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Pyrolysis has long been associated with pollution and inefficiency, particularly in developing markets where outdated methods dominate.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

India has launched an anti-dumping investigation into imports of Halo-Isobutene-Isoprene Rubber (HIIR) from China, Singapore and the United States, following a complaint from Reliance Sibur Elastomers Private Limited, the Directorate General of Trade Remedies (DGTR) said in a notification.

The domestic producer alleged that the three countries were exporting the rubber to India at unfairly low prices, causing injury to the local industry. The company has sought the imposition of anti-dumping duties on the product, which is used in tyre inner liners, hoses, seals, tank linings, conveyor belts and protective clothing.

The DGTR said there was prima facie evidence that imports had risen “significantly” and were being sold below normal value, resulting in price depression and affecting the domestic manufacturer’s capacity utilisation and profitability. The authority noted that the dumping “is causing material injury to the domestic industry”.

The investigation will cover the period from July 2024 to June 2025, with an examination of injury trends dating back to April 2021.

HIIR, also known as halobutyl rubber, is classified under the broader synthetic rubber tariff category. Reliance Sibur Elastomers is currently the only producer of the material within India.

If the investigation confirms dumping and injury, the DGTR may recommend the imposition of duties to offset the impact and “remove the injury to the domestic industry”. Interested parties have 30 days to submit data and make their representations to the authority.

The global carbon black market is projected to grow from USD 27.88 billion in 2024 to USD 44.77 billion by 2034, expanding at a compound annual growth rate (CAGR) of 4.85 percent between 2025 and 2034, according to a new report by Towards Chemical and Materials, a research arm of Precedence Research.

The study estimates that the global market volume will rise from around 15.15 million tonnes in 2025 to 21.83 million tonnes by 2034, growing at a CAGR of 4.14 percent, driven primarily by increasing demand for tyres, automotive components and high-performance plastics.

Carbon black – a fine black powder made through the incomplete combustion of hydrocarbons – is a critical material used to reinforce rubber in tyre production and enhance strength, durability and UV resistance in plastics, coatings, and batteries.

Asia Pacific accounted for about 58 percent of global market share in 2024 and is expected to remain the largest and fastest-growing regional market, supported by expanding tyre and rubber manufacturing bases in China, India and Southeast Asia. The region’s carbon black market was valued at USD 16.95 billion in 2025 and is projected to reach USD 26 billion by 2034.

“The Asia Pacific region continues to lead both in production and consumption of carbon black, owing to its strong automotive, tyre and plastics industries,” the report noted, adding that China remains the world’s largest producer and consumer.

The furnace black segment dominated the market in 2024, accounting for about 60 percent of global industry share, due to its superior reinforcing properties in tyres and versatility in plastics and coatings. Meanwhile, the tyres and rubber products segment held a 55 percent share, reflecting the material’s indispensable role in the automotive sector.

Performance applications such as batteries, conductive polymers, and specialty coatings are emerging as key growth drivers. Demand for specialty carbon black and conductive grades is rising with the proliferation of electric vehicles, renewable energy systems, and electronics manufacturing.

Artificial intelligence (AI) is also shaping the carbon black industry, with automation and predictive analytics enhancing process efficiency, product consistency, and sustainability, the report said. AI-driven systems are enabling real-time monitoring and predictive maintenance in production plants, reducing waste and energy consumption.

Sustainability remains a key trend, with manufacturers investing in greener technologies, renewable feedstocks and recovered carbon black (rCB) from recycled tyres to meet circular economy goals. “Turning end-of-life tyres and rubber waste into recycled carbon black is opening new sustainable pathways for producers,” the study noted.

Among key players profiled in the report are Tokai Carbon Co., Ltd., Continental Carbon, Jiangsu C-Chem Co., Ltd., Himadri Speciality Chemical Ltd., Sid Richardson Carbon & Energy Company, Cancarb Limited, Philips Carbon Black Ltd., OCI Company Ltd., Columbian Chemicals Co. (Birla Carbon), Aditya Birla Group, and Raven SR, LLC.

Recent industry developments include PCBL Chemical Ltd.’s establishment of a wholly owned US subsidiary in Delaware in July 2025 to enhance supply chain localisation and strengthen its North American footprint, as well as the West Bengal government’s efforts to attract foreign investment in its carbon black industry to support the electric vehicle, tyre, and battery markets.

The report also forecasts rapid growth in North America, fuelled by clean manufacturing practices, sustainable process adoption and expansion in high-performance plastics and battery applications. Europe, meanwhile, is benefiting from stricter environmental regulations and the EU Green Deal, which are promoting eco-friendly and specialty grades.

The global carbon black market is expected to maintain steady long-term growth as manufacturers diversify into advanced applications and invest in sustainable production technologies to meet evolving industrial and environmental demands.

Kraton Corporation, a leading global producer of speciality polymers and high-value biobased products derived from pine chemicals, has revealed a new strategic initiative for its Berre, France facility. The plan involves streamlining its polymer operations to concentrate exclusively on manufacturing USBC products, which will result in the cessation of HSBC production at that site.

This move is designed to bolster Kraton's long-term competitiveness by optimising its manufacturing footprint in reaction to a global overcapacity for HSBC. The company has formally started an information and consultation process with the local Works Councils, with a final decision expected following this mandatory period. The company has reaffirmed its commitment to supplying HSBC from its broader global network and to leveraging its worldwide presence to continue adapting to market demands.

Prakash Kolluri, President, Kraton Polymers, said, “Our aim with this plan is to strengthen Kraton’s long-term competitive position by optimising our manufacturing footprint in response to changing market dynamics associated with global overcapacity of HSBC production capability. With this step, we are preparing Kraton for a sustainable future by securing Kraton’s position as the leading global HSBC producer. Kraton is fully committed to supporting our customers through this transition with supply of HSBC products produced within our unmatched global manufacturing network. We recognise the impact of these actions, and are committed to a safe, respectful and supportive transition. The health, safety and well-being of the employees remain our top priorities.”

Continental is accelerating its transition towards a circular economy by systematically increasing the use of renewable and recycled materials in its tyres. The company, which averaged a 26 percent sustainable material share in 2024, has set an ambitious target to raise this to at least 40 percent within five years. This strategy involves not only internal innovation but also actively encouraging its supply chain to develop and provide more sustainable raw materials.

A critical area of development is finding green alternatives for reinforcement materials like steel and textiles, which are essential for tyre safety, durability and performance. These materials can constitute over 18 percent of a passenger car tyre, and even more in commercial vehicle tyres. Continental is already integrating recycled steel and is pioneering the use of polyester yarn made from recycled PET bottles. Depending on the tyre size, the carcass of a single passenger car tyre can incorporate the equivalent of up to 15 bottles. This recycled polyester, developed with partner OTIZ, is verified to cut CO₂ emissions by approximately 28 percent compared to conventional materials and is already featured in production tyres like the UltraContact NXT.

The company's sustainable material portfolio extends beyond reinforcements. It includes synthetic rubber derived from used cooking oil, bio-based resins from waste streams and silica obtained from rice husk ash. Complementing these material advances is a commitment to greener manufacturing processes. Together with Kordsa, Continental has developed COKOON, an adhesion technology that bonds textiles to rubber without harmful chemicals. In a move to uplift the entire industry, this innovative solution has been made available to all tyre manufacturers as a free, open-source license, demonstrating Continental's broader commitment to fostering industry-wide sustainability.

Dr Matthias Haufe, Head of Material Development and Industrialization, Continental Tires, said, “We are not reinventing the wheel – but we are reinventing the tyre, with more sustainable materials and more environmentally compatible production processes. It’s not just about the rubber itself. We also focus on the materials that give the rubber its shape and make tyres stable and safe. Recycled steel and polyester yarn made from recycled PET bottles are important for more sustainable tyre production. Our goal is to use at least 40 percent renewable and recycled materials in our tyres within five years. Every alternative material brings us an important step closer to this goal. When it comes to sustainability, it’s not just the materials we switch to, but also those we deliberately do without.”