Life Green Vulcan

High performance devulcanized masterbatches for the reuse of end-of-life tyres in high-volume technical compounding applications

Rubber conversion, one of the partners of the Life Green Vulcan project, has developed a powerful method for obtaining high-quality rubber from End-of-Life Tyres (ELT) without compromising performance when implemented in new, sustainable products.

An innovative mix of devulcanized Natural Rubber/Styrene-Butadiene Rubber (NR/SBR) masterbatch, recovered from ELTs, has been transformed into new products and used as a substitute for raw rubber, both in technical components for automotive vehicles (spring pads) and in new tyre production (e.g. PCR tread), both tested by industry partners Stellantis and Bridgestone, respectively.

From the tyre to innovative components

Collection and treatment of End-of-Life Tyres (ELT)

Devulcanization of rubber from ELT and development of a new material

Industrialized product with high content of recycled ELT

Production of technical items with 20% devulcanized rubber

Production of PCR treads with 10% devulcanized rubber

The challenge for reusing ELT rubber

Vulcanized rubber is very difficult to recycle, which is why waste from ELT is used at very low concentrations in tyre production (less than 3%).
The rubber devulcanization method, patented by Rubber Conversion, has demonstrated its enormous potential for the development of high-quality raw materials from ELT

The problems addressed through different steps

Production of an innovative mix of devulcanized Natural Rubber/Styrene-Butadiene Rubber (NR/SBR) masterbatch developed by Rubber Conversion
A new sustainable shock absorber has been designed and manufactured for the Alfa Romeo Tonale with a 20% weight concentration of recycled ELT, as well as a PCR tyre tread with a 10% weight concentration of recycled ELT.

The results achieved

Significant reduction in CO2 emissions: The LCA analysis, performed in line with ISO 14040 and ISO 14044 standards, considered the entire life cycle of a product (from the acquisition of raw materials, through production and use, to disposal), with the Cradle -to-Gate approach.
The technology developed by Rubber Conversion significantly contributes to establishing a scalable supply of quality sustainable materials derived from ELTs for the European tyre and automotive industry, enabling them to achieve their decarbonisation goals.
The technology is also being successfully tested for the production of other automotive components and rubber-based products such as gaskets and shoe soles, broadening market application and the potential overall positive impact on decarbonisation.