Plastic Energy launches TACFILLER, a low-carbon, circular carbon black alternative from recycled plastic, reducing emissions and promoting sustainable rubber manufacturing.
Plastic Energy Ltd., a global frontrunner in chemical recycling, has become the first company in the plastic chemical recycling sector to commercialize ‘char,’ a byproduct of its proprietary TAC™ chemical recycling technology. Marketed under the brand name TACFILLER, this innovative product provides a lower-carbon, circular substitute for conventional carbon black—a material widely used in rubber manufacturing to enhance durability and performance but known for its significant environmental footprint.
The launch of TACFILLER is particularly timely as the rubber industry faces mounting pressure to lower its emissions and adhere to regulatory frameworks such as the EU’s End-of-Life Vehicles Directive, which requires higher recycled content in vehicle components and emphasizes reduced environmental impact. TACFILLER presents a sustainable and scalable solution capable of helping manufacturers meet these stringent requirements while promoting circularity. Notably, it is the first product of its kind to achieve REACH registration, the regulatory standard governing most chemical substances manufactured or imported into Great Britain. Acting as a direct carbon black replacement, TACFILLER enables the rubber industry to significantly cut emissions and achieve recycled content targets.
Traditional carbon black, produced from fossil fuels, is energy-intensive and contributes substantially to global greenhouse gas emissions—estimated at 29–79 million metric tonnes of CO2 annually. By contrast, TACFILLER is derived from post-consumer plastic waste, reducing reliance on virgin fossil resources. A comprehensive Life Cycle Assessment conducted by Plastic Energy found that TACFILLER’s production results in up to 89% lower emissions compared to conventional carbon black, underscoring its environmental advantage.
The product originates from Plastic Energy’s proprietary TAC™ chemical recycling process, which transforms hard-to-recycle, post-consumer plastics into TACOIL™, a recycled feedstock that can replace fossil-derived oils in the manufacture of new plastics. This process prevents plastic from ending up in landfills or incineration facilities, thereby reducing waste and lowering associated emissions by up to 78% relative to incineration. By incorporating TACFILLER into its offerings, Plastic Energy can potentially achieve an overall recycling rate approaching 90%, further enhancing the circularity and sustainability of its operations.
Ian Temperton, Chief Executive Officer of Plastic Energy, emphasized the significance of this innovation: “Carbon black production is highly energy-intensive, and the rubber industry urgently needs sustainable alternatives. We are proud to pioneer circular products derived from plastic waste, which otherwise often ends up in landfills or incineration. TACFILLER not only helps reduce environmental impact but is also commercially viable, demonstrating the immense potential of recycled plastics in both the plastics and rubber industries.”
Plastic Energy is collaborating with leading manufacturers, including Standard Profil, to ensure that TACFILLER can be seamlessly integrated into their products. Yusuf Güner, Group R&D Materials Senior Expert at Standard Profil, stated: “We explored TACFILLER as a partial replacement for carbon black and, following extensive trials, confirmed its feasibility. The results are encouraging and open the door to new possibilities, which we are actively evaluating for future applications.”
TACFILLER represents a significant step forward in sustainable manufacturing, enabling the rubber industry to embrace circular economy principles, drastically reduce emissions, and utilize plastic waste as a valuable resource.
