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Fornnax Unveils World’s Biggest New Product Development Centre and Demo Plant

Ewan Scott
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Fornnax Unveils World’s Biggest New Product Development Centre and Demo Plant

In a monumental step toward advancing global recycling technology, Fornnax Technology has unveiled one of the world’s largest New Product Development (NPD) centre and demonstration plants, covering more than 12 acres of land

 This groundbreaking facility represents a major milestone in Fornnax’s long-term vision to become a global leader in recycling solutions by 2030.

This state-of-the-art facility will serve as a hub for new product development, specifically designed to cater to evolving application demands. Fornnax also plans to use the centre to upgrade its existing range of shredders and granulators by increasing their capacity, improving energy efficiency, and reducing downtime. These enhancements will not only boost equipment availability, ensuring operational readiness for up to 20 hours per day, but also validate newly developed equipment for as long as 3,000–15,000 hours based on the product and under real-world conditions.

Commenting on this significant achievement, Jignesh Kundariya, Director and CEO of Fornnax Technology, shared his insights on the importance of in-house development capabilities; “Innovation in product development is the key to success of becoming a global leader. With this new facility, we now have the speed, flexibility, and controlled environment to design, test, and validate new technologies in just 6 to 8 months something that would take significantly 4-5 years at a customer site. We aim to validate each machine as per global standards, rigorously testing every critical part and assembly under Engineering Build (EB) and Manufacturing Build (MB) protocols. We’ve also developed an endurance test setup, giving us a clear edge in staying ahead of industry demands and delivering solutions that are future-ready.”

The new plant is powered by a robust New Product Development framework based on a Gate Review Process that ensures precision, cross-functional input, and performance at every stage, here’s the brief overview:

Gate 0: Market Research & Ideation

The initial process is led by Sales & Marketing Team to capture the voice of the customer, analyse the product demand and prepares a tentative concept and budget for management evaluation and strategic alignment in the next development phase.

Gate 1: Strategic Review

The Leadership Team manages this stage, evaluating market growth, potential, and conducting a competitive cost analysis. This review ensures strategic alignment, laying the groundwork for the project’s economic viability and market position before proceeding.

Gate 2: Design Conceptualization

The Design Team takes ownership of this gate, developing detailed CAD designs, the Bill of Materials (BoM), and integrating features. Sequential reviews are then conducted by the Manufacturing Team for manufacturability, the Service Team for ease of maintenance, and the Safety Committee for comprehensive safety validation.

Gate 3: Final Design Approval

This stage incorporates all feedback and addresses open points from prior reviews, ensuring a refined design. The primary objective is to guarantee the machine is easy to manufacture, simple to operate, and straightforward to service, securing comprehensive approval before the physical build begins.

Gate 4: Engineered Build (EB) – Validation Phase

A functional prototype is constructed during this phase, undergoing 6–8 months of rigorous validation and endurance testing. This critical period ensures the design performs as intended and is durable under demanding, real-world conditions, confirming its readiness for further development.

Gate 5: Manufacturing Build (MB) – Production Readiness

In this final stage, the design is meticulously optimized for efficient mass manufacturing. Once completed, the equipment is officially declared ready for large-scale production and commercial scaling, marking the transition from development to market readiness.

Tailored Testing and Customer Demonstration

One of the key features of this new centre is its open-door policy for customers looking to validate their materials and applications. Clients who are uncertain about which equipment suits their specific shredding or recycling needs can now bring their material to the NPD centre. Here, they can observe performance across multiple machines and operating conditions.

This approach provides a risk-free, real-world testing environment that empowers customers to make informed investment decisions regardless of the application type or material. Also, upgrade their existing technology to the latest advancements to stay ahead of the curve.

Comprehensive Support for Sales and After-Sales Services

The new facility also houses an OEM training centre, which will be instrumental in developing a skilled operators and maintenance engineers for existing and future customers. Regular sessions will be conducted for the Fornnax sales and after-sales team, as well as sales partners across regions, to ensure everyone is up to date with the latest advancements and operational procedures.

This comprehensive training approach not only enhances the customer experience but also ensures that the equipment performs at optimal efficiency throughout its lifecycle.

Pioneering Future Recycling Solutions

Beyond just validating known materials, the centre will support in-depth research for emerging recycling applications such as E-waste, Cables, Fridges, Aluminium, or Auto Shredder Residue (ASR), Lithium-Ion Batteries and other miscellaneous applications.

In cases some where customers bring new or unfamiliar materials, Fornnax’s highly qualified engineering and R&D teams will conduct feasibility studies, performance tests, and design tailored solutions accordingly.

This agility in responding to client needs will further reinforce Fornnax’s position as a solutions-driven technology provider, capable of tackling even the most complex recycling challenges.

Shedding more light on this, Kundaria says; “Our goal is to empower customers with clarity and confidence before they invest. This facility allows them to test their own materials under real-world conditions, compare machines, and see results firsthand. It’s not just about selling equipment; it’s about building trust through transparency and delivering solutions that truly work for their unique needs.”

With over a decade of expertise and dominance in India’s tyre recycling market, coupled with a significant global footprint spanning Australia, Europe, the GCC, Asia, and beyond, Fornnax’s international-grade equipment has redefined the industry legacy.

By becoming a champion in manufacturing high-capacity recycling equipment, such as Primary and Secondary Shredders, Granulators, and Separation Systems, Fornnax has established itself as a leader in the field.

Building on this success, Fornnax is poised for further growth, with a strong focus on Tyre, Municipal Solid Waste, E-waste, Cable, and Aluminium recycling. The company plans to scale its offerings, capture a larger share of the global market, and enhance its revenue streams through these high-demand verticals.

The advanced NPD centre and demo plant will not only increase Fornnax’s revenue from its recycling operations but also is a testament to Fornnax’s commitment to progress, sustainability, and customer-centric innovation.

By integrating R&D, training, testing, and customer engagement under one roof, Fornnax is laying the groundwork for the next generation of recycling technologies.

Fornnax extends an invitation to industry partners, customers, and stakeholders to visit the demo plant and experience firsthand the scale and potential of a facility that will undoubtedly set a global benchmark in recycling innovation.

Linda Mitchell on the Science and Innovation Shaping Australia’s Tyre Recycling Future

Richard Wilson
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Linda Mitchell on the Science and Innovation Shaping Australia’s Tyre Recycling Future

Episode 8 of TRR Video Insights is available and we speak with Linda Mitchell, Science and Innovation Manager for Tyre Stewardship Australia and winner of the 2025 Young Professional of the Year award.

TSA’s Science and Innovation Manager Explores the Research Paving the Way for Progress

Linda discusses her excitement about tech-based processing and the potential for using Australia’s vast mining tyre resources in innovative ways. She emphasises the need for consistency, standardisation, and understanding the value of different tyre materials to overcome technical barriers and grow the market.


Chapters:

0:00 Introduction to TRR Video Insights & Linda Mitchell

1:10 Tech-Based Processing & Mining Tyre Potential

1:47 Developing Consistent Materials & Understanding Value

2:49 Overcoming Technical Barriers: Standards & Specifications

3:56 TSA Research Projects: Data Sheets & Chemical Analysis

5:46 Conclusion

Recent Valorpneu ELT Management Projects and Initiatives in Portugal

Naida Jahić
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Recent Valorpneu ELT Management Projects and Initiatives in Portugal

Portugal’s Valorpneu has recently completed several new projects focusing on ELT management, sustainability, and raising awareness

One of the projects includes Greenfest Braga and Valorpneu joining forces from 26 to 28 September in Praça da República, offering a broad program that focuses on sustainability for families and the general public. Activities included talks, workshops, showcookings, music and an eco-market. During the event, Valorpneu promoted environmental awareness, supporting the programme’s commitment to sustainable practices.

Valorpneu was also a part of ACAP’s “Agricultural Mechanisation – Strategies for a Sector in Transformation” forum, held on 9 September at CNEMA Santarém. The event examined key challenges in the sector, including technological innovation, automation, the ageing machinery fleet and business structure, and the need for targeted regulation and competitiveness measures.

On 21 September in Pegões, the 20th edition of the Yamaha Trophy took place, attracting 336 participants. During the event, Valorpneu had a chance to promote its “Na Pista pelo Ambiente” initiative, raising public awareness about proper tyre care. Valorpneo also promoted its initiatives at Autódromo do Algarve during the European Le Mans Series on 17–18 October and the final round of the 20th Yamaha Trophy on 18 October in Torres Verdas.

Another one of its projects was the 23rd Valorpneu Network Meeting, which took place from 10 to 11 November in Madeira. The event gathered network operators, partners, collaborators and stakeholders in Portugal to discuss sector-relevant issues and exchange experiences, challenges and opportunities.

Together with Jardim d’Areias, Valorpneu also organised children’s activities in Lisbon as part of the Triennale’s youth programme, introducing young participants to the world of recycling and demonstrating how used tyres can be creatively incorporated into play.

In November, Valorpneu also released a study highlighting the growing importance of RFID tags in tyre management, noting their adoption by major manufacturers in recent years. According to the Valorpneu study, RFID improves inventory control, real-time access to technical specifications and overall decision-making across the supply chain, offering a versatile solution that enhances tracking and management of both new and used tyres.

First Porous Lane Residential Parking Bay in New Zealand

Naida Jahić
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First Porous Lane Residential Parking Bay in New Zealand

Watersmart project-managed the site with the first Grey Porous Lane coating on a residential parking bay in New Zealand

According to Watersmart, the client was redeveloping their property and wanted to create additional parking without compromising stormwater management or increasing impermeable surface area. Considering its the area with the steep slope and is close to landscaped areas, the client wanted a surface that was durable, permeable and low-maintenance, with the ability to handle vehicle load while preventing flooding and water pooling issues.

Watersmart, a distributor of Porous Lane in New Zealand, project-managed the site and provided technical consultation throughout the process. The team used Porous Lane Traffic Mix in Grey (55m²) to achieve performance and an aesthetic match with the existing concrete driveway. Watersmart also guided the main civil contractor on base preparation, including one compacted layer of GAP65, and two layers (100mm each) of GAP20 to ensure stability and trafficability.

Watersmart is the only provider on the market offering a permeable surfacing system with permeability exceeding international standards up to 8-10 times, contributing to long-term performance and sustainability outcomes. The use of Porous Lane helped with effective stormwater management, reducing runoff and filtering pollutants before they reach the road network. It also provided surface strength — reducing the risk of ravelling and extending the lifespan of the installation.

Porous Lane permeable driveways are designed to help with stormwater management by allowing water to infiltrate through the surface, which reduces runoff and supports on-site detention. Stormwater filtering removes pollutants, and captured water can be redirected to tanks, garden areas or the stormwater network. Each square metre incorporates the equivalent of three Australian waste tyres, with a design life of 25 years.

Porous Lane Reimagining Permeable Pavements with End-of-Life Tyres

Richard Wilson
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Porous Lane Reimagining Permeable Pavements with End-of-Life Tyres

In our seventh episode of TRR Video Insights, we speak with Bradley Camgoz Posselt, Market Development Director for Porous Lane. Bradley discusses the significant role permeable pavements play in urban infrastructure, turning rainwater from a waste product into a resource that supports urban greenery, reduces heat island effects, and enhances sustainability.

Porous Lane Transforming Tyre Waste into Circular Economy Solution

Bradley explains how Porous Lane‘s technology transforms post-consumer tyres into a high-performance solution for flooding and runoff, contributing to the circular economy.

Chapters:

0:00 Introduction to TRR Video Insights & Bradley Camgoz Posselt

1:03 The Importance of Permeable Pavements for Cities

1:41 Turning End-of-Life Tyres into Sustainability Solutions

2:15 Creating Demand for Recovered Materials

3:02 Landmark Projects: New Zealand & Australia

4:17 Conclusion

When is a Tyre Waste?

Ewan Scott
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When is a Tyre Waste?

Recently, Tyre and Rubber Recycling was advised of a possible loophole regarding waste tyres, after a short investigation we have a clarification from the Environment Agency

It had been reported to us by a permitted recycler than an Environment Agency inspector was unclear on when a tyre was a waste, and who could declare it a waste.

The EA inspector argued that since the tyres might be resold as part worn, or as casings for retreading, they were not waste. His argument ran that the retailer was not in a position to classify the tyres, therefore they may not be waste when they left his premises, so they could be moved by anyone with a van to a third party where they may or may not be classified as waste.

This idea ran contrary to the understanding of the law by the Tyre Recovery Association, the NTDA, and most players in the market. It seemed incredulous that an EA inspector might have this idea, so Tyre and Rubber Recycling asked the Environment Agency for a clarification.

The initial response was probably an AI generated answer, as it covered all the bases. It did, however state; “Waste is defined as any substance or object which the holder discards, intends to discard or is required to discard.” Which is pretty clear, if you are not going to use a tyre, it is waste (that gives rise to other questions – such as if a retailer gives tyres to a third party to build an rammed earth retaining wall, are those tyres waste?)

However, the same response has a link to a document – Check if your material is waste.

The guidance on waste has a list of factors impacting on waste criteria, which we will not list here, but it does say this; “All the factors must be considered. It’s not possible to decide if something has been discarded based on a single factor, unless the law specifically says that it must be disposed of.”

This is possibly where the idea that a tyre might not be waste at the point of removal came from.

Tyre and Rubber Recycling went back to the EA seeking a further clarification and gave the reason why we were asking the question. The reply came back with the clear wording; “A tyre removed by a garage and left with the garage is a waste.  Once retreaded and marked accordingly or inspected as a part worn and marked accordingly, it ceases to become a waste.”

There is no ambiguity in the EA interpretation, a tyre removed from a vehicle is deemed waste until it is considered to meet the end-of-waste criteria.

As a result of the matter being raised, the EA is advising operational staff accordingly.

All players in the UK tyre sector can be clear, the tyres removed from vehicles are waste. There is no abdicating responsibility by saying they MAY be retreaded or resold as part-worn. They must be treated as waste and handled accordingly.

Rubberised Asphalt at Scale: Grant Bosma’s Perspective on NZ’s Future Roads

Richard Wilson
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Rubberised Asphalt at Scale: Grant Bosma’s Perspective on NZ’s Future Roads

Episode 6 of our TRR Video Insights from the Round Trip: Tyre Recycling and Conveyor Belt Summit concerns rubberised asphalt, as we talk to Grant Bosma, formerly Principal Surface Engineer at the New Zealand Transport Agency.

Can Rubberised Asphalt Transform New Zealand’s Roads? Grant Bosma Thinks So

Grant discusses his hopes for upscaling the use of rubber in roads in New Zealand and the challenges the product faces in achieving this goal. He highlights the major benefits of rubberised asphalt, such as improved longevity, waterproofing, and cracking resistance, describing the simultaneous reduction of waste tyre stockpiles as a “win-win”.

Chapters:


0:00 Introduction to TRR Video Insights & Grant Bosma

0:54 Hopes for Upscaling Rubber in NZ Roads

1:09 Benefits of Rubberized Asphalt: A Win-Win

1:53 Status of Trials & Need for Infrastructure

2:38 Challenges: Cost & The “Chicken and Egg” Scenario

3:10 The Role of Public Policy & Roading Authorities

3:40 Conclusion

Daniele De Maria from Proge Plast Joins the Tyre Recycling Podcast in Melbourne

Richard Wilson
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Daniele De Maria from Proge Plast Joins the Tyre Recycling Podcast in Melbourne

Daniele De Maria from Proge Plast Engineering joined The Tyre Recycling Podcast for Episode 82, reporting directly from the Round Trip Tyre and Conveyor Belt Recycling Summit in Melbourne.

Proge Plast Engineering Feature in Episode 82 of The Tyre Recycling Podcast

In this episode, Daniele outlines Proge Plast’s innovative manufacturing technologies that transform recycled rubber crumbs into high-performance products for the sports and construction sectors. He details the company’s unique extrusion and injection moulding processes and explains their strategy for global expansion through local partnerships, ensuring that manufacturing solutions remain regional to effectively close the loop.

Chapters:

0:00 Introduction to Episode #82 from the Round Trip Summit

2:15 Daniele De Maria’s Objectives for the Event

3:10 Overview of Proge Plast Engineering

4:53 Deep Dive: Rubber Granular Extruder Technology

6:14 Innovations in Injection Molding

7:19 Handling Contaminants & Production Outputs

8:51 The Importance of Regional Manufacturing Models

10:54 Strategy for Partnerships and Joint Ventures

11:59 Proge Plast’s Global Footprint & Market Focus

16:09 Mechanical vs. Chemical Recycling: Proge Plast’s Stance

17:35 Re_soft: Shock Pads and Product Development

19:56 Achieving 70-80% Recycled Content

22:00 Future Applications: Infrastructure, Mining & Sound Insulation

23:22 Conclusion to Episode #82

Major Recognition for Adele Rose

Ewan Scott
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Major Recognition for Adele Rose

Huge congratulations to 3R’s CEO, Adele Rose — winner of the 2025 Sustainable Business Awards’ Transformational Leadership Award!

Adele Rose has been celebrated by the Sustainable Business Network for her outstanding leadership at 3R Group Ltd and her influence beyond the organisation. This accolade is a testament to both her personal vision and the pivotal role 3R plays in developing a regenerative, circular economy for Aotearoa New Zealand.

Nearly Two Decades of Impact

Rose has steered 3R for almost twenty years, championing and scaling some of the most significant product stewardship programmes across New Zealand. These include Tyrewise, Resene’s PaintWise, the Battery Industry Group (B.I.G.), and Agrecovery, which 3R managed until 2017 before passing it on to support its next stage of growth. Throughout her tenure, Rose has skilfully navigated complex policy, industry, and community environments with clarity and purpose.

Under Rose’s leadership, 3R has revolutionised some of New Zealand’s most challenging waste streams, creating robust and trusted systems. She has helped transform the founding vision of a “world without waste” into measurable, practical actions that increase in impact each year.

Influence Beyond 3R

Rose’s influence reaches far beyond the company. As Chair of the Āmiomio Aotearoa Advisory Group, she has played a crucial role in advancing systems-level thinking around regeneration, resource flows, and policy for long-term circularity in Aotearoa New Zealand.

Key Achievements with Adele at the Helm

  • Tyrewise: New Zealand’s first regulated tyre stewardship scheme now boasts over 5,000 partners and has collected millions of end-of-life tyres.
  • Paint Takeback Programmes: Partnerships with Dulux and Wattyl provide nationwide recycling opportunities for paint and packaging.
  • Stewardship Projects: Through these initiatives, 3R is helping to prevent legacy chemicals from harming communities and ecosystems.

Rose’s vision extends well beyond reducing waste; she is dedicated to regeneration. Her leadership is about designing systems that place circularity and wellbeing at their core. Rose is not simply creating programmes—she is nurturing a new way for Aotearoa New Zealand to approach resources, responsibility, and our shared future.

Continental Expands Use of Recycled PET, Recycled Steel, and COKOON in its Tyres

Ewan Scott
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Continental Expands Use of Recycled PET, Recycled Steel, and COKOON in its Tyres

Continental is further advancing its commitment to sustainability by integrating renewable and recycled materials into its tyre production processes

Dedicated to the principles of the circular economy, the company is also motivating its suppliers to innovate and provide increasingly sustainable materials for tyre manufacturing. In 2024, renewable and recycled materials made up an average of 26% of Continental’s tyre production. The company has set an ambitious target to raise this figure to at least 40% within the next five years.

Expanding the Use of Sustainable Reinforcement Materials

One of Continental’s primary goals is to identify and implement more sustainable alternatives to traditional raw materials used to reinforce tires. These reinforcement materials are crucial for ensuring dimensional stability and maintaining tyre performance throughout their lifespan. In passenger car tires, reinforcement materials—mainly steel and textiles—constitute approximately 18% of the total materials used, and this proportion is even higher in commercial or specialty vehicle tires. To address this, Continental is increasing its use of recycled steel and polyester yarns made from recycled PET bottles. Additionally, the company is incorporating more sustainable manufacturing methods, such as COKOON bonding technology, in its tyre production. Innovative alternatives are also being explored across all raw material groups, including synthetic rubber derived from used cooking oil, resins from bio-based waste, and silica sourced from rice husk ash.

Continetal’s matthias Haufe

Matthias Haufe, Director of Materials Development and Industrialisation at Continental Tires, explains, “We are not reinventing the wheel, but the tyre, with more sustainable materials and more environmentally friendly production processes. It’s not just about the rubber itself. We also focus on the materials that shape the rubber and make tyres stable and safe. Recycled steel and polyester yarn made from recycled PET bottles are important for more sustainable tyre production. Our goal is to use at least 40% renewable and recycled materials in our tires within five years. Every alternative material brings us a significant step closer to this goal.”

Recycled Reinforcement: Advancing the Use of Sustainable Steel and Polyester Yarn

Steel and polyester play pivotal roles in ensuring tyre performance and safety. Steel is present in several tyre components. In commercial and specialty vehicle tires, for example, high-strength steel cords are used to reinforce the casing, delivering exceptional durability, high load capacity, and enabling retreading. Steel is also utilised as reinforcing wires in the bead core of passenger car, commercial, and specialty vehicle tyres, running along the circumferential edges of the rubber bead to securely attach the tyre to the rim. Furthermore, steel cords are found in the tread layers of various tyre types, where they enhance puncture resistance, tread stability, and comfort, while also reducing noise, boosting fuel efficiency, and extending the range for both combustion and electric vehicles. Continental is increasingly using recycled steel in its tyre portfolio, ensuring that this shift does not compromise safety or performance.

Alongside steel, Continental is emphasising sustainability in its use of polyester textile materials. Polyester yarn made from recycled PET bottles is used to reinforce passenger car tyre casings, improving the stability of the rubber bead. Depending on the tyre size, the casing material for a single tyre can be made from up to 15 recycled PET bottles. This polyester yarn is woven into a robust textile cord that absorbs internal tyre pressure forces and maintains dimensional stability, even under high loads and temperatures. In collaboration with textile manufacturer OTIZ, Continental has developed ContiRe.Tex technology, which transforms recycled PET bottles into high-performance polyester yarn suitable for tyre casings. This process, verified by SGS, a leading inspection and certification company, reduces CO₂ emissions by about 28% in PET cord fabric for tires compared to fossil fuel-based alternatives. Continental already uses this innovative polyester yarn in standard passenger car tyres, such as the UltraContact NXT. The recycled PET bottles used in this process are sourced exclusively from regions without closed-loop bottle recycling systems.

Recycled PET textiles from KORDSA

COKOON: A Smarter, More Sustainable Bonding Technology

“When it comes to sustainability, it’s not just about the materials we switch to, but also those we deliberately forgo,” states Haufe. In collaboration with Kordsa, a global leader in textile reinforcement materials, Continental has developed COKOON, an environmentally friendly bonding standard for rubber/textile compounds. This technology enables the bonding of textile reinforcement materials to rubber compounds without the use of resorcinol or formaldehyde in the textile dip bath. To foster industry-wide sustainability, Continental and Kordsa have made COKOON available as an open-source, royalty-free solution for all tyre manufacturers and their suppliers. Interested companies are encouraged to request samples and adopt this innovative approach.

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