In 2023, Zeppelin Systems launched the Zeppelin Sustainable Tire Alliance, an international network dedicated to making the tire recycling process more efficient and sustainable. The goal is to recover high-quality secondary raw materials suitable for use in the production of new tires—helping to conserve valuable resources.

In response to growing environmental pressures, rising energy costs, and increasing resource scarcity, the alliance’s partners—spanning the entire value chain—rely on innovative technologies to recycle end-of-life tires and promote a more sustainable tire production industry for today and tomorrow.

For large-scale projects, customers and investors need a reliable basis for decision-making. Feasibility studies conducted at the beginning of a project help ensure its successful completion by providing solid figures, data, and facts for the planned business case—including ROI indicators.

Using process descriptions, 3D models, layout plans, operating costs, technical documentation, on-site infrastructure, and Green Factory aspects, we transform ideas and visions into concrete, reliable business plans. As an experienced plant engineering partner, Zeppelin Systems prepares these feasibility studies, evaluates all necessary requirements and local conditions, and delivers a compact decision-making foundation—including a cost estimate—for project implementation.

The remaining parts of the tire are fed into material recycling processes—such as pyrolysis. In pyrolysis, end-of-life tires are broken down into raw materials, producing, among other things, recovered carbon black (rCB) and pyrolysis oil.

Separated textile fibers are processed into stabilizers for stone mastic asphalt. The product derived from these fibers during tire recycling acts as an asphalt binder, stabilizing and reinforcing asphalt mixtures to create homogeneous and long-lasting road surfaces. In fact, the additive offers superior performance compared to conventional stabilizers—it reduces water ingress, fatigue, thermal cracking, and rutting.

In a subsequent refinement step, the rCB obtained from pyrolysis is thoroughly purified to remove ash content and sulfur. The result for the industry: rCB with consistent, reproducible quality and purity—comparable to conventionally produced industrial carbon black. Additionally, valuable zinc- or silicon-based products can be recovered from the separated ash content, enabling the tire industry to close further material loops for the first time.

Only by understanding the product in every detail can plants be designed to operate safely, with optimized processes, high energy efficiency, and cost-effectiveness. The bulk material technical center in Friedrichshafen is equipped with all components and systems relevant to process engineering. It is also home to one of the world’s largest bulk material libraries—containing the knowledge our experts have accumulated over decades of handling a wide range of materials.

Two large-scale test facilities for granulates, powders, and additives allow trials to be carried out at full industrial scale—including special configurations where required. Our experts determine all relevant design parameters and conduct precise result analyses, giving you a solid foundation for your investment decision. A few examples of application cases include: