Zeppelin Systems has been awarded the engineering contract for constructing a second ReOil pyrolysis plant, with construction slated to commence in February 2024. 

By establishing this new pyrolysis plant, ReOil has significantly expanded its annual recycling capacity, now capable of processing approximately 60,000 tons per year. This state-of-the-art facility, covering roughly 27 acres, is a testament to the ingenuity and engineering expertise provided by Zeppelin Systems.

Having already supplied the initial engineering groundwork for the new plant in 2019, Zeppelin Systems has been awarded the completion contract, underscoring the high level of customer satisfaction. As the primary engineering partner, Zeppelin Systems delivers comprehensive turnkey solutions, encompassing plant technology, process engineering, and final plant planning, all from a single source.

“A flagship project for Zeppelin Systems with a signalling effect. Only a few companies can implement such complex and extensive projects virtually anywhere in the world,” says Dr Markus Vöge, CEO of Zeppelin Systems GmbH, adding: “The aim is to offer process solutions in the future that can be provided as part of license models. For example, the ELT pyrolysis plant as a turnkey product from Zeppelin Systems.” Guido Veit, Vice President of Sales, Plastic and Rubber at Zeppelin Systems GmbH, adds: “ReOil’s engineering contract is the first project as part of the Zeppelin Sustainable Tyre Alliance. This makes us proud and demonstrates the strength of the alliance. In addition, we will continue to work hard to bring additional processes to technological maturity and strengthen the network in terms of the circular economy.”

ReOil Managing Director Paweł Mikuśkiewicz is also delighted with the very successful partnership between Zeppelin Systems and ReOil: “We knew that this major project could only be planned and built with the help of an experienced and internationally active plant engineering partner. That’s why we chose Zeppelin Systems, and we really appreciate our long-standing, trusting business relationship.”                                                          

Zeppelin Systems, a trusted partner in plant engineering for the rubber and tyre industry, has taken a significant step towards a more sustainable future by launching the Zeppelin Sustainable Tire Alliance in March 2023. This collaborative initiative aims to work alongside global partners in reshaping the tyre production and recycling process in a more environmentally conscious manner.

Among the esteemed members of this technology alliance is the Polish firm ReOil, known for establishing Europe’s largest pyrolysis plant dedicated to recycling old tyres in 2015. Over the years, ReOil has successfully recycled approximately 20,000 tonnes of old tyres annually. Once operational, this colossal plant is expected to reintegrate about 60,000 tonnes of old tyres into the sustainable circular economy annually.

ReOil, a leading operator in raw material recycling, employs continuous pyrolysis to break down rubber from discarded tyres into valuable substances like gas, oil and recovered Carbon Black (rCB). These recycled materials find application in various industries, including textiles, tyre manufacturing, rubber components, plastics, steel production, and even aviation fuel. Since its commissioning in 2015, ReOil has effectively recycled around 70,000 tonnes of old tyres, reaching a stable and profitable operational state in 2020.

Kraton Corporation, a leading global producer of speciality polymers and high-value biobased products derived from by-products of pine wood pulping, has received an International Sustainability and Carbon Certification (ISCC) PLUS certification for its manufacturing facility in Niort, France.

Kraton can now supply 100 percent ISCC PLUS-certified AMS and AMS Phenolics resins using a mass balance attribution approach thanks to the certification. Kraton's dedication to promoting the biobased and circular economy is further demonstrated by the Niort facility's accreditation. Kraton is committed to lowering carbon emissions and accelerating the shift to a more sustainable future by empowering clients to include more environmentally friendly products into their supply chains.

An independent multi-stakeholder project, the International Sustainability and Carbon Certification (ISCC) is a leading certification method that guarantees accurate mass-balancing bookkeeping and reporting of renewable and recycled materials across the supply chain.

Lana Culbert, Kraton Pine Chemicals VP of Marketing, said, “Our SYLVARES™ and SYLVATRAXX™ brands feature a range of high-performance AMS and AMS Phenolics resins used in speciality adhesives and tyre applications. Our ISCC PLUS journey began in 2021 with the certification of our Sandarne, Sweden facility. Earning this certification for our Niort plant marks a significant milestone, further expanding our portfolio of sustainable solutions.”

Sumitomo Rubber Industries, Ltd. has said that it has clarified the process of rubber breakdown, a crucial element that affects tyre longevity, through joint research with Professor Gert Heinrich at Dresden University of Technology (Saxony State, Germany).

In a special session called ‘Combining Physics, Chemistry & Engineering of Rubber: A Symposium in Honor of Charles Goodyear Medalist Gert Heinrich’, which was held in honour of the Professor's medal-winning achievement, the findings were presented in an invited talk at the American Chemical Society, Rubber division, ACS 2025 Spring Technical Meeting held in Orlando, Florida, US, on 6 and 7 March. Professor Heinrich is a member of the Leibniz Institute of Polymer Research Dresden, which took part in the collaborative effort.

Tyre durability is determined by cracking processes, which result in the development of cracks and rips in a rubber substance. The endurance of rubber was previously mostly assessed using tearing tests, but there were still numerous unanswered concerns regarding the microscale structural alterations at the crack tip. This effort identified a factor that determines the start and propagation of cracks in rubber by analysing the force applied to a fracture tip using a simulation approach. In rubber, a crack tip undergoes dilatation deformation to create voids, or microvoids within the item. The fracture gets worse as the voids expand and come together. It was also discovered that the tension focused on the fracture tip is lessened when voids emerge.

The German Rubber Industry Association (Wdk) is advocating for a thorough and legally enforceable regulation of the end-of-waste status for Germany and the whole of Europe. The association is pusing for the circular economy to be strengthened for tyres.

Valuable secondary raw materials are still legally regarded as waste since there are no consistent standards for the end-of-waste status, according to Stephan Rau, Technical Director of the WDW. This restricts the market integration of sustainable recycled materials, impedes investments and creates legal uncertainties. “We call for a comprehensive and binding end-of-waste regulation for Germany and the whole of Europe to strengthen the recycling sector, facilitate investment in modern technologies, and sustainably reduce the CO₂ footprint of the rubber and tire industry,” he said.

In order to adhere to the prescribed waste hierarchy and stop illicit exports, Rau also emphasised that lawmakers must quantitatively and openly document waste tyre flows. He added that waste tyres should only be gathered by approved disposal companies and pre-sorted based on their intended use.

On the important role of mechanically recycled tyre granules and powder, Rau said, "This is an important secondary raw material that is already used in a variety of durable and safe products. A clearly defined end to its waste status must be made more economically viable. To ensure the market success of tyre granules, a risk-based approach to assessing chemical ingredients is essential. Binding limit values ​​must be assessed using a migration analysis, i.e. based on their bioavailability. Second, the use of tyre granule products must become mandatory in the construction industry and infrastructure projects. The goal is clear: Recycling must be economically viable."

Kuraray, a global speciality chemicals company and one of the largest suppliers of industrial polymers and synthetic microfibres, has received ISCC PLUS certification for its thermoplastic elastomers SEPTON and HYBRAR as well as Liquid Rubber produced at the Company’s Kashima Plant at Ibaraki Prefecture.

ISCC PLUS makes sure that certified products, such biomass and recycled raw materials, are appropriately handled throughout their supply chains, including the manufacturing process, by applying the mass-balance technique.

In the five years preceding up to its centenary in 2026, Kuraray is carrying out its medium-term management strategy, PASSION 2026. In order to achieve the long-term Kuraray Vision 2026 of being a speciality chemical company that grows sustainably by integrating new foundational platforms into its own technologies and contributing to customers, society and the planet, the company will keep growing its range of products that improve the natural and living environments.