Japan’s Zeon Corp has established a new research facility at its Zeon Chemicals Yonezawa site to develop plant-based production processes for synthetic rubber raw materials as it accelerates efforts to decarbonise its operations and support a circular economy.

The new lab will focus on advancing biofermentation and chemical reaction technologies to produce butadiene and isoprene—key building blocks for synthetic rubber—directly from plant-derived feedstocks.

“This facility will accelerate the development of biotechnology to produce butadiene and isoprene directly... to contribute to the realisation of a circular economy,” the Tokyo-based company said.

The initiative is part of Zeon’s “STAGE30” medium-term business plan, which includes a target to cut group-wide carbon dioxide emissions by 42 percent by fiscal 2030 from 2020 levels. The company has made “Promoting a transformation of monozukuri to realise carbon neutrality and a circular economy” its top strategic priority under the plan.

The research centre, completed on 23 May, spans 590.34 square metres and features laboratories with local exhaust ventilation alongside office and meeting spaces. Yamagata Prefecture partially funded it under its Business Location Promotion Subsidy Programme.

The project is also supported by Japan’s Green Innovation Fund, run by the New Energy and Industrial Technology Development Organization (NEDO), which backs long-term industrial decarbonisation initiatives. Zeon is collaborating with Yokohama Rubber Co and several academic institutions on two key development themes, including the use of plant-based and sustainable materials for producing rubber intermediates.

Zeon said it aims to commercialise the technology for producing butadiene and isoprene from plant sources by 2034.

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As the tyre industry confronts electrification, sustainability mandates and shifting supply chains, Milliken Textiles is focusing on specialised textile reinforcements rather than volume tyre cord. The strategy reflects a deliberate choice to concentrate on high-value niches where engineering expertise, rather than scale, defines competitiveness. Products such as Beadwrap and Millicap highlight how materials hidden inside tyres can influence safety, rolling resistance and rubber consumption.

The global tyre industry is approaching a structural turning point, driven by electrification, sustainability targets and changes in manufacturing footprints. For Milliken, this transition is creating opportunities for specialised textile reinforcements that improve tyre performance while reducing material usage.

Speaking about the company’s strategy, Lieven Keymeulen, Marketing Director at Milliken Textiles, explained that the US-based materials science company has deliberately avoided competing in the high-volume tyre cord market dominated by large suppliers.

“We are more of a speciality textile reinforcement supplier,” Keymeulen said. “We are not looking at mainstream tyre cord applications. We are focused on specialised solutions.”

Instead of commodity tyre cord production, the company positions itself as a development partner to tyre manufacturers seeking customised solutions for specific applications.

“As a textile company, we are active in many different markets, so we can take knowledge from other applications and bring that into tyres,” Keymeulen explained. “That allows us to develop products that are much more specific than standard tyre cord.”

Over time, the company has also developed strong application knowledge, investing significant effort in understanding how its materials behave inside tyres. This helps refine its textile solutions further.

OCTAGONAL STEELCORD SOLUTIONS

One example of this approach is Beadwrap, a reinforcement designed as a safety component within tyres. It is particularly relevant for larger tyres, where it helps maintain structural integrity, and for passenger car radial tyres with orthogonal design solutions, where it secures the structure and stabilises the tyre. Another established offering is Millicap, which supports tyre performance improvements linked to sustainability. With the rise of electric vehicles, rolling resistance has become a critical parameter because it directly affects battery range. Tyres that reduce rolling resistance can also reduce rubber consumption, resulting in cost savings and lower carbon emissions.

Although around 90 percent of the tyre market consists of mass-market tyres, the company has deliberately chosen not to focus on that segment.

“The mass market is highly crowded, with many companies offering similar products and limited opportunities for differentiation,” Keymeulen said. “Our strategy is to remain innovation- and technology-driven, concentrating on specialised applications where we can offer unique, customised solutions.”

HIDDEN VALUE IN NICHE COMPONENTS

The tyre industry is vast, meaning even niche components can generate significant volumes. Products like Beadwrap may represent only a small portion of a tyre, but when each tyre uses several centimetres of material across millions of tyres, volumes quickly become substantial.

Although such components remain hidden inside the tyre, the company’s primary focus is not end consumers but tyre manufacturers and their engineering teams.

“A key part of our role is educating engineers within tyre companies about the capabilities of textile reinforcements and how they can improve tyre performance,” Keymeulen explained. “Manufacturers typically approach us with specific technical challenges, and we work together on customised solutions.”

Global supply-chain diversification and geopolitical concerns are also influencing partnerships, as tyre makers increasingly prefer suppliers with a balanced global presence. With operations in United States, Europe and India, Milliken offers a more resilient supply base.

“Collaboration often begins in the early stages of tyre development, focusing first on understanding the application and the problem,” he noted. “Over time, this builds strong trust with tyre manufacturers.”

The company also collaborates with machine suppliers, enabling it to present tyre makers with semi-finished integrated solutions that combine materials with compatible processing equipment. This ensures alignment between materials, machinery and manufacturing processes.

FOCUS ON INDIA AND EMERGING REGIONS

India is a key market for the company, partly because many Indian tyre manufacturers operate relatively modern equipment, making them competitive and more open to adopting new technologies.

While the company cannot be equally active in every region, such as the Chinese domestic market, it maintains strong engagement with Indian manufacturers as well as Japanese and Korean tyre brands.

“Innovation does not always start with large tyre manufacturers,” Keymeulen said. “Tier-II companies can often be more agile and willing to test new ideas more quickly.”

Regionally, Europe is gradually regaining momentum, Korean tyre manufacturers remain highly innovative, and Southeast Asia continues to drive industry growth.

SUSTAINABILITY AND MATERIAL EFFICIENCY

Looking ahead, tyre companies have ambitious sustainability goals, with many targeting tyres made entirely from renewable or sustainable resources by around 2050. A major contribution to this transition will come from recycled yarns, particularly recycled nylon, which remains one of the best-performing reinforcement materials but is difficult to recycle at scale.

While tyres cannot be produced without rubber, textile solutions can help reduce rubber usage.

One important contribution comes from specialised tackified textile reinforcements, produced using a proprietary dipping process that makes the material naturally adhesive. This eliminates the need for calendaring the textile with an additional rubber layer and enables direct placement within the tyre structure.

“This approach is particularly valuable in space-constrained areas such as the bead,” Keymeulen explained. “By eliminating extra rubber layers, we can reduce thickness and rubber consumption.”

Similar benefits apply to Millicap. According to customer data, rubber savings can reach around around 200 grammes for smaller 15-inches tyres to 500 grammes and more for large size tyres, leading to lower tyre weight and reduced carbon emissions.

Millicap is currently produced mainly using nylon, with a polyester version also available. Over time, the expected transition is towards recycled polyester.

ADAPTING TO INDUSTRY SHIFTS

The industry has faced several structural challenges following the Covid-19 pandemic, while the global tyre manufacturing footprint continues to shift geographically. New capacity is increasingly located in India and Southeast Asia, while European production is moving towards Eastern Europe and parts of Africa.

To remain close to customers, Milliken is reconsidering the traditional model of a few large factories.

“We are exploring smaller, strategically distributed operations,” Keymeulen said. “The idea is to create regional hubs that can source yarns and raw materials locally.”

Currently, the company operates major tyre-related production plants in United States and Europe, along with a processing facility in Bengaluru, India. The Bengaluru plant focuses on slitting and converting master rolls into customised formats closer to customers, with plans to expand its capabilities over time.

NEW AVENUES FOR GROWTH

In terms of tyre segments, the truck and bus radial market remains the largest for the company, while solutions also enable entry into passenger car tyres.

Another growing focus area is bicycle tyres, driven by rising demand for off-road and electric bicycles, which require higher strength and cut resistance.

“In tyre construction, steel cord has historically been dominant,” Keymeulen explained. “Textile reinforcements offer far greater flexibility for innovation. That opens up many more possibilities for optimising performance.”

The company is also exploring new variations of Millicap, including hybrid material concepts and alternative structures aimed at further improving tyre efficiency.

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The tyre industry faces growing pressure to reduce fossil-based inputs, prompting a shift towards bio-based materials as industrial alternatives. Once a niche research area, bio-based solutions are now entering mainstream engineering as manufacturers balance performance and sustainability. This shift is clear in next-generation fillers, with companies like UPM advancing lignin-based solutions from concept to commercial validation.

Florian Diehl, Director of Sales RFF at UPM Biochemicals GmbH, explained that the company positions its BioMotion renewable functional fillers (RFF) as a new material class that addresses sustainability while delivering measurable performance gains.

NEXT-GEN FILLERS

Functional fillers are not peripheral to tyre design; they are central. Typically accounting for nearly 30 percent of a tyre’s composition, materials such as carbon black and precipitated silica have defined performance characteristics for decades. Against this entrenched backdrop, UPM’s innovation is not incremental – it is structural. “This is not a one-to-one drop-in replacement for carbon black, but rather a new material class that sits somewhere between carbon black and silica, with some properties closer to carbon black and others closer to silica,” said Diehl.

This approach is intentional. Instead of matching legacy materials, UPM expands the formulation options for tyre engineers, though this adds complexity. “You cannot just take out carbon black and put in RFF without making adjustments, because while it can replace both carbon black and silica to some extent, it requires changes in the formulation and curing system,” Diehl added.

Adoption will require iterative, collaborative development between material suppliers and tyre manufacturers.

PROOF THROUGH PARTNERSHIP

The collaboration between UPM and Nokian Tyres marks a key milestone in applying material innovation. In June 2024, they introduced the Green Step Ligna concept tyre, the first to use UPM BioMotion RFF, a fully renewable, wood-based lignin material. In this tyre, all fossil-derived carbon black in the sidewalls has been replaced by the lignin-based filler.

The concept tyre demonstrates the practical viability of lignin-based material in tyres and sets a higher benchmark for environmental responsibility in the industry.

For UPM, this collaboration is a strategic turning point. It marks the company’s entry into global tyre markets with renewable functional fillers and supports scaling its biorefinery business through proven application value.

Diehl noted that such collaborations are essential for industrial validation.

“The Nokian Tyres case is the only one we can discuss publicly, but we are working with most major tyre companies behind the scenes, even though we are not allowed to disclose their names,” he said.

PERFORMANCE STILL DOMINATES

Despite the strong sustainability narrative, Diehl was unequivocal that performance remains the primary driver of adoption. “For example, Nokian Tyres reported that when they replaced virgin carbon black in the sidewall, they observed improved rolling resistance, which is a clear performance advantage,” he said. This is consistent with early test findings, which suggest that substituting traditional fillers with RFF can enhance efficiency while reducing environmental impact.

Rolling resistance is particularly critical in electric vehicles, where it directly influences battery range. “In inner liner applications, we have seen that it improves air impermeability, meaning the tyre retains air pressure better, which is another functional benefit,” Diehl noted.

UPM’s data confirms improved air retention and efficiency as key outcomes.

The material’s lower density also reduces weight. “Compared to carbon black and silica, our material has a lower density, so you need less material, which makes the final product lighter and further supports improvements in rolling resistance,” Diehl said.

LIGNIN: UNLOCKING AN UNDERUTILISED RESOURCE

The foundation of UPM’s innovation lies in lignin, a natural polymer that has historically been undervalued. “Lignin is the second most abundant natural polymer and is present in all plants, but in the paper industry, it is typically separated and burned as an energy source rather than being used as a material,” Diehl explained.

For UPM, this represented a strategic opportunity. “As a company with deep expertise in wood handling and wood chemistry, we decided to move from fibre-based applications to the molecular level and develop biochemicals,” he said.

Through proprietary processing, lignin is transformed into a rigid particulate filler with controlled surface properties. “We developed a process that converts lignin into a particulate material that behaves like a filler, with tunable surface area and without the typical polymer characteristics,” Diehl added.

This transition – from waste stream to high-performance material – illustrates the broader industrial shift towards biomass valorisation.

SCALING FROM CONCEPT TO INDUSTRY

While the concept tyre proves technical feasibility, scaling is the next critical step. “The material is just becoming commercially available, and manufacturers prefer to test it from the final production site rather than pilot batches, so the current limitation is availability while our Leuna Biorefinery is in its start-up phase,” Diehl explained.

UPM’s Leuna biorefinery is central to addressing this. “At our biorefinery in Leuna, we will produce a total of 220,000 tonnes of biochemicals, with renewable functional fillers representing a significant share,” he said.

The facility itself represents a substantial industrial commitment, with investment exceeding EUR 1 billion and designed to convert sustainably sourced hardwood into next-generation biochemicals.

Crucially, scalability is underpinned by feedstock availability. “Lignin is already available at industrial scale in pulp and paper mills, so if the market adopts our solution, we can scale production significantly,” Diehl added.

COMPLEMENTARY MATERIAL STRATEGY

The rise of recovered carbon black (rCB) adds complexity to sustainability efforts. UPM positions its material as complementary rather than competitive. “We see our solution as complementary, meaning tyre manufacturers can use recovered carbon black alongside our renewable functional fillers to replace fossil-based carbon black,” Diehl said.

He also challenged assumptions around cost. “There is a perception that recovered carbon black is cheaper, but in some European markets, we hear that it can even be more expensive than virgin carbon black,” he noted. This suggests future tyre compounds will likely blend recycled and renewable inputs, rather than rely on a single alternative.

MARKET STRATEGY: PREMIUM FIRST

UPM’s commercial approach follows a well-established pathway for advanced materials. “As with most new materials, we expect initial adoption in premium segments before it gradually expands into the mass market, although this transition will take time,” Diehl said.

Premium manufacturers are expected to lead this transition, with emerging global players likely to follow as they move up the value chain.

ELECTRIFICATION DRIVES CHANGE

The rise of electric vehicles introduces new performance constraints. “Electrification will have a clear impact on tyre design because vehicles are becoming heavier and have higher torque, which makes wear resistance more critical,” Diehl said.

UPM is already adapting. “With our current solutions, we would not yet fully meet all requirements in such applications, which is why we are already working on a second generation that can compete more effectively,” he added.

SUSTAINABILITY

UPM’s RFF is positioned as a 100 percent renewable, CO₂-negative solution (from cradle to gate, considering the biogenic carbon and purchasing 100 percent green electricity), contributing to reduced reliance on fossil-based materials. However, Diehl is candid about market realities. “A few years ago, sustainability was the dominant driver, but today the focus has shifted towards combining sustainability with performance,” he said. “The willingness to pay higher prices is currently limited, which is a challenge, even though we believe our material delivers additional value,” he added.

REGULATION NOT ENOUGH

“There are discussions around end-of-life tyre regulations that could include bio-based quotas, which would support solutions like ours,” Diehl said. Yet he remains cautious. “Ultimately, the product must deliver performance, because regulations can change and cannot be relied upon as the only factor,” he added.

“We designed our processes so that the material can be handled and dispersed in a similar way to traditional carbon black and silica,” Diehl said. “When tyres containing our material are recycled, the filler will end up in pyrolysis oil, similar to natural rubber,” he added.

MEASURED TRANSFORMATION

UPM’s strategy focuses on systematic integration: introducing a new material class, validating it through partnerships and scaling it through industrial infrastructure. The Nokian Tyres concept tyre offers a tangible glimpse of what that future may look like: a tyre in which fossil-derived fillers are partially or fully replaced by renewable alternatives, without compromising performance. As Diehl concluded, “we are convinced the product delivers the performance and provides additional value, and will succeed in the market.”

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Solvay has secured a favourable ruling from the European Patent Office, which upheld the validity of its European patent EP 3 971 138 B1 following a challenge by WE Soda Ltd. The opposition, initiated on 13 February 2025, concluded with a decision on 19 May 2026 that maintains the patent’s protection with only minor amendments. While the ruling is subject to potential appeal, it reinforces Solvay’s position regarding its proprietary industrial processes.

Granted in May 2024, the EP ’138 patent safeguards Solvay’s method for treating and recycling purge streams in the production of sodium carbonate and sodium bicarbonate. The intellectual property extends to the overall manufacturing process that incorporates this recycling technique, as well as the final products derived from it. This patent is part of a broader family that includes EP 2 878 579 B1, which is already the subject of a separate legal dispute between the two companies.

In a related Dutch legal battle, Solvay had initiated infringement proceedings in August 2021 against WE Soda and its affiliates, including Turkish subsidiaries, concerning the EP ’579 patent. The District Court ruled in Solvay’s favour on 3 December 2025, affirming the patent’s validity and issuing an injunction that prohibits the defendants from importing and supplying their products to the Netherlands. WE Soda and the associated entities have since appealed that judgment, with the appeal currently pending.

The recently upheld EP ’138 functions as a unitary patent, which enables Solvay to pursue infringement actions through the Unitary Patent Court in a single, expedited proceeding covering at least eighteen member states. Such actions offer the potential for injunctions to block imports of infringing goods across a wide jurisdiction. Solvay has reiterated its commitment to protecting its innovations and vows to take decisive legal measures globally to enforce its intellectual property rights, viewing such enforcement as fundamental to maintaining fair market competition.

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India’s zinc oxide industry is undergoing a structural shift from volume-driven manufacturing to value-led specialisation and Punia Group’s trajectory reflects both the opportunity and the pressure within this transition. As demand from tyres, EVs and global markets intensifies, the company is expanding its capabilities while navigating volatility in raw materials, regulatory tightening and supply chain disruptions. Its evolution underscores a broader industry reality that growth is no longer defined by scale alone but by consistency, sustainability and the ability to stay competitive in an increasingly complex global ecosystem.

For over four decades, Punia Group of Industries has steadily transformed itself from a modest, commodity-focused manufacturer into a forward-looking player in zinc oxide. The company’s journey reflects not just its own resilience but also the broader evolution of India’s manufacturing ecosystem.

In its early years, the business operated in a market driven largely by volumes and cost competitiveness. However, with a clear understanding that long-term sustainability required differentiation, the organisation began investing in process improvements, quality consistency and customer-centric innovation.

Over time, strategic inflection points such as technology upgrades and introducing efficient systems enabled the company to move up the value chain and strengthen its market position.

Underpinning this evolution has been a strong foundation of ethics, transparency and disciplined governance, which has guided every phase of growth.

“The zinc oxide and rubber chemicals industry itself is undergoing a significant transformation. What was once a commoditised, price-driven sector is now being reshaped by increasing demands for performance and sustainability,” noted Chief Executive Officer Siddharth Punia.

He added, customers, particularly in the tyre and automotive sectors, are seeking materials with consistent quality and lower environmental impact. While commodity segments continue to exist, the competitive advantage today lies in innovation, compliance and the ability to meet evolving global standards.

Against this backdrop, Punia Group is charting its next phase of growth with a clear and structured vision for the next three to five years.

THE NEXT PHASE

The company is focusing on expanding production capacity in a calibrated manner, ensuring that every addition is backed by robust demand visibility and operational readiness. A key area of alignment is with the growing demand from electric vehicles, advanced tyre technologies and industrial applications that require precision-engineered materials.

The organisation’s approach remains firmly rooted in systematic growth prioritising sustainability, efficiency and long-term value creation over short-term scale. This is evident by the company obtaining IATF 16949 and REACH certifications.

“The global business environment has become increasingly complex in recent years. Supply chain disruptions triggered by the Covid-19 pandemic followed by ongoing geo-political tensions such as those in the Middle East have had a direct impact on raw material sourcing and pricing,” contended Punia.

He added that zinc, being a globally traded commodity, has experienced considerable volatility, affecting cost structures across the industry. In response, companies are rethinking their supply chain strategies by diversifying sourcing, building strategic inventories and reducing overdependence on specific geographies.

Punia Group has taken pro-active steps in this direction by strengthening supplier relationships and exploring regional procurement options, ensuring continuity while adhering to its principles of fair and responsible sourcing.

TICKING THE CONS

Operating in this environment also brings a unique set of challenges. “Raw material price fluctuations, stringent environmental regulations and demand uncertainty linked to global economic cycles remain key concerns,” said Punia.

The company’s response has been grounded in discipline and foresight, investing in energy-efficient and environmentally compliant technologies, driving process innovation to reduce waste and maintaining agile production systems.

“Importantly, these efforts are guided by a strong ethical framework that emphasises compliance, environmental stewardship and accountability to all stakeholders including customers, employees and the communities we operate in,” he noted.

GRABBING THE OPPORTUNITIES

At a macro level, India’s emergence as a strategic manufacturing and consumption hub offers significant opportunities for the zinc oxide and rubber chemicals industry. The country benefits from competitive cost structures, a rapidly expanding domestic market driven by automotive and infrastructure growth and supportive government initiatives aimed at boosting manufacturing and exports.

Additionally, global supply chain re-alignments are creating opportunities for India to position itself as a reliable alternative to traditional manufacturing bases, further strengthening its role in the global value chain, informed Punia.

Reflecting on its 40-year journey, Punia underscores the importance of adaptability, cost discipline and principled decision-making. He stated, “Building a manufacturing-led business in a cyclical industry requires not just operational excellence but also consistency in values and vision.”

The company’s emphasis on systematic, step-by-step growth has enabled it to navigate multiple economic cycles while maintaining financial and operational stability. Past disruptions, whether economic downturns or supply shocks, have reinforced the importance of resilience, diversification and long-term planning.

CATERING TO DEMANDS

The company recently commissioned its new Tirupati plant that will be a modern, environmentally focused facility using the widely adopted French process to manufacture zinc oxide.

This involves vaporising zinc metal, reacting it with oxygen to form zinc oxide, then cooling, filtering, testing and packaging the final product. The plant will produce multiple grades tailored to customer requirements.

“Raw materials will largely come from zinc dross sourced locally and globally from the galvanising industry. The process is designed as a closed-loop, zero-waste system, where by-products are re-used,” he said.

“Over the past decades, technology has continually evolved and we have consistently stayed ahead of the curve, adopting innovations well before they became industry standard. We introduced efficient collection systems that are not only environmentally responsible but also enhance product quality while prioritising worker safety,” informed Punia.

He contended that the plants’ re-designed furnaces enable cleaner, more efficient combustion, reducing emissions and delivering meaningful energy savings. Automation has been integrated wherever feasible to improve consistency and operational efficiency, while the health and safety of the workforce remain central to every decision that the company makes.

“Beyond operations, we are equally committed to giving back to the community. We actively support nearby villages through healthcare initiatives, encourage and sponsor sports activities and contribute to local infrastructure development, reinforcing our role as a responsible and engaged stakeholder,” he said.

Sustainability efforts like reducing fuel consumption through heat recovery and furnace optimisation has already achieved 15–20 percent savings. The company is also enroute to install heat recuperators and planning a transition to solar energy to meet most electricity needs.The facility also set internal benchmarks for efficiency and sustainability, particularly through improved energy utilisation and process optimisation.

During the Covid period in 2020, the company expanded this plant significantly, reinforcing its role as a high-output, strategically important unit. In addition to serving domestic demand, the Gujarat location offers strong logistical advantages for exports, especially through proximity to western ports like Mundra, enabling access to global markets.

“Even as the Tirupati plant strengthens southern reach, the Gujarat facility continues to anchor the company’s western and export-oriented operations, making the two plants complementary in terms of geography and market coverage,” said Punia.

FUTURE OUTLOOK

Looking ahead, the alignment between industry and government policy will play a crucial role in sustaining growth momentum. While India has made notable progress in supporting the speciality chemicals sector, further reforms in areas such as regulatory simplification, faster environmental clearances and infrastructure development can significantly enhance ease of doing business and global competitiveness.

As the industry continues its transition from commoditisation to specialisation, companies that combine innovation with integrity will define the future. With its strong ethical foundation, commitment to systematic growth and forward-looking strategy, Punia Group of Industries is well-positioned to capture emerging opportunities while contributing meaningfully to India’s evolving industrial landscape.

Punia Group’s growth narrative is compelling, but sustaining momentum will depend on execution amid volatility and rising expectations. As the industry shifts towards specialisation, the real test lies in balancing cost pressures with innovation and sustainability, ensuring that expansion translates not just into scale but into durable competitive advantage.

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