Perpetuus GNP Masterbatch Cuts Truck Tyre Mixing Time and Energy Usage

SOUTH WALES, UNITED KINGDOM, October 22, 2026 /CourierPR/ -- Perpetuus Advanced Materials has announced significant advancements in the tyre manufacturing process, reducing mixing time and energy consumption. According to an industrial assessment, the company’s surface-engineered graphene nanoplatelet (GNP) masterbatch can cut truck tyre mixing time by 21% and reduce mixing energy by 45%, eliminating two mixing stages in the process.

The assessment, based on truck and bus radial (TBR) tyre production, demonstrated that the Perpetuus masterbatch can save about 165 kWh per tonne of compound. This translates to substantial financial and operational benefits for tyre manufacturers. For a reference mixing line producing 10,000 tonnes of compound annually, Perpetuus estimates direct annual process savings of approximately US$240,000. These savings come from reduced electricity costs, carbon black loss, and manpower requirements.

Specifically, the savings break down as follows: about $165,000 in electricity at $0.10 per kWh, $45,000 in carbon black loss, and $30,000 in manpower. The carbon black estimate assumes 30% carbon black in the compound, 1% fly loss avoided, and $1.50 per kg. These savings can be even more significant for manufacturers in regions with higher electricity tariffs. At $0.20 per kWh, the annual electricity saving would be worth about $330,000.

The Perpetuus GNP masterbatch supplies approximately 90-95% by weight of the relevant compound, including natural rubber, carbon black, and GNPs. This reduces the complexity of the mixing process, freeing up capacity on existing production lines. On the same line, the time saved would free enough mixer capacity for about 2,000 more tonnes of compound a year, or approximately 40,000 more TBR tyres at 50 kg of compound per tyre. At an illustrative value of $200 per tyre, this could support up to $8 million a year in additional gross tyre production value.

The company sees the largest opportunity in the capacity released, which can support more compound production from the same installed mixing assets or defer additional capital expenditure. This is particularly relevant in India, one of the world’s largest and most competitive tyre manufacturing markets. The financial value of the energy reduction will rise proportionately for manufacturers paying higher electricity tariffs.

Perpetuus will now work with tyre manufacturers to repeat and validate these results on their own formulations and production equipment under agreed test and confidentiality protocols. The company invites tyre manufacturers in India and internationally to evaluate the Perpetuus masterbatch using their own compounds, production equipment, and operating benchmarks to judge the results for themselves.