Sustainable Development Goals
Project Status:
Completed 2007-2011 | Feasibility Study & Product Testing
Organizations Involved:
Klean Industries, Hosokawa Group, Mitsubishi Materials Corporation, Onahama Refining & Smelting Co, Tokyo University, Tokyo Institute of Technology, Toyo Construction
Services:
Design & Engineering, Due Diligence, Component Supply
Introduction
Klean Industries offers world-class recovered carbon black (rCB) equipment for the industrial-scale production of rCB from end-of-life tires. Our turnkey pyrolysis systems are engineered for maximum energy efficiency, modular scalability, and commercial reliability. Whether you're launching your first rCB plant or expanding an existing operation, our technology delivers the precision, safety, and ROI needed to meet global demand for sustainable carbon black alternatives.
The Challenge
Used tires are often overlooked in discussions about the circular economy, yet they present a significant environmental and economic challenge. Approximately 3.4 million tons of end-of-life tires (ELTs) are collected annually in the European Union (EU) alone. Tire production is a resource-intensive process, consuming vast amounts of natural resources and emitting large quantities of CO2.
For decades, one of the biggest challenges in the tire pyrolysis industry has been the inability to produce high-quality recovered carbon black (rCB) that could compete with virgin carbon black (vCB) in mainstream applications. While pyrolysis systems could thermally decompose end-of-life tires and recover carbonaceous char, most outputs remained coarse, impure, and inconsistent—unsuitable for use in rubber, plastic, or pigment industries.
Without refined processing systems and standardized specifications, the recovered material was often treated as a low-value filler, or worse, disposed of entirely. The absence of proven equipment solutions for micronization, classification, and purification meant that pyrolysis remained an incomplete recycling method, failing to capture the value embedded in tire-derived materials fully.
One of the key materials in tire manufacturing is carbon black, a reinforcing filler that enhances durability. However, traditional carbon black production is highly unsustainable:
Despite the increasing demand for sustainable alternatives, the market lacks a consistent, high-quality supply of recovered carbon black (rCB) at scale. Large tire manufacturers, such as Continental, aim to increase the use of recycled materials from 4% to 10% by 2025, highlighting the urgent need for advanced tire recycling solutions.
The Solution
Klean Industries recognized this issue early and took action. In the early 2000s, Klean operated commercial-scale tire pyrolysis facilities in Japan and began exploring ways to transform recovered char into valuable renewable carbon black (rCB). Realizing that equipment innovation was critical, Klean became the first pyrolysis technology company to collaborate with Hosokawa Micron Group, a global leader in powder processing technology based in Japan.
In 2005, this collaboration resulted in extensive trials using Hosokawa's specialized equipment to process carbon char from Klean’s tire pyrolysis systems. Through these efforts, Klean and Hosokawa achieved:
The technical partnership helped prove that tire pyrolysis char could be upgraded into rCB suitable for use in plastics, coatings, masterbatch, rubber compounding, and other industrial applications.
This was a pivotal advancement. It demonstrated that, with the proper post-processing, pyrolytic carbon black can be standardized, monetized, and circularly reintegrated, thereby replacing fossil-derived virgin carbon black.
Klean’s Broader Role in the Recovered Carbon Black Ecosystem
Beyond this early work with Hosokawa, Klean Industries has remained a global leader in rCB development, refining not only the process of pyrolysis but also how the full value chain surrounding recovered carbon materials is managed.
Klean’s systems are engineered to produce consistent, high-grade rCB through:
Klean’s recovered carbon black solutions can be tailored to displace traditional carbon black grades such as N300, N500, N600, and some N700 series in various end-use markets. This includes:
Unlike conventional carbon black, which is produced through the combustion of fossil fuels, Klean’s rCB is derived from waste materials, primarily end-of-life tires, making it a more sustainable, circular, and lower-carbon alternative. Klean’s recovered carbon black production can reduce lifecycle emissions by up to 90% compared to traditional methods.
Klean Industries is at the forefront of tire recycling innovation, utilizing advanced pyrolysis and patented milling technology to produce high-quality recovered carbon black (rCB). The process transforms end-of-life tires into valuable commodities, including oil, gas, steel, and rubber, contributing to a more sustainable circular economy.
Innovative Pyrolysis & Milling Technology
Klean Industries’ cutting-edge CBk milling system is designed to adapt to the varying quality of tire char and optimize carbon black recovery. Unlike unprocessed rCB, which has limited commercial value, refined rCB is 10 times more valuable, making it a viable and sustainable alternative to virgin carbon black.
Key features of Klean Industries’ rCB processing technology:
By leveraging high-quality milling and classification systems, Klean Industries enhances the value and usability of rCB for tire production, conveyor belts, rubber parts, and even paint manufacturing.
The Outcome
Klean Industries’ early collaboration with Hosokawa Micron laid the groundwork for the modern rCB industry. It demonstrated that:
This case study stands as proof of Klean’s long-standing innovation and commitment to building a fully circular tire recycling solution. The company continues to work with leading technology vendors and end-users to scale up rCB production across North America, Europe, and Asia.
With growing demand for sustainable alternatives in the rubber and plastics sectors, Klean’s rCB offering is not just a technical solution; it is a cornerstone of the circular economy for tires.
Klean Industries’ tire recycling experience and technology solutions are helping the industry transition towards a more sustainable and circular future, with tangible environmental and economic benefits:
With over a billion tires consumed annually worldwide, the need for efficient, high-value recycling solutions has never been greater. Klean Industries’ pioneering approach is setting new standards for tire waste management, demonstrating that sustainability and profitability can coexist.
Join the Circular Economy Revolution
Learn how Klean Industries can help your business reduce its carbon footprint and integrate sustainable materials into your supply chain. Contact us today to explore our cutting-edge solutions for tire recycling and recovered carbon black production. We can provide turn-key, standalone modular units for any project globally.
Looking to manufacture recovered carbon black? Klean Industries delivers fully integrated rCB pyrolysis systems designed for high-throughput, energy-efficient operations using tires, rubber, or mixed elastomeric waste.
Our modular platforms enable phased scale-up, and our engineering team supports you from design through to commissioning.
Request a Custom Equipment Quote or Feasibility Package >> GO.
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