Char, a valuable byproduct of chemical recycling, is being investigated as a potential substitute for carbon black in rubber manufacturing, providing a fresh avenue for this material.

Source: LetsRecycle

Produced during the breakdown of plastics at high temperatures, char has mostly been regarded as a secondary output with limited applications beyond energy recovery.

However, recent trials have demonstrated char's effectiveness as an alternative to carbon black, a widely used additive that enhances rubber's strength and longevity.

Chemical Recycler Launches Char Product

Plastic Energy, a chemical recycling firm, has announced the commercial introduction of TACFILLER, a char-based alternative to carbon black derived from recycled plastic waste.

This new product is a result of the company's TAC chemical recycling process, which transforms difficult-to-recycle plastics into TACOIL, a recycled feedstock for creating new plastics.

A Life Cycle Assessment indicates that TACFILLER can reduce carbon emissions by up to 89% compared to traditional carbon black, which is usually produced through the partial combustion of heavy petroleum products.

A ‘Drop-in Alternative’ for the Rubber Industry

Plastic Energy notes that carbon black production is both energy-intensive and carbon-heavy, contributing between 29 and 79 million metric tonnes of CO₂ emissions globally each year.

Carbon black is energy intensive, and the rubber industry needs alternatives. We’re proud to lead our industry by creating new circular products from plastic waste. Less than 10% of plastic is recycled globally, yet it’s a valuable resource that should be reused. Our technology allows us to reduce plastic waste sent to incineration and landfill by finding sustainable uses for it in the manufacture of new plastic – and now rubber.

^{Plastic Energy’s Chief Executive Officer, Ian Temperton}

TACFILLER is presented as a "drop-in" solution, aiding manufacturers in lowering their carbon footprint while upholding performance standards.

This development aligns with increasing regulatory pressures, such as the EU’s End-of-Life Vehicles Directive, which mandates higher recycled content and reduced environmental impact in automotive components.

Industry Uptake

The company is collaborating with various manufacturers, including automotive sealing systems specialist Standard Profil, to assess and validate TACFILLER’s effectiveness in rubber applications.

We boldly explored the use of TACFILLER to partially replace carbon black in our products. After a series of rigorous trials, we have validated its feasibility and are encouraged by the results. This opens exciting possibilities for future applications, which we continue to evaluate with curiosity and care.

^{Yusuf Güner, Group R&D Materials Senior Expert at Standard Profil}