Perpetuus Advanced Materials has announced its first nano-engineered graphene-enhanced masterbatch compounds, tailored specifically for commercial, passenger, and industrial tire manufacturing. The initial release will soon expand to include polymer and elastomer masterbatches for use in industries such as hoses, seals, gaskets, V-belts, and conveyor belts.
By utilizing its environmentally friendly plasma treatment process, Perpetuus incorporates its advanced graphene into the masterbatch. This innovation is now available in industrial quantities, enabling tire manufacturers to integrate this breakthrough material into their existing production workflows.
The Perpetuus plasma process is uniquely environmentally safe, avoiding traditional wet acid, solvent, or surfactant treatments. This eliminates the need for energy-intensive drying stages and the disposal of post-production toxic waste. The dry plasma process significantly reduces energy consumption and aligns with Perpetuus’s dedication to sustainable, large-scale production.
The graphene masterbatch combines Perpetuus’s surface-engineered, plasma-treated graphene with natural rubber, carbon black, and other standard industry fillers, forming an advanced base material for tires and other rubber products.
Integrating this masterbatch into tire tread formulations offers remarkable performance improvements. Road tests have reportedly shown up to a 40% reduction in tire tread wear, enhanced braking, and improved handling, particularly in wet conditions. The superior dispersion and bonding of ingredients also minimize PM2.5 tire wear particles, a major contributor to air pollution, resulting in cleaner air quality.
John Buckland, CEO of Perpetuus Advanced Materials, said: “In the 20 years since graphene was discovered, almost every use for the material has been developed in laboratories around the world, however the lack of affordable high quality graphenes has prevented known commercial applications coming to market. Our plasma treated surface engineered graphenes solve this problem which are now available in commercial quantities to all sectors of industry.”
This innovation supports key regulatory initiatives, including the UK’s Clean Air Act 2022 and the EU Clean Air Policy, which aim to ensure citizens’ right to clean air. Additionally, reducing tire-derived particles and chemicals in road runoff offers potential benefits for aquatic ecosystems and urban water quality.
Perpetuus’s masterbatch comprises over 90% of the essential ‘dry mix’ components required for tire production and is delivered in convenient pre-mixed 25 kg blocks. This eliminates the need for plasticizers, process oils, compatibilizers, and resins—many of which are toxic and have been banned in several EU countries. Furthermore, this innovation improves factory air quality by reducing airborne ‘fly material’, enhancing safety and occupational health.
Looking ahead, Perpetuus Advanced Materials plans to launch its GRAPHENE C6 range of motorcycle and PCT tires in 2026. Additional graphene masterbatch formulations, including Styrene Butadiene Rubber, will also be introduced for passenger car tires. The flexibility of the masterbatch production process positions it as a sustainable solution for various rubber applications across multiple industries.
