The automotive and trucking industries have a pressing sustainability problem. As the global production of vehicles continues to rise, so does the demand for rubber products, especially for tires. Globally we are producing 2.35 billion car and truck tires per year, each of which must be managed at their end of lives. To make matters worse, tires are getting bigger and EVs wear out tires faster due to increased vehicle weight and torque, both of which are accelerating the pounds/kilograms of end-of-life (ELT) tire rubber that will need to be managed. The urgency for effective, sustainable alternatives has never been more necessary. Yet, solutions to address this need have been few and far between. Until now. Prism Worldwide, a leader in innovative material solutions focused on ELT recycling, has developed a patented technology that is attacking this problem head-on. A new partnership between Prism and Sherwood Industries, an extruder specializing in thermoplastic sheets, is applying this solution to extruded thermoplastic elastomers (TPEs).
A New Approach to an Age-Old Problem
When Prism and Sherwood came together to collaborate, their goal was to introduce sustainable TPEs derived from recycled tires into the extruded rubber industry, where they have long been a staple in various vehicle applications such as cup holders, bin mats, mud flaps, wheel well protectors, and a variety of under hood/exterior components.
What sets this new approach apart is the significant percentage of recycled content incorporated into the formula for the extruded sheets; content derived from a process that uses old consumer tires as a feedstock. This partnership has paved the way for a high-tech solution that transforms what was once considered low-tech material into a versatile resource, extending its potential far beyond its traditional use in playground surfaces or shredded mats. By elevating end-of-life tires to high-performance TPEs for use in automotive components, a major waste challenge turns into a compelling opportunity. Rather than piling up in landfills or being used as fuel, old tires are being used as a foundational material for TPEs and plastics, as well as being reintroduced into new tires, setting in motion a truly circular system of sustainability.
The Technology
Through a series of test production runs, Prism and Sherwood worked closely to refine and perfect the extruded TPE sheets for pilot customers. Sherwood’s incorporation of Prism’s Ancora polymer — a high-performance thermoplastic elastomer made with a high percentage of recycled materials derived from ELTs — into their process marks a significant advancement. The result? A sustainable solution that effectively meets the automotive industry’s demands for durability and performance.
These TPEs can be used both inside and outside vehicles, where durability and performance are crucial. Prism’s TPEs are engineered to meet the rigorous requirements of these automotive, truck and trailer components, ensuring long-lasting performance in critical areas of the vehicle.
Traditionally, recycled materials have been perceived as inferior or less reliable than virgin materials, especially in high-performance environments. However, the result of this collaboration challenges that notion, proving that sustainability does not have to come at the expense of quality. It demonstrates that through innovation and iteration, recycled materials can match the performance of new, non-recycled alternatives. Converting old tires into superior engineered TPE material not only reduces waste but also helps manufacturers meet their sustainability goals.
Turning Sustainability Into a Viable Reality
In 2024 alone, Sherwood produced more than 7.5 million square feet of extruded rubber sheets across four production lines. Thanks to positive customer feedback and successful trials, the company is now ready to scale up for full commercialization. To support anticipated growth, Sherwood has also secured a new extruder dedicated to producing sustainable rubber sheets that incorporates Prism’s TPEs.
The advantage is undeniable — these materials stand on par with virgin materials while also pushing sustainability further down the road. By reducing reliance on new, non-recycled resources this marks a major step forward, allowing the automotive industry to integrate high levels of recycled content without compromising product quality. As the demand for sustainable products continues to rise, the result of this collaboration stands out as one of the few viable solutions in a market that has long struggled to meet this need.
