After more than three decades in tyre recycling, Pliteq CEO Paul Downey argues that despite rising sustainability rhetoric, the industry’s core technologies and material flows have barely evolved. While perceptions of recycled materials have improved, real innovation, he said, has been slower, narrower and far more uneven than expected.

Paul Downey, Chief Executive Officer of Pliteq, has worked in end-of-life tyre recycling since 1990. In that time, he expected major breakthroughs in pyrolysis and tyre-to-tyre recycling. He says they never came.

“When you look at pyrolysis, that hasn’t really changed in 30 years,” Downey said in an exclusive interview with Tyre Trends. “When you look at the use of rubber back into tyres, still a very small percentage of waste tyres goes back into new tyres,” he added.

Despite more money, more participants and more attention on recycling, he describes the sector as remarkably static. These, he said, were the areas where he expected research and to unlock scale. “Frankly the needle hasn’t moved very far in all those years. I’ve only seen very, very small changes in the last 30 years,” Downey noted.

One reason is energy. “Tyres take a tremendous amount of energy to grind up. So, you still need a lot of energy. Energy challenges are going to be an ongoing issue,” he said, pointing to wider stress on energy infrastructure.

That energy intensity affects both mechanical recycling and pyrolysis, where tyres are broken into oil, gas and carbon black. While refining recovered carbon black has long been studied, Downey says progress has been limited.

“You can refine the carbon black to make it more useful by tyre companies in terms of not degrading the quality of the finished tyre,” he said, adding that this has been researched for decades without dramatic improvement.

Pyrolysis remains minor in North America with a significant share of tyres still used as tyre-derived fuel. Downey divides end-of-life tyre use roughly into thirds viz-a-viz moulded goods, tyre-derived fuel and applications such as rubber-modified asphalt, which he says has also seen limited uptake since 1990.

After university, Downey joined a company that was already working with tyre manufacturing waste with materials that could not be used in new tyres due to quality deviations.

“When you produce a tyre, about two to three percent of the materials are off-spec. These materials can’t be used to make a tyre, so that becomes waste. That waste, combined with ELTs, was processed into noise and vibration products, primarily for automotive, heavy truck, and off-the-road vehicle applications,” he explained.

“This was back in the early 1990s. The original use was non-tyre. It was mostly in the noise and vibration space for vehicles,” Downey said.

In 1998, after developing multiple patents in Canada and the United States, Downey founded his own company. Initially, the business model revolved around licensing those patents to manufacturers, largely in the US. Over time, that approach evolved. “When I formed Pliteq, I stopped doing the licensing. All of the patents are now being used by the company,” he said.

FROM PATENTS TO PLITEQ

Today, Pliteq focuses on manufacturing finished products rather than licensing technology. The company produces sound and vibration control materials, insulated floor mats and building products made from recycled ELT rubber. Its applications range from isolating vibration caused by subway and railway lines to managing noise and vibration from HVAC systems, pumps, compressors and mechanical rooms in buildings.

“We’re looking at all the places in or around a building under construction where rubber could be used,” Downey explained.

Asked what has changed in the tyre recycling industry over the last 30 to 35 years, Downey’s answer is candid. “Remarkably, little has changed,” he quipped.

While markets for recycled tyres have expanded, the underlying technologies and material flows remain largely the same. Pyrolysis, often cited as a future solution for ELTs, has not progressed as dramatically as expected. “That hasn’t really changed tremendously in 30 years,” Downey noted.

Similarly, efforts to put recycled rubber back into new tyres have seen limited success. “There have been some efforts by major tyre companies but still a very, very small percentage of waste tyres goes back into new tyres. Those were areas where I thought there was a lot of potential for research, but the needle hasn’t moved very far,” he said.

Where the industry has evolved more meaningfully is in moulded goods. “That’s where we’ve seen the most development,” Downey said, pointing to sound and vibration products, underlayments and recycled rubber flooring used in schools, hospitals, gyms and fitness facilities. In North America, he estimates that moulded goods account for roughly one-third of ELT usage.

Another third of ELTs is used as tyre-derived fuel, while the remainder goes into applications such as rubber-modified asphalt, an area Downey says existed in 1990 and has not seen significant market uptake despite ongoing research.

CHANGING PERCEPTIONS

One of the most significant shifts Downey has witnessed is not technological but cultural. “When I started, recycling was a bad word. People didn’t want to buy recycled products because they thought it was garbage,” he said.

That perception has changed substantially. Today, architects, builders and developers show strong interest in sustainable materials, particularly in construction. While Downey does not attribute this shift directly to regulation, he acknowledges a broader market preference for sustainability.

“Now people don’t view recycling as inferior. That attitude has definitely changed over the last 30 years,” he said.

Moreover, public scrutiny around recycled rubber has intensified in recent years, particularly regarding the use of crumb rubber in athletic fields. Downey addressed these concerns directly, referencing studies he has reviewed.

“I haven’t seen any research that shows a correlation between crumb rubber and health issues. The Synthetic Turf Council conducted a multi-year study that showed exactly the opposite,” he said.

In Downey’s view, the primary concern around crumb rubber is environmental rather than medical. “It’s a powder. Potentially, it can wash away into the water supply,” he said.

Pliteq, however, is not active in the turf infill market. “We don’t sell crumb into athletic fields. We strictly manufacture moulded goods for sound control, vibration isolation, flooring and building products,” Downey clarifies.

SCALE AND FOOTPRINT

Pliteq operates offices in seven countries and sells into approximately 50 markets worldwide. Its main manufacturing facility is located in Canada, supported by two smaller plants in United States. Collectively, these facilities produce about 44,000 metric tonnes of finished products annually.

To achieve this output, Pliteq consumes roughly 60,000 metric tonnes of ELTs. “We don’t use the steel or textile,” Downey explained, referring to the components removed during tyre processing.

The company sources tyres primarily from North America, tapping into a collection network that has been established over the past three decades. ELTs are categorised into three distinct groups viz-a-viz passenger and light truck tyres, heavy truck tyres and mining or off-the-road tyres, each with different rubber compositions and properties.

“We keep those three categories separate. The amount and type of rubber are quite distinct,” Downey said.

Pliteq’s patents focus on application and use rather than core processing technologies. Beyond patents, the company relies heavily on proprietary know-how. “We have a number of trade secret processes that we don’t disclose,” Downey said.

These include particle selection, tyre source selection, screening, cleaning, formulation, mixing and moulding. “We do things in a way that nobody else in the world is doing. That allows us to achieve certain quality levels, surface finishes and performance characteristics that aren’t generally available,” he says.

Quality control is embedded throughout the manufacturing process. Downey estimated that each product passes through around seven distinct quality checks, supported by machine operators, automated systems and visual inspections. Any waste generated during production is reprocessed and reused, reinforcing a closed-loop manufacturing approach.

Pliteq operates a hybrid business model. Technology development, product design and manufacturing are largely centralised, while sales, warehousing and distribution are managed regionally. This structure allows the company to adapt products to local market needs.

“Some markets have very distinct requirements. What’s needed in UK might not be required in Singapore, Australia or US,” Downey said.

THE ROAD AHEAD

Looking forward, Downey sees gradual rather than dramatic change. Energy consumption remains a major challenge as tyre grinding is energy-intensive. Broader issues such as energy infrastructure strain and shifting global trade patterns also weigh on the industry.

Despite these challenges, Pliteq continues to reinvest its earnings back into the business. “We’re on a growth curve. We reinvest all the money back into the company and into the markets,” Downey said.

The company is currently operating at around 80 percent capacity, a level Downey stated is close to optimal. Expansion will focus first on strengthening existing teams across its seven offices before opening new locations.

“We’ve built the manufacturing model so it can scale as demand grows. But we only put new facilities where the market can sustain them,” he said.

After more than three decades in the ELT space, Downey remains pragmatic. The industry may not have transformed as dramatically as once hoped, but in moulded products and building applications, Pliteq continues to carve out a space where recycled tyres deliver measurable performance and growing acceptance in the built environment.

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Kumho Tyre UK has strengthened its leadership team with the appointment of Luke Emery as Sales Director for South East England, a move that coincides with the company’s expanding product range and reports of growing demand across the region. Bringing 22 years of deep-rooted experience in the tyre sector, Emery’s background spans both motorsport and passenger car applications, positioning him well to drive commercial performance in this key territory.

His appointment forms part of Kumho’s ongoing investment in its UK operations, reflecting a continued commitment to reinforcing the domestic team as demand rises for an increasingly diverse product portfolio. In this new role, Emery will work alongside the existing UK management and sales teams to deliver dedicated support to customers throughout the South East, ensuring the business remains responsive to evolving market needs.

Richard Lyons, Managing Director, Kumho Tyre UK, said, “We are delighted to welcome Luke to the Kumho team, adding to the enrichment of our team that we have seen over the past few months. The UK market has shown excellent acceptance of our latest products and Luke’s appointment reflects our commitment to building a talented, future-focused team that can support our customers and continue driving the growth of the Kumho brand across the UK.”

Emery said, “Having worked at Kumho in the past, I’m delighted to return at such an exciting time for the brand. Kumho has built a strong reputation for delivering high-quality tyres that offer excellent value and performance, and the market response to the new products has been extremely positive.”

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Clemson University has announced the appointment of Dr Saied Taheri to the External Advisory Board of its Mechanical Engineering department, strengthening ties between academia and research leadership. The move highlights the institution’s continued focus on advancing engineering education through experienced global contributors. Dr Taheri’s longstanding association with Clemson, where he completed his undergraduate, master’s and doctoral studies in mechanical engineering in 1984, 1986 and 1990, respectively, positions him as a deeply connected figure familiar with the university’s academic values and institutional goals.

Currently a professor at Virginia Polytechnic Institute and State University, Dr Taheri also serves as Director of the NSF-supported Industry–University Cooperative Research Center for Tire Research (CenTiRe). His career spans both academia and industry, including a tenure as a senior engineer at Goodyear Tire & Rubber Company and an adjunct faculty role at the University of Akron between 1998 and 2007. Since joining Virginia Tech in 2007, he has mentored a significant number of scholars. His research contributions have focused on tyre and vehicle dynamics, simulation technologies, intelligent tyre systems and chassis control.

In his new advisory capacity, Dr Taheri is expected to contribute to shaping departmental strategy and fostering innovation-driven initiatives. His combined expertise in research, teaching and leadership is anticipated to support Clemson’s efforts to enhance student outcomes and maintain excellence in mechanical engineering.

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Toyo Tire U.S.A. Corp. has announced the promotion of four veteran sales management team members to director-level positions, effective 1 March 2026. Ken Cole, Shawn Blythe, Bill Carroll and Steven Shearer each assume expanded responsibilities across distinct areas: Cole steps into commercial accounts sales, Blythe takes on strategic accounts distribution, Carroll now oversees national retail channel, car channel and motorsports tyres and Shearer moves into sales operations and training. These leadership changes underscore the company’s dedication to cultivating internal talent and adapting to an evolving tire industry landscape.

Ken Cole, who joined Toyo in 2017 as Senior Manager for Truck Sales in the eastern region, brings over 25 years of industry experience to his new post as Director of Sales for Commercial Accounts. He succeeds Bill Barfield, who retired at the end of 2025. Shawn Blythe, a more than five-year Toyo veteran previously serving as Senior Manager for Strategic National Accounts Distribution, continues in a similar vein as Director of Strategic Accounts Distribution, focusing on driving success alongside company partners.

Bill Carroll’s new role as Director of National Retail Channel, Car Channel and Motorsports Tyres follows a tenure marked by progressive leadership, including positions as District Sales Manager, Regional Sales Manager and Senior Manager for Strategic Retail Accounts. Meanwhile, Steven Shearer, a Toyo team member since 2012 who most recently served as Senior Manager of Marketing Communications, transitions to Director of Sales Operations and Training. In this capacity, he replaces Anne Holland, who is set to retire at the end of March.

Mike Snyder, Vice President – Sales, Toyo Tire U.S.A. Corp., said, “Ken, Shawn, Bill and Steve have shown strong leadership as senior managers of their respective teams and have been integral in the success of Toyo over the years. Their promotions are well deserved and have enabled Toyo to solidify the mid-level management team that carries the organisation into the future. I’m confident that their leadership will ensure the company’s continued growth over the coming years.”

Cole said, “I am honoured for the opportunity and look forward to helping lead Toyo’s continued growth in the commercial tire business. We have a great sales team, and we will continue to focus on delivering high-quality commercial tyres through the best servicing dealers in the industry.”

Blythe said, “Toyo’s success has been built on strong partnerships with our customers, our dealers and our talented team at Toyo. I look forward to continuing to grow those relationships and deliver results and the reliability that our customers trust every day.”

Carroll said, “I will continue to bring my passion forward in my new director role and expand Toyo’s presence in the market. Toyo makes a fantastic product, and I am passionate about supporting our dealers, consumers and commercial needs.”

Shearer said, “My goal is to continue advancing sales programmes, tools and communications that improve the ease of doing business and drive success for both Toyo Tires and our customers. I am committed to supporting our dealers, and their success is central to everything we do.”

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Apollo Tyres Ltd has secured the second position among BW Businessworld India’s Top 5 Most Sustainable Companies in the Automotive Components sector, marking a significant recognition of the company’s dedication to responsible and future-oriented business operations. The ranking underscores the organisation’s consistent efforts to embed sustainability into its corporate framework, highlighting its progress in aligning industrial performance with long-term environmental and social accountability.

In addition to this sector-specific accolade, Apollo Tyres has been named among BW India’s Top 60 Most Sustainable Companies for the 2024–25 edition, a distinction drawn from a broader evaluation of the country’s top 200 corporations. Further cementing this achievement, the company has also been featured within the Top 30 most sustainable organisations among that select cohort. The assessment involved a comprehensive review across a wide range of Environmental, Social and Governance parameters, providing a holistic evaluation of Apollo Tyres’ sustainability initiatives and their measurable long-term impact.

The BW Sustainability World platform continues to serve as a key forum for industry leaders, fostering the exchange of insights, inspiration and actionable strategies aimed at accelerating sustainable transformation across sectors. Apollo Tyres remains steadfast in its commitment to driving meaningful change and contributing to a more sustainable future, building on these recognitions as benchmarks of its ongoing journey.

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