Sustainability in elastomers

Elastomers are indispensable in modern industry – whether in seals, vibration elements, hoses or insulation. They are found in almost every technical product, from automotive engineering and mechanical engineering to medical technology. But while their elasticity and resistance make them indispensable materials, their production and disposal pose considerable ecological challenges for industry. Conventional elastomers are mostly based on petroleum-based raw materials, are energy-intensive in production and difficult to recycle.

Increasing demands for sustainability, resource efficiency and climate protection are therefore fundamentally changing material development. Bio-elastomers, recycling processes and digital process optimisation are now the key topics of sustainable rubber technology.

Sustainability aspects in elastomer production

• Energy efficiency and emission reduction: Modern plants with heat recovery, lower vulcanisation temperatures, use of renewable energies.
• Resource conservation: Use of recyclates, bio-based plasticisers, mineral substitutes and sustainable fillers.
• Optimised raw material origin: Preference for local supply chains, certified sources and low-CO₂ transport.
• Chemical and additive management: Reduction of toxic ingredients, replacement with environmentally friendly alternatives.
• Water and waste management: Closed loops, filtration, reuse of process water, minimisation of residual materials.
• Process optimisation through digitalisation: Sensors, AI and simulations to reduce rejects and energy consumption.
• Sustainable packaging and logistics systems: Use of recyclable packaging and efficient transport solutions.

Recycling of elastomers: processes, limits and advances

The recycling of vulcanised elastomers is technically demanding, as the three-dimensionally cross-linked molecular structure cannot simply be melted down. Nevertheless, there are several processes that give rubber products a second life. In mechanical recycling, used parts are shredded, granulated and incorporated as rubber powder into new mixtures or used for applications such as sports floors and road surfaces. Although the material properties are slightly reduced, this process makes an important contribution to resource conservation.

A further advance is devulcanisation, in which the sulphur bridges in the polymer network are selectively cleaved. Chemical, thermal or mechanical processes – for example by microwaves or ultrasound – make it possible to partially regenerate the material. The reprocessed elastomer obtained in this way can be processed back into new products to a limited extent.

In addition, chemical recycling is gaining in importance. Here, elastomers are broken down into their basic chemical building blocks with the help of solvents, enzymes or catalysts. These can then be re-polymerised or used as starting materials for other products. The goal is a closed loop in which raw materials are reused as completely as possible.

If material recycling is not possible, thermal recovery remains an option. Due to their high calorific value, elastomers are well suited for energy recovery in modern incineration plants. Under controlled conditions, heat and energy can be recovered while modern filter systems minimise emissions.

These developments show that recycling in the elastomer industry is complex but increasingly feasible. With every advance, the vision of fully circular elastomer production comes closer.

Bio-elastomers: sustainable materials with a future

While recycling of plastics mainly concerns the end of the life cycle, bio-elastomers start at the beginning – with the raw material base. They use renewable sources such as sugar cane, castor oil or starch to replace synthetic polymers.

Natural rubber – the classic in transition

Natural rubber (NR) is bio-based, but not automatically sustainable. Cultivation in tropical regions can lead to deforestation, soil erosion and loss of biodiversity. In addition, plantation farming often competes with food production. To meet these challenges, manufacturers are increasingly relying on sustainable cultivation methods, mixed crops and reforestation programmes.

Certified plantations, fair working conditions and transparent supply chains are therefore gaining in importance. FSC- or PEFC-certified natural rubbers are now regarded as the benchmark for responsible sourcing. The use of alternative plant sources such as dandelion rubber (Taraxacum kok-saghyz) is also coming into focus, as it grows in temperate climates and enables local, sustainable production.

Synthetic bio-elastomers from bio-based monomers

New developments such as bio-EPDM, bio-NBR or polyisoprene from sugar cane ethanol show that synthetic elastomers can also increasingly be produced in an environmentally friendly way. These materials have the same technical properties as their fossil counterparts, but offer a significantly better carbon footprint. Modern biotechnological processes enable the conversion of plant raw materials into monomers such as isoprene or butadiene, which are then polymerised into high-quality bio-elastomers.

This considerably reduces the CO₂ footprint of the entire production chain. Pilot projects in the automotive industry, in the consumer goods sector and in medical technology demonstrate their practical suitability. Developments in which waste materials such as wood residues or algae serve as raw material are particularly exciting – a further step towards a circular economy.

Life cycle assessment and compostability

Not every bio-based elastomer is automatically biodegradable. What is decisive is the life cycle assessment, which takes into account all phases from raw material extraction through use to disposal. Only if energy consumption, emissions and recyclability are in a balanced ratio does a genuine ecological advantage arise.

Research institutions are therefore working on degradable elastomers that decompose in an environmentally neutral way after use or can be returned to new products. Compostable elastomers based on PLA or polybutylene succinate (PBS) already show promising results – particularly for applications in the medical and packaging sector. The challenge is to combine biodegradability with the high technical requirements for tightness, elasticity and chemical resistance of plastics.

New developments such as bio-EPDM, bio-NBR or polyisoprene from sugar cane ethanol show that synthetic elastomers can also increasingly be produced in an environmentally friendly way. These materials have the same technical properties as their fossil counterparts, but offer a significantly better carbon footprint. Pilot projects in the automotive industry, in the consumer goods sector and in medical technology demonstrate their practical suitability.

New material developments and circular concepts

Material development today is closely linked to digitalisation and sustainability of plastics. Modern laboratories use AI, simulation and big data to develop new mixtures with targeted properties – resource-saving and recyclable. Combinations of bio-based and conventional elastomers enable tailored properties with a simultaneously reduced CO₂ footprint. Hybrid materials combine elasticity with electrical conductivity, self-healing or sensor technology and open up new application possibilities, for example in robotics or medical technology.

A central advance lies in the development of intelligent additives and self-healing systems. After damage, these materials can regenerate their structure independently through chemical reactions. This considerably extends service life, lowers resource consumption and reduces waste volumes. In addition, such systems promote circularity, as components have to be replaced less often.

A further aspect is the digital traceability of materials. So-called digital material passports allow origin, composition and recyclability to be documented without gaps. This creates transparency throughout the entire supply chain and facilitates targeted reuse at the end of a product's life. In combination with automated sorting systems and AI-supported analyses, closed loops are created in which elastomers are no longer regarded as waste but as a resource.

These new material developments show that sustainability and high technology are not contradictory. Rather, a new generation of intelligent elastomers is emerging that are functional, durable and fully circular – a decisive step towards a resource-conserving industry.

Comparison of selected sustainable elastomers

Material type	Raw material base	Recyclability	Biodegradability	Main applications	Sustainability advantage
Natural rubber (NR)	Plant-based (hevea, dandelion)	Limited	Partly	Tyres, seals, hoses	Renewable raw material, CO₂-neutral with sustainable cultivation
Bio-EPDM / Bio-NBR	Sugar cane, plant oils	High	No	Automotive, construction, industry	Reduced CO₂ footprint through bio-based monomers
Thermoplastic elastomers (TPE)	Fossil or bio-based	Very good	No	Profiles, cables, housings	Recyclable, energy-efficient processing
Compostable elastomers (PLA, PBS)	Bio-based	Low	High	Packaging, medical technology	Biodegradable, low disposal effort
Hybrid elastomers	Mixture of fossil & bio-based sources	Medium	No	Medical technology, robotics	Functionality with reduced environmental impact

Sustainability in application: durability and ease of maintenance

The service life of an elastomer product is a central factor in its environmental impact, because every additional spare part produced means new raw material and energy input. A durable sealing element saves energy, material and maintenance costs over many years. Correct dimensioning, protection against UV radiation, optimised geometries and suitable additives can significantly extend service life. Correct storage and maintenance also contribute considerably to elastomers retaining their function over many years. In sensitive sectors such as medical technology, food processing or the chemical industry, materials that are more resistant to ageing, ozone, temperature and chemical influences are increasingly used. This not only reduces operational failures but also conserves resources.

In addition, the topic of repairability is gaining in importance: seals or components with replaceable parts or regenerative coatings can be used multiple times. Self-healing materials enable virtually maintenance-free use over long periods and are an important building block of sustainable product design.

Economic and regulatory aspects

Sustainable elastomers have long ceased to be a purely environmental topic and are now a strategic competitive factor. Companies that switch to ecological materials and processes at an early stage secure advantages in tenders and customer relationships. Legal requirements such as the EU chemicals strategy, the REACH regulation, the European Green Deal and national climate targets are driving this development forward. Manufacturers increasingly have to provide evidence of material origin, energy consumption and recyclability. This leads to growing demand for certified, transparently documented elastomer products.

The switch also pays off economically: energy-efficient plants and recycling of production waste reduce costs in the long term. In addition, sustainable products improve brand perception and open up new markets – particularly in sectors that pay attention to environmental standards, such as construction, mobility and medical technology. Life cycle cost analysis is also becoming increasingly important, in which not only the purchase price but the entire effort over the service life is assessed.

Future prospects: circular economy as a guiding principle

The future of the elastomer industry lies in a consistent circular economy in which materials, data and energy flows are fully integrated. From raw material extraction to recycling, a closed material loop is created that avoids waste and keeps resources in the system. Future developments focus on fully regenerable elastomer systems that can be used an infinite number of times through chemical or enzymatic recycling. In addition, new partnerships between material manufacturers, mechanical engineering companies and research institutions will emerge in order to create standardised platforms for material exchange, take-back and certification.

A further future trend is the digital circular economy: AI, blockchain and material passports enable seamless traceability of every material. This makes it possible to decide in a targeted manner at the end of a product's life whether a component is regenerated, recycled or recovered for energy. In combination with renewable energy and automated production systems, the elastomer production of the future could operate almost emission-free.

Elastomers between innovation, responsibility and the future

Sustainability in elastomers means rethinking the entire life cycle – from the origin of raw materials through production and use to reuse in the loop. Advances in bio-elastomers, energy-efficient production, recycling and digital process control show that technical excellence and ecological responsibility are not opposites. The future belongs to intelligent, circular elastomers that combine functionality, durability and environmental awareness. Companies that actively shape this transformation benefit not only from a better environmental footprint but also from a stronger market position and long-term economic viability.

Innovation and responsibility thus become two sides of the same coin – and make elastomers one of the most exciting materials of tomorrow's sustainable industry.

FAQ

Which elastomers are particularly sustainable? Thermoplastic elastomers (TPE) and bio-based variants are regarded as particularly resource-saving, as they can be recycled or reprocessed.

How does devulcanisation work in detail? The sulphur bridges that stabilise the molecular network are chemically or thermally dissolved in order to make the material plastically processable again.

Are bio-based elastomers always better for the environment? Not necessarily. What is decisive is the overall balance: energy input, land use, transport routes and recyclability must be taken into account.

What role does digitalisation play in elastomer development? Digital material models and AI-supported simulations enable more precise control of formulations and processes – this saves time, resources and energy.

How can industry close loops more effectively? Through standardised take-back systems, cooperation along the value chain and the use of digital material passports, elastomers can in future be specifically returned to new products.