birla Carbon intends to highlight its role as a dependable innovation partner. This infrastructure is built to ensure consistent quality and supply chain resilience, allowing for effective collaboration even in fluctuating market conditions.

Sustainability will be woven throughout the company’s engagement at the expo. Birla Carbon plans to detail its journey towards achieving net zero carbon emissions, spotlighting advancements like its Continua Sustainable Carbonaceous Material (SCM). The widespread ISCC Plus certification across its global manufacturing sites will also be featured, underscoring its commitment to traceable and responsible sourcing practices throughout the value chain.

John Davidson, Chief Sales, Marketing & Sustainability Officer, Birla Carbon, said, “Birla Carbon brings a range of innovative carbon black solutions, backed by its decades of manufacturing leadership, at a time when the industry is focused on maximising tyre performance across diverse mobility requirements. As mobility evolves towards electric and more energy-efficient platforms, carbon black is increasingly becoming a key performance enabler, directly influencing durability, rolling resistance and lifecycle emissions. Tire Technology Expo provides an impactful global platform to demonstrate how our advanced carbon material solutions are engineered for modern mobility and sustainability.”

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Sri Trang Agro-Industry Public Company Limited (STA) is advancing Thailand’s agricultural digital transformation through its homegrown platform, the Sri Trang Friends application. Launched in 2019 with the vision of providing a comprehensive digital tool for rubber farmers, the platform has since evolved to serve a broader agricultural community, including palm growers. It is designed to streamline access to information, services and various support mechanisms, creating a direct link between the company, farmers and supply chain participants.

A key recent development is the introduction of the Friends Shop feature and the Friends Point rewards system. This enhancement integrates local merchants from communities nationwide into the application, allowing farmers to conduct convenient transactions while helping to lower their daily expenses. The points accumulated can be used as cash equivalents or exchanged for a wide range of benefits, including essential goods and services, thereby stimulating local economic activity. The platform’s utility has also been extended to Sri Trang Group employees and the general public, who can now earn and redeem points for discounts or payments at participating outlets such as supermarkets, fuel stations and coffee shops. This expansion ensures the app delivers practical, lifestyle-oriented advantages to a wider user base.

According to Executive Director Vitchaphol Sincharoenkul, the application was originally conceived under the concept of ‘One App, Complete Services for Rubber Farmers’ to strengthen farmer engagement, improve coordination efficiency and ensure fully traceable and transparent produce trading. Beyond these operational goals, it also opens new marketing channels for local communities and fosters deeper collaboration across the agricultural value chain. The company is actively broadening its network of partners to diversify the benefits and merchant options available to users.

Currently, the Sri Trang Friends platform has attracted over 150,000 registered users, with more than 40 community merchants across various regions either already onboard or preparing to join. This growth underscores the company’s commitment to leveraging a Thai-developed digital solution to empower modern farmers, reinforce local economies and drive sustainable long-term progress within the nation’s agricultural sector.

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Himadri Speciality Chemical Ltd (HSCL) has officially launched commercial production at its new 70,000 metric tonne per annum speciality carbon black line in Mahistikry, West Bengal. This brownfield expansion elevates the company’s total carbon black manufacturing capacity to 250,000 MTPA, with 130,000 MTPA specifically dedicated to speciality grades at this single location. As a result, the Mahistikry facility now holds the distinction of being the largest site in the world for speciality carbon black production.

The development represents a pivotal achievement in the company’s strategic roadmap, solidifying its global standing in the advanced materials sector. By significantly increasing its speciality portfolio, the company is better positioned to meet the rigorous demands of high-value industries such as plastics, inks, paints and coatings. The project integrates cutting-edge process technology with stringent quality controls and energy-efficient systems, ensuring that premium-grade products are consistently delivered to an international client base.

Financially, the new capacity is set to positively influence revenue streams and bolster margins over the coming years. The expanded scale not only enhances operational efficiency and supply chain dependability but also accelerates the company’s ability to innovate and respond to market shifts. As worldwide demand increasingly favours tailored, high-performance carbon solutions, this enhanced infrastructure provides a distinct competitive edge through improved agility and product development capabilities.

Anurag Choudhary, CMD & CEO, Himadri Speciality Chemical Ltd, said, “The commencement of commercial operations of our 70,000 MTPA Speciality Carbon Black line at Mahistikry marks the beginning of the next phase of growth in our advanced carbon materials journey. With this expansion, Mahistikry becomes the world’s largest single-location Speciality Carbon Black facility, with a capacity of 130,000 MTPA. This milestone significantly enhances our production capabilities and positions us strongly to capture rising global demand in premium, application-specific segments such as plastics, inks, paints, coatings and other specialised industries. We remain committed to disciplined expansion, operational excellence, sustainability and delivering high-performance solutions that create long-term value for all stakeholders.”

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Solvay has announced that it will optimise the soda ash production capacity at its Torrelavega site in Spain from 600 kilotonnes to 420 kilotonnes, effective from the third quarter of 2026 and pending the required consultation process. This decision is a direct response to ongoing global oversupply and persistently high energy and carbon costs in Europe.

By optimising its operational level, the company aims to strengthen the long-term competitiveness and sustainability of its remaining production at the facility. The Torrelavega site will continue to serve regional customers by focusing on soda ash and premium sodium bicarbonate, with supply guaranteed through both local operations and Solvay’s global network. Importantly, sodium bicarbonate production will remain unaffected.

This adjustment also supports the company’s commitment to the energy transition, including a major biomass initiative designed to significantly reduce coal usage at the site. As a result of the capacity reduction, a net decrease of up to 77 positions is expected. Solvay is committed to managing this transition responsibly and will engage closely with employee representatives to develop socially supportive solutions and measures for those impacted.

Etienne Galan, President of Solvay Soda Ash & Derivatives, said, “Solvay is taking decisive steps to enhance the competitiveness and sustainability of its soda ash operations. Soda ash is critical for essential applications, and Solvay remains firmly committed to the business. We are strategically investing now to cement our competitiveness for decades to come, including the deployment of carbon neutral soda ash processes as part of our energy transition roadmap. At the same time, we urgently need the regulatory framework to align with our industrial reality and the investments that are needed for this transformation.”

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