With the ever-increasing global dialogue for sustainability and environmental responsibility, recycling has emerged as a vast frontier of untapped potential, especially for products with intricate chemical compositions and special active surface properties. This potential becomes particularly apparent in one challenging area: the disposal of medium to large sized vehicle tyres that have reached the end of their lifecycle. Thanks to RubberJet Group, an innovative entity co-founded by Tommaso Verri and his Partners passionate on Innovation and Sustainability, it is in progress a game changer of the field that is revolutionizing the big-size tyre recycling field with its factories around the world.

Every year, one billion tyres reach the end of their lifecycle, adding to the estimated four billion already occupying landfills and stockpiles globally, according to the Tyre Industry Project for the World Business Council for Sustainable Development (WBCSD). These discarded tyres, especially the medium-big tyres, pose a severe environmental risk, but also represent a massive opportunity waiting to be fully realised.

This is where RubberJet Group, an innovative Cleantech Group, leads the way in green technology through its proprietary ground breaking High Pressure Water Jet Technology (HPWJ).

“By transforming end-of-life tyres (ELT) from an environmental concern into a valuable asset, our proprietary High-Pressure Water Jet Technology is driving the tyre industry towards a more sustainable and promising future for different applications, says Mr. Tommaso Verri, co-founder and CEO of RubberJet Group.

A Look into the Cutting-Edge Tech

The goal of RubberJet’s novel technology lies in using high-pressure water jets to break down ELTs into reusable high-quality secondary raw materials. These materials, represented by chemically active rubber powders, can be incorporated into the new tyre or other rubber compounds.

This process begins with thoroughly cleaning the big ELTs, stripping the rubber from the steel carcass using only high-pressure water jets and then drying the wet rubber. The final product is separated into rubber powders and granules of different sizes, tailored according to the end user’s needs. Exposing the rubber to high-pressure water jets serves dual objectives—it breaks the sulphur bonds allowing it to have a final material that is already devulcanised and, therefore, ready to be vulcanised again in the new rubber compounds. This property is unique to RubberJet’s technology as it offers an eco-friendly devulcanisation process. A crucial aspect of HPWJ technology’s devulcanisation is it achieves size reduction and rubber devulcanisation simultaneously, without the need for any chemical agents that can degrade the rubber’s properties and consume substantial energy.

At the end of the process, it yields two high-quality primary products—RubberJet Powder (RJP) with a particle size of up to 400 microns and 800 microns and a RubberJet Granulate (RJG) of 0.9 to 3.3 mm or 3.4.4 mm. Free from metallic residues, these materials offer a wide range of applications. RJP and RJG can be used to manufacture new tyre compounds and high-quality, pure regenerated compounds. Their versatility extends to traditional rubber applications like infill for artificial sports fields, conglomerates for urban safety, agglomerates for acoustic insulation, and door dock mats, to name a few. The products can also be used to construct shockproof flooring for sports areas, paving for cycle paths, and various other artefacts.

So far, the HPWJ technology has demonstrated its ability to recycle different types of tyres, including those from trucks, earth moving machine tyres, and mining tyres. The latest target has been rubber track at the end of life, which until now has not been processed by traditional technologies.

Facilitating Circular Economy with Sustainability

RubberJet’s approach epitomises the principles of the circular economy, transmuting waste tyres into precious materials and closing the tyre lifecycle loop.

The rubber industry faces the challenge of reducing the usage of virgin rubber, a situation underscored by the European Commission classifying natural rubber as one of the 17 critical raw materials. In line with this, the industry is amplifying its commitment to sustainability by identifying green and sustainable materials that can substitute virgin raw materials. RubberJet’s product perfectly aligns with this direction.

The company’s technology also significantly impacts environmental preservation by eliminating the need for incineration or landfilling medium and large tyres. This aligns with various UN Sustainable Development Goals (SDGs), most notably SDG 12 (Responsible Consumption and Production), SDG 13 (Climate Action), SDG 15 (Life on Land) and the objectives of European Green New Deals.

“Our technology displays reduced energy costs and represents a 100 percent ecological commitment, which empowers our partners and clients worldwide to achieve unique and economic benefits by reducing their CO2 impacts as well,” says Mr. Verri.

By transforming end-of-life tyres (ELT) from an environmental concern into a valuable asset, our proprietary High-Pressure Water Jet Technology is driving the tyre industry towards a more sustainable and promising future for different applications

This claim is substantiated by the Life Cycle Assessment (LCA) conducted on RubberJet’s products, which quantifies their reduced environmental impact, including lower carbon emissions. The study validates a reduction equivalent to two-thirds compared to the production of natural rubber.

Valuing these achievements, the company is also relentlessly pursuing various certifications, having already achieved ISO 9001 and the Silver Medal of EcoVadis Certification. It aims to secure additional certifications in the near future, as indicated by its certification path on the website. RubberJet is making efforts to provide clients with certificates that acknowledge their role in cutting down CO2 emissions by choosing its recycled products over conventional rubber.

Charting the Course with Promising Future

RubberJet is actively involved in various projects throughout Europe and is expanding now with additional factories around the world through its new entity RubberJet Group.

RubberJet Group has secured a LIFE Tender, the most important funding tender organised by European Commission, together with one of the most important tyre retreading companies in Europe, Piave Tyres, and the leading tyre recyclers association, the European Tyre Recycling Association (ETRA). This partnership aims to develop and install the first-ever chamber capable of recycling giant mining tyres of 4.2 metres. This innovative plant is set to start operations by the beginning of 2024 and is poised to transform the mining tyre recycling industry.

RubberJet’s alliance with multinational plant provider Zeppelin marks another considerable stride towards widening its global influence. With Zeppelin’s assistance, it plans to provide numerous plants worldwide, particularly in areas where the disposal of medium and larger tyres presents a significant challenge. In addition, RubberJet has just announced a relevant distribution agreement with the world’s largest chemical product distributor, BRENNTAG.

“Brenntag and RubberJet have signed this agreement to play a leading role together in making our planet greener. Brenntag has recognised the unique properties of our final product, produced by our technology and together with their global presence, we will be able to make a huge impact with our RubberJet Group and our factories to be installed worldwide,” says Mr. Verri.

RubberJet’s innovative approach and commitment to sustainability have not gone unnoticed. The company has secured prestigious awards at European and global levels, including the Tire Technology International Awards in previous years. They were also nominated as Best Tyre Recycler Industry Supplier in 2023 for the prestigious Recircle Awards. RubberJet has the distinction of becoming the first Italian company to win the Edison Awards in the ambitious sustainability category, a recognition often dubbed as the ‘Oscar of innovation.’ Last but not the least, RubberJet has been awarded by Manufacturing Technology Insights Europe among the “Top 10 tyre and rubber solution providers” and as “Company of the Year” for the incredible impact they are generating in the tyre industry. However, its ambition extends beyond accolades. The company remains dedicated to supporting the sustainability goals of its clients. This synergistic partnership mindset underscores its pledge to promote a greener planet through eco-friendly practices.