PPG: Treated Silicas Enable Tire Manufacturing Energy Savings and Reduced Complexity

Manufacturers across the U.S. continually strive to reach their environmental, social and governance (ESG) ambitions through innovative products, reduced greenhouse gas emissions, supplier and partner relationships and process improvements. In fact, a recent survey by the National Association of Manufacturers found that a primary sustainability focus of manufacturers is energy efficiency and reduction.

Pair the manufacturing sector’s, and mostly all industries, drive toward sustainable solutions with the clear need to accelerate the transition to cleaner, safer, more inclusive transportation systems.

As the automotive industry experiences an uptick in future-forward innovation across the industry, the global megatrends of urbanization, surging demand for transportation, and an urgent need for climate action will accelerate this transition. This includes cleaner, safer, more inclusive transportation systems. The tire and rubber industry plays a crucial role in this transition.

The tire and rubber industry has been facing increasing pressure to reduce energy consumption and improve efficiency in recent years. Rising fuel costs, a wide range of environmental legislation, and increased public consideration for energy usage and the environment continue to drive the pursuit of fuel efficient and longer lasting automobile tires. As a result, the tire industry is compelled to broaden its focus on the “magic triangle” of fuel efficiency, traction and treadwear to meet these demands.

Silica is a favored filler in vehicle tires due to its ability to provide superior fuel efficiency compared to the conventional carbon black filler in tire rubber compounds. However, although silica reduces rolling resistance and offers fuel consumption savings throughout the tire’s lifespan, it has a significant impact on energy usage during tire manufacturing.

It is widely known in the industry that mixing silica into rubber compounds requires long mixing times and high temperatures to provide adequate silica dispersion and an efficient silanization reaction. Thus, the manufacturing considerations of silica can include reduced productivity due to longer mixing times, higher mixer energy consumption, higher mixer wear and volatile organic compound (VOC) emissions.

One promising solution to achieve industry environmental and energy saving goals is the use of treated silicas.

Why Do Tire Manufacturers Use Silicas?

Untreated silica has certain limitations, such as poor dispersibility in rubber, which can make it difficult to incorporate into rubber compounds. To overcome these limitations, silica can be treated with various chemicals and surface coatings to modify its properties.

Treated silicas are engineered to have unique surface properties that can improve the performance of rubber compounds and reduce energy consumption during the manufacturing process, and they are commonly used in various industrial rubber applications.

In the tire industry, treated precipitated silicas, such as PPG AGILON® high-performance silica products, have emerged as a promising approach to achieving energy savings and improving the performance of rubber compounds, particularly in tire manufacturing.

By reducing the viscosity of rubber compounds, treated silicas can help to reduce energy consumption during the mixing process and offer improved tire performance including reduced rolling resistance and fuel consumption savings during the tire’s lifetime. Energy savings are also achieved by eliminating unnecessary mixing times and temperature for silanization.

Benefits of Treated Silicas

One of the main advantages of treated silicas is their ability to improve the reinforcing properties of rubber compounds. The surface coatings on treated silicas can enhance the interaction between the filler and the rubber matrix, resulting in improved mechanical properties such as tensile strength, tear resistance and abrasion resistance. This can lead to longer lasting and more durable rubber products.

Additionally, the use of treated silicas can help to reduce the amount of energy required during the mixing process. By reducing the viscosity of the rubber compound, treated silicas can help to reduce the amount of energy required to mix the compound and improve the overall efficiency of the mixing process. This can be particularly useful in applications such as tire manufacturing, where large amounts of rubber compounds are mixed and energy consumption is a significant concern.

Treated Silicas and Sustainability

The use of treated silicas in the rubber industry can also have significant sustainability benefits. By reducing energy consumption during the manufacturing process, treated silicas can help to reduce greenhouse gas emissions and improve the overall sustainability of the industry. Additionally, the improved mechanical properties of rubber compounds can lead to longer lasting and more durable products, reducing the need for frequent replacements and ultimately reducing waste.

Furthermore, the use of treated silicas can help to reduce the amount of natural resources required in the manufacturing process. By improving the efficiency of the mixing and curing processes, treated silicas can help to better allow the replacement of synthetic rubbers with natural rubber. This can help to conserve natural resources and reduce the environmental impact of the industry.

In conclusion, as the demand for energy-efficient and high-performance rubber products continues to grow, the use of treated silicas is likely to become increasingly important in achieving these goals while also promoting sustainability and reducing the environmental impact of the industry and adjacent industries.

For additional and more detailed information, you can read PPG’s recent white paper “Energy Savings of Treated Silicas” www.ppgsilica.com/getmedia/a0f24285-59c1-4486-ace9-4f4cbf01ea40/Silica_Agilon_White_Paper-06-20-23-SINGLE-PAGE.pdf.aspx. 

Lucas Dos Santos is PPG senior research associate, Silica Products, Specialty Coatings and Materials. He has more than a decade of professional years of experience in R&D in rubber and tire industry. He holds a Ph.D. in polymer science from the University of Akron and a B.S. in chemical engineering from Universidad Nacional del Litoral. On June 28, 2023, PPG issued a white paper titled, “Energy Savings of Treated Silicas,” written by Dos Santos.