Paul Lloyd: “Farrel Pomini’s core business lies in supplying processing equipment for the plastics and petrochemical industries."

Pyrolysis has long been associated with pollution and inefficiency, particularly in developing markets where outdated methods dominate. However, technological advancements and a stronger push for circularity are transforming this perception. HF Group, through its subsidiary Farrel Pomini and WF Recycle-Tech, is at the forefront of this shift, introducing a continuous pyrolysis system that promises cleaner and more efficient tyre recycling. Unlike traditional batch processing, its technology ensures consistent output, better resource recovery and reduced emissions.

Pyrolysis has always been considered to be a dirty business. However, with the changes in technology and the increasing hunt for circularity across the tyre industry, businesses are attempting to redefine the age-old tyre recycling process and remove the malice associated with it.

Farrel Pomini is one such entity with the HF Group that is attempting to make pyrolysis cleaner. WF Recycle-Tech, established in 2013, started commercial operations in 2022 with selling its first pyrolysis unit in 2024, slated to be operational in 2026.

Speaking to Tyre Trends, President Paul Lloyd said, “Farrel Pomini’s core business lies in supplying processing equipment for the plastics and petrochemical industries. While its continuous mixer can be used for rubber applications, it is primarily designed for plastic masterbatches and compounds. The company operates across multiple divisions with its plastics compounding equipment focusing on niche applications for highly filled and temperature-sensitive materials. Although the plastics market is significantly larger than the rubber sector, Farrel Pomini targets specialised segments within it. Expanding its footprint in sustainability, the company has developed recycling systems for both plastics and rubber. The end-of-life tyre recycling solution was developed in collaboration with its group company, WF Recycle-Tech.”

Tyre pyrolysis has long been regarded as a polluting industry, particularly in developing countries where unregulated plants often operate at night to evade environmental scrutiny. In markets like India, many such facilities shut down due to non-compliance, reinforcing the industry’s reputation as a ‘dirty business’.

Lloyd further explained, “In Europe, the focus is shifting towards sustainability, driving innovation in pyrolysis technology. Traditional methods relied on large kilns, where tyres were burned with external heat over extended periods. The process was inefficient, labour-intensive and environmentally damaging, requiring extensive manual cleanup.

HF Group has taken a different approach, developing a continuous pyrolysis system that eliminates these challenges.”

Instead of batch processing, the system ensures a constant flow of material, allowing for the controlled capture of gases, liquids and solid outputs. The process begins with pre-grinding tyres into metal-free rubber crumb (6–20 mm), which is then fed into the machine via a hopper. Operating at a capacity of 1,500 kilogrammes per hour, the system requires only continuous material input while automatically managing output streams including recovered oil and gas.

Apropos to the pain points that the company wanted to address, he noted, “Over the past decade of developing this solution, several key learnings and priorities emerged. First and foremost, the goal was to create an efficient pyrolysis system that could consistently process tyre waste at an industrial scale. Second, the decision to develop a continuous rather than batch-based system was fundamental as continuous pyrolysis offers greater consistency, scalability and efficiency. Third, integrating a continuous mixer in the pre-processing stage became a major focus as it significantly improved the homogeneity and quality of the output materials. Finally, optimising the recovered output, particularly recovered carbon black, became the primary objective. Initially, the project was focused on tyre-derived oil (TDO), but as the market evolved, the emphasis shifted to producing the highest-quality rCB, aligning with upcoming ASTM standards and stringent industry requirements.”

By integrating advanced processing controls, the solution ensures cleaner, more efficient pyrolysis, positioning itself at the forefront of sustainable and cleaner tyre recycling.

THE OUTPUT

HF Group’s expertise in mixing technology creates a natural synergy between its traditional business and its expansion into tyre recycling. While the company is known for its tyre curing and rubber mixing solutions, it also has a plastics mixing division; this same mixing technology plays a crucial role in its pyrolysis process.

The recycling system starts with tyre crumb, which is fed into a high-shear Farrel Continuous Mixer originally designed for plastics processing. The mechanical shear heating raises the temperature of the material to 330 degrees Celsius. This ensures uniform heating before the material enters the pyrolysis chamber, where temperatures increase to between 520 degrees Celsius and 580 degrees Celsius. The continuous system eliminates inefficiencies seen in traditional batch pyrolysis, where prolonged heating cycles lead to higher energy consumption and inconsistent output.

Material recovery is a key advantage of the system. For every tonne of tyre crumb processed, approximately 50 percent is converted into pyrolysis oil, yielding 550–570 litres. Around 40 percent becomes recovered carbon black (rCB), a critical raw material that can replace virgin carbon black in industrial applications. The remaining 10 percent is gas, which can be used to power the system, further improving energy efficiency.

Beyond throughput, the system’s design significantly reduces overall energy demand. Mechanical shear heating minimises reliance on external thermal energy, while the continuous process prevents heat loss and optimises fuel efficiency.

Additionally, rCB from the pyrolysis process requires 60–70 percent less energy to refine, further enhancing sustainability.

“Pyrolysis fundamentally relies on heat and time in the absence of oxygen. Under these conditions, tyres thermally degrade, breaking down into vapour, which is condensed into oil and a solid residue, which is now widely used as recovered carbon black (rCB). This output can be further refined for industrial applications, creating a circular economy within the rubber industry,” explained Lloyd.

CHALLENGING INTEGRATION

The primary challenge for tyre manufacturers in adopting rCB is achieving performance characteristics comparable to virgin carbon black. Similarly, tyre pyrolysis oil must meet stringent quality standards to serve as a feedstock for high-value applications beyond just fuel. The company’s continuous pyrolysis system addresses these concerns by enhancing the quality and usability of both outputs.

“In the case of tyre pyrolysis oil, if used as a fuel, the calorific value may vary slightly, but it remains a viable option. However, its greater potential lies in serving as a feedstock for sustainable carbon black or even virgin carbon black production. The consistency of the oil’s composition determines its suitability for high-end applications, making process control a critical factor,” noted Lloyd.

He added, “For rCB, higher quality directly translates into increased usability across different applications. While rCB will never completely replicate virgin carbon black, superior grades enable a higher substitution rate. In some cases, a high-quality rCB can replace up to 30 percent of virgin carbon black, whereas lower-quality alternatives may only allow a 15 percent substitution. This increased usability not only enhances sustainability but also raises the material’s commercial value.”

HF Group’s rCB, produced through its WF Recycle-Tech process, has been extensively tested across multiple industries. It has demonstrated strong performance in plastics masterbatch applications, technical rubber goods and even tyre manufacturing. One major tyre producer has already validated its suitability for substitution in new tyres, underscoring its industry acceptance.

A key differentiator of the process lies in its patented two-stage pyrolysis system. While continuous pyrolysis itself is well established, HF Group’s innovation stems from its integration of a high-shear Farrel Continuous Mixer in the first stage.

This approach ensures uniform heating, eliminates direct heat exposure and optimises the pyrolysis reaction in the second stage. The result is a more efficient process that yields higher-quality recovered carbon black and cleaner tyre pyrolysis oil.

PERSEVERING THROUGH LIMITATIONS

The primary limitations of the system, Lloyd noted, revolve around scalability, operational efficiency and material consistency. The current processing capacity of 1,500 kilogrammes per hour is relatively low. Scaling up production rates while maintaining efficiency and reliability is an ongoing challenge. The key challenge is ensuring long-term operational stability and optimising run times.

Another significant factor is feedstock variability, particularly in markets like India, where used tyres from different sources such as passenger cars, trucks and buses are often mixed without segregation. The ideal scenario would involve processing a uniform type of tyre with a consistent rubber composition, but in reality, recycling operations must work with what is available.

“There are two main approaches to addressing this viz-a-viz meticulous sorting, which ensures consistency but is time-consuming and costly, or strategic blending, which creates a stable output by balancing material variations. The current system has been designed to handle diverse feedstocks without sorting, using a consistent blend of tyres to produce a predictable output,” said Lloyd.

In the long term, technological advancements such as artificial intelligence or tracking mechanisms for tyres could enhance sorting processes, making recycling operations more efficient. However, for now, the focus remains on refining the system to handle real-world feedstock conditions while delivering high-quality outputs. The continuous processing system also provides flexibility to adjust parameters and optimise results, making it a robust solution even in environments where feedstock quality is unpredictable.

MARKET TALK

The return on investment for pyrolysis systems is quite favourable, but it carries risks, especially in the early stages. A well-managed system operating efficiently for 6,000–7,000 hours per year, with a stable feedstock supply and consistent product quality, can generate strong financial returns, explained the executive.

However, challenges arise if there are interruptions in material supply, equipment downtime or fluctuations in product quality. These factors introduce uncertainty, which can make securing financing more difficult. That said, the market for TDO and rCB is growing, providing ample opportunities for revenue. Companies that can differentiate its output and meet quality standards can command premium prices, further improving ROI.

The market focus for HF Group’s advanced pyrolysis solutions primarily includes recyclers looking to add more value to their processes, material users such as tyre manufacturers and technical rubber companies seeking sustainable raw materials and new businesses emerging in response to industry needs.

“In the US and Europe, there is a growing entrepreneurial push to bridge the gap between traditional recycling and the sustainability requirements of the tyre industry. However, in markets like India and other parts of Asia, the challenge lies in shifting perceptions. Many existing pyrolysis operations use older-generation systems. The transition to modern, cleaner and more efficient systems requires education, proof of performance and financial support. Despite these challenges, India remains a strong market for HF, as the industry values high-quality technology and is willing to invest in the best solutions once the benefits are clearly demonstrated,” informed Lloyd.

Over the next five years, the company’s primary goal is to establish a proven track record with the first full-scale pyrolysis system, demonstrating its performance, reliability and efficiency. Once this is achieved, the focus will shift to helping potential customers secure financing by reducing perceived risks, making it easier for them to invest in the technology.

Alluding to the next phase of development, Lloyd informed, “The next phase of development focuses on three main areas. The first priority is industrialising the system to ensure it operates efficiently, consistently and reliably over long production cycles. This transition from pilot-scale to full-scale manufacturing is where HF Group’s expertise in engineering advanced processing equipment comes into play. Secondly, efforts are underway to further refine the pyrolysis reaction to enhance output quality and efficiency. Lastly, ongoing research and development is focused on post-processing improvements, particularly the removal of ash from recovered carbon black to increase its usability in high-performance applications.” n

Ecolomondo Corporation, a Canadian developer of sustainable technology for recycling scrap tyres, is reporting significant commercial progress at its Hawkesbury TDP facility. The company is experiencing a substantial rise in demand for its recycled products, leading to strong sales growth.

A key development involves a major customer who, since mid-July 2025, has purchased 12 truckloads of recovered carbon black (rCB), representing approximately 276 metric tonnes. This client has signalled its intention to increase order volumes further as it transitions its business from another supplier. In another positive step, a second US-based customer has formally approved Ecolomondo's recovered carbon black for use in its manufacturing supply chain and is anticipated to commence bulk orders imminently. Additionally, the company has successfully shipped its 26th tanker of tyre-derived oil, amounting to 520 metric tonnes with an estimated value of USD 416,000.

This upward trend is reflected in the financial results. For the period from 1 January to 31 August 2025, revenues reached USD 640,986, a 91 percent increase compared to the USD 336,078 recorded during the same timeframe in 2024. This growth is largely attributed to the rising sales of recovered carbon black. To support the escalating production needs, Ecolomondo plans to hire and train additional personnel for the Hawkesbury facility. The company notes that, as expected during this operational ramp-up phase, the facility is not yet generating gross margins and continues to operate at a loss.

Jean-François Labbé, Interim CEO, Ecolomondo Corporation, said, “These milestones demonstrate the reliability of our production and the repeated nature of revenues we are building.”

ARLANXEO has reinforced its commitment to sustainable manufacturing with the recent award of the International Sustainability and Carbon Certification (ISCC) PLUS standard to its Chloroprene Rubber (CR) plant in Dormagen, Germany. This facility, producing materials under the Baypren brand, becomes the company's sixth site to achieve this globally recognised standard, underscoring a corporate-wide strategy for environmental responsibility.

The ISCC PLUS certification is instrumental for ARLANXEO's Eco product portfolio, a growing line of bio-based and circular synthetic rubbers. The certification employs a mass balance approach, which allows for the tracking of sustainable raw materials through the production chain. This system enables the integration of renewable feedstocks into existing manufacturing processes, providing customers with independently verified proof of a reduced carbon footprint in the final product.

Complementing this certified production process is the advanced formulation of specific Baypren grades. The company offers Baypren 616, a sulfur grade engineered for enhanced safety and regulatory compliance. Unlike conventional alternatives, this product is manufactured without nitrosamine-forming chemicals, making it entirely free of these hazardous substances. Consequently, Baypren 616 is not classified as dangerous goods or as toxic to aquatic life, offering a safer solution that aligns with evolving regulatory standards like EU REACH. This dual focus on certified sustainable production and inherently safer product chemistry positions ARLANXEO as a leader in providing responsible rubber solutions to the market.

Edwin van Grootendorst, Global Head – Business Specialty Elastomers, ARLANXEO, said, “The ISCC PLUS certification of our CR plant reaffirms ARLANXEO's ongoing commitment to providing our customers with high-performance rubber. To ensure that Baypren meets both current and future requirements of our customers, this was therefore the next logical move for us to take. As an established partner, we want to continue playing an active role in shaping the future of a sustainable synthetic rubber market in order to ensure customer satisfaction. ARLANXEO therefore continues to invest in production, safety and sustainability to remain a strong player in the market.”

Michael Eßmann, Head – Category Management Chemicals, ARLANXEO, said, “Securing ISCC PLUS certification is a testament to our dedication to sourcing materials responsibly and sustainably. We have worked diligently to ensure that our supply chain aligns with the highest standards of environmental and social responsibility. This certification reflects our commitment to continuous improvement and sustainable growth.”

Mathe Group, a specialist in recycling radial truck tyres, has undertaken a significant multi-million-rand investment in advanced machinery designed to transform steel recovery into a major revenue source. This strategic upgrade focuses on extracting high-purity, or ‘clean steel’, for export to international markets such as India and South Korea, marking a shift from treating steel as a mere by-product to valuing it as a key income stream.

A central part of this investment involves the installation of state-of-the-art de-beading machines. Unlike older methods that damaged the steel rings embedded in tyre sidewalls, this new technology removes the beads entirely intact and free of rubber. This preserves their quality, making them easier to process and package, and allows them to be sold as a premium product for industrial applications like blasting, replacing virgin steel. The first units are already operational, with a third machine scheduled for delivery. These new, electrically-driven de-beaders will also lower maintenance costs and reduce emissions compared to the previous oil-hydraulic systems.

Furthermore, the company is commissioning an in-house clean steel mill with an integrated automated packaging line. Currently, extracted steel is sent to India for cleaning before being forwarded to South Korean manufacturers. By bringing this cleaning process to its Hammarsdale facility, Mathe Group will drastically reduce rubber contamination from 10 percent to under two percent. This enhanced purity means the steel can be bagged and loaded directly into shipping containers for the port of Durban, commanding double the price on the international market because it requires no further reprocessing. The upgraded system is expected to export 108 tonnes of clean steel weekly.

This comprehensive re-engineering of the production process recovers an additional eight percent of rubber crumb from each tyre and is set to create new jobs. The new steel extraction system is projected to be fully operational by January 2026.

Cabot Corporation has released its 2025 Sustainability Report, detailing the company's advancements in 2024 and introducing a new set of objectives for 2030. The report demonstrates significant momentum, with Cabot having already met 11 of its 15 sustainability targets for 2025 ahead of schedule and anticipating further progress on the remaining goals this year.

Notable achievements from the reporting period include a community investment of USD 10 million in its local operating areas and a reduction in greenhouse gas (GHG) emissions intensity by more than five percent, which surpassed the 2025 goal early. The company also reported its highest level of beneficial waste reuse in over six years, diverting significant material from landfills. In product innovation, Cabot launched the REPLASBLAK family, its first black masterbatches to receive International Sustainability & Carbon Certification (ISCC) PLUS. Furthermore, the company reinforced its commitment to reducing plastic pellet loss by securing Operation Clean Sweep Europe certification for its two masterbatch facilities in Belgium.

Looking forward, Cabot has established a new framework of 2030 Sustainability Goals, shaped by a comprehensive materiality assessment conducted in 2024. This assessment involved extensive research, peer benchmarking and consultations with internal teams and external stakeholders to identify six priority areas. The resulting 2030 targets include a 15 percent reduction in Scope 1 and Scope 2 GHG emissions intensity and a 20 percent absolute reduction in sulphur dioxide emissions. The goals also encompass ambitious energy and water management targets, such as exporting 250 percent of the energy the company imports and reducing freshwater withdrawal intensity by 10 percent at sites in water-stressed regions. Additional objectives focus on lowering the average product carbon footprint by five to 10 percent and achieving a 25 percent reduction in safety incident rates.

Developed in accordance with Global Reporting Initiative (GRI) Standards, the full 2025 Sustainability Report, which also supports Cabot's commitment to the United Nations Global Compact, is available for review on the company’s website.

Sean Keohane, President and CEO, Cabot Corporation, said, “Sustainability is central to who we are at Cabot and serves as the foundation for our purpose of creating materials that improve daily life and enable a more sustainable future. By leveraging advanced chemistry and innovation, we are supporting our customers in tackling complex sustainability challenges, all while working to minimise our own environmental impact across our global operations. I am immensely proud of the accomplishments our team has made to advance our sustainability priorities and look forward to building on this momentum with the launch of our new 2030 Sustainability Goals, aimed at generating positive, lasting impact for our customers, communities and the world.”

Jennifer Chittick, Senior Vice President – Safety, Health and Environment (SH&E) and Chief Sustainability Officer, Cabot Corporation, said, “As a global leader in our industry, it is our responsibility to set forward-looking goals that challenge us to elevate our sustainability performance. Our 2030 Sustainability Goals are not just benchmarks, they are a strategic framework to guide how we innovate, operate and create long-term value for all our stakeholders. Achieving these goals will require cross-functional collaboration, creativity and a shared commitment to continuous improvement. Our ability to meet them will position Cabot as a differentiated leader in sustainability, both within the chemical industry and beyond.”