ERJ Elastomers for Sustainability - Top 10

ERJ March/April issue saw the introduction of a new format for the Elastomers for Sustainability (E4S) programme and Top 10 rankings.

The table is now being updated on a ‘rolling basis’ in each issue of European Rubber Journal print magazine throughout the year.

Also, the E4S programme has now been expanded to also include sustainability-related advances in tire and rubber-product manufacturing technologies.

The new-look programme will culminate in the E4S Awards, with the winning projects to be announced at the yearend.

HF Mixing Group: Smart Final Mix

 AI-based algorithm Smart Final Mix is capable of optimising final mixing processes in the tire and technical rubber goods industries. By using the tool for optimising industrial processes in the technical rubber goods and tire industries, energy savings of up to 29 % could be achieved. As shown in a technical paper, within the algorithm, data on batch-temperature, energy-consumption and mixing-quality are linked to each other and then optimised. The technology, thereby, enables the optimal process-parameter settings that apply to the final-mixing process to be calculated. To describe the final mixing process, HF Mixing developed mathematical models and approaches to measure mixing-quality and batch-temperature and link these to energy-consumption. These parameters all relate to rotor speed, which is used for the mathematical modelling system, according to the HF Mixing paper.

Judging comments

Impressive to see that energy-savings of almost 30% can be achieved through using this app… This AI-based software tool is a very welcome development for rubber processing companies under increasing pressure due to rising energy costs while striving to support the tire & rubber industry in meeting net-zero targets.  By optimising energy-intensive processes the app offers significant benefits by increasing energy efficiency in the mixing room.

Evonik: Advanced rubber recycling formulation

Essen, Germany-based Evonik AG has developed a process that enables the use of up to four times more recycled rubber in new tires than is possible with existing methods. The level of rubber recyclate incorporated into tires has been very limited up to now as the polymer structure hampers interaction with other materials, according to Evonik.

In particular, it said, the sulphur bonds create a highly robust, three-dimensional network, which conventionally has an upper limit of about 5% when it comes to introducing ground tire rubber from end-of-life-tires into new tires.Using a special formulation containing vinyl silanes, Evonik says it can now reverse the vulcanisation “more effectively than previously possible” –  cleaving the sulphur bridges in the rubber, while leaving “as many of the long carbon chains as possible untouched.”

In trials, recyclate levels in the rubber blend could be increased to up to 20%, said Evonik, which is now set to start next-stage testing and trials – towards seeing customers use the system in commercial-scale industrial production.

Judging comments

Impressive that the technology can deliver a four-fold increase the effectiveness of conventional devulcanization processes and raise the proportion of recyclate in rubber blends up to 20%. As Evonik states: “Rubber is far too valuable a raw material to be used only once in tires. We want to incorporate it into a circular system.”

Scores very highly in terms of potential for upcycling: allowing four-fold increase in the level or rubber recyclate that can be incorporate into compounds.

As a major player in the field of rubber chemicals, Evonik is well equipped to deliver on the significant potential offered by this technology.

UPM Biochemicals: Renewable functional fillers

UPM has provided an update on the progress of its project to establish a €1.2bn, 220ktpa biorefinery in Leuna, Germany.  Having initiated commissioning and start-up in late 2024, QA checks identified certain corrective works required in the sugars-to-chemicals process. “Sequential start-up in the other units continues, [with] integrated commercial production of the site expected to start in H2 2025,” it stated

Output from the site will include lignin-based renewable functional fillers (RFFs) – alternatives to carbon black and other rubber fillers for tires, automotive profiles, hoses, seals, footwear, flooring and other products.

“Commercial interest in our products and side streams has been confirmed with customer agreements,” said Massimo Reynaudo, president and CEO of parent group UPM-Kymmene. “We are managing a sales and product qualification pipeline that is multiple times the annual capacity."

Other reported developments at UPM Biochemicals include: it gaining FSC, PEFC, ISCC+ certifications and passing an ISO 9001 pre-audit; and further engagement with global tire and rubber-product manufacturers for approvals of RFF.

Judging comments

While the start-up of the Leuna plant is now scheduled for later this year, UPM has again supplied high-quality information with detailed updates to support its continued high ranking in the E4S programme. The latest form shows further progress being made with the commercialisation of RFFs, including through increased engagement with automotive OEs and industrial rubber parts manufacturers.

Klockner Desma: PCF Navigator Ecos

Fridingen, Germany-based Desma has developed an app that provides a detailed overview of the wide-ranging factors that determine the CO2 footprint of individual moulded rubber articles. The PCF Navigator Ecos also shows which measures can be used to achieve which reduction effects, according to the rubber injection moulding machine maker.

The technology, it added, enables quick decisions to be made “on the optimum production process [with information] on the range in which the individual CO2 footprint of the article to be produced will be.”

In addition to the specific data of the respective machine type, the PCF Navigator Ecos contains a database with suggested values for a wide range of elastomer types. The Desma CoolApp is fully integrated to verify the use of cold runner technology, so that the actual material and cycle time savings can be taken into account as realistically as possible.

Judging comments

With the capability to incorporate such a broad range of parameters that determine the carbon footprint of injection moulded rubber products, the Desma app can support manufacturers in meeting their environmental goals and commitments. The ability to quickly display the impact of even minor changes to the process parameter and/or materials characteristics is also impressive.

Silox: New engineered generation of sustainable activators

In the E4S 10 entry for its ActiECO+ products, Silox said it developed a ‘flexible’ process technology for the precipitation of zinc-based solutions into zinc oxide (ZnO) – with a ‘circular/green’ option in the new portfolio activators.

Production involves precipitation of zinc-based ingredients into ZnO with precipitate dried or calcined to remove water and/or CO2 yielding “ a large variety of morphology.”

According to Silox, the vulcanisation efficiency of ZnO is improved by maximising contact between particles and the components of formulation: with high-surface-area, small particles “uniformly dispersed” throughout the rubber matrix.

The new product is said to ‘perform like an active ZnO, avoid the need for reformulation and offer benefits in terms of cost-control and ease of transportation & storage.’

Silox cited examples, including a 5 phr formulation for ‘white seal applications’, where the high-purity ZnO product is claimed to offer: ‘Limitless shelf life, improved blending and limitless shelf life – as well as having a low carbon footprint and being non-ecotoxic.’

Better dispersion is achieved ‘as the shape and morphology optimised for rubber mixing leading an improved ‘micro-structure’ of the compound,’ the company stated.

According to Silox, production is now up to 10ktpa within two years. Sales are now “up to around10 customers in non-tire sector, with final approvals on-going-on with two tire manufacturers.”

Judging comments

The Silox technology appears based on innovative developments both in terms of process engineering front and the optimisation of morphology of the rubber activators. The entry includes concise details about the ZnO technology, chemical composition and formulatons, backed up with IP patent details. Still early days, but this seems a solid advance offering significant sustainability benefits to the tire & rubber industry and is generating good commercial take-up.

Hankook, Hyosung, SK Chemical: Chemically Recycled PET Tire

Update: A video showcasing SK Chemicals’ circular recycling technology has won a gold medal at the "2024 International Business Awards, a global competition that evaluates companies worldwide across a range of criteria, including promotional activities. SK topped the technology segment of the video category for its titled ‘SK chemicals Closed Loop Solution’, which illustrates the process of transforming polymer waste into products identical to petroleum-based alternatives via collection, crushing, washing, depolymerisation, and polymerisation process.

As previously reported, Hyosung Advanced Materials has employed SK’s technology in the development of  high-strength recycled PET-based tire cords for use in Hankook’s iON tires – a product with 45% sustainable material content.

Judging comments

High-quality presentations and promotional activities have a crucial role to play in the introduction of any sustainable-materials technology –within the rubber & tire industry and the global commercial and consumer sectors more generally.  So, well done here to SK for increasing awareness of the complex chemicals recycling value-chain to a high-profile international audience.

Mitsubishi Chemical Group: Synthetic leather from bio-based polyurethane

Tokyo-based Mitsubishi Chemical Group’s (MCG) plant-derived polyol BioPTMG has been adopted by Kahei Co. Ltd as a synthetic leather material.

In addition, items such as shoulder bags and tissue cases made with this bio-synthetic leather will be sold on the market via Triple A Co. Ltd, a planner and marketer of sustainable products.

Developed by Mitsubishi Chemical in 2021, BioPTMG is a plant-derived polyol said to impart flexibility, durability, and high resilience to polyurethane and polyester products.

A “unique” refining technology avoids colouring occurs during production, so that the materials can be used in a wide range of interior design, fashion, industrial and other applications.

Meanwhile, a biomass content of 92% or more reduces both the consumption of petroleum, and GHG emissions as the plant-based raw materials absorb CO2 as they grow.

Judging comments

Very encouraging to see a project showing a full value-chain for a bio-based elastomer material; from plants in the ground to high-end products on sale at a commercial retailer. Would score this even higher if there were more details about this development, includimg the “unique” refining process that avoids coloration, as well as about the 92%+ bio-content.

Asahi Kasei Europe: New selectively hydrogenated SBR for reduced 6PPD usage

Asahi Kasei previously reported on the enhanced ozone resistance of its selectively hydrogenated styrene-butadiene rubber and its ability to allow reduced usage of 6PPD in the rubber compounds.

In its latest update, Asahi explains how further studies have shown that the HSBR makes it possible, to not only reduce usage of the antioxidant/antiozonant, but also to improve mechanical properties, including fatigue resistance.

(For further details see E4S 9 report)

Arkema (with sportswear major ON): Recyclable, high-performance running show CloudNeo

Update: This May, On launched two new products from its circular Cyclon programme: the Cloudrise Cyclon for everyday running and the Cloudeasy Cyclon for training and all-day wear. Both products are available via On’s subscription service Cyclon. Once returned, On will take care of the recycling of the products. Customers can sign up for Cyclon for a monthly fee of around €25. The Cloudrise employs a 90% bio-based upper engineered from polyamide 11 derived from castor beans. The bottom unit is engineered from Pebax a 30% bio-based copolyester thermoplastic elastomer. For the Cloudeasy shoe, On partnered with Loop Industries, a producer of fibres based on chemically recycled PET.

Judges comments

While €400 a year likely busts the footwear budgets for the vast majority of athletes, it is encouraging to see this recycling model –  involving the impressive use of Arkema’s bio-based elastomer materials – is now fully up & running with Swiss maker On also offering new Cyclon products.

(For further details see E4S 9 report)

Tosoh Corp: New composites of chloroprene rubber and cellulose nanofibres

Tosoh Corp. has started to manufacture and sell a newly developed grade of the company’s Skyprene chloroprene rubber. The SG Series features a composite of chloroprene rubber and cellulose nanofibres.

To commercialise the SG Series, Tosoh collaborated with Bando Chemical Industries to incorporate the composite in transmission belts that Bando produces and has begun selling.

The collaboration was in conjunction with the Japanese government’s New Energy and Industrial Technology Development Organization (NEDO)’s subsidy program.

An alternative to fossil-derived reinforcing fillers, such as carbon black, CNF is “a biomass-derived, high-performance material that is one-fifth the weight of yet more than five times stronger than steel.”

Historically, however, integrating CNF with rubber materials has presented technical challenges in processes such as compounding and mixing.

Tosoh said its proprietary technology makes possible the uniform and fine dispersal of CNF in chloroprene rubber.

Tosoh is exploring expanded applications for the SG Series and accelerating its development of manufacturing technologies for consistently high-quality mass production.