Continental has developed a concept tire containing around 43% recycled materials as part of the EU-funded ZEvRA project, which focuses on circularity in electric vehicles. ZEvRA stands for “Zero Emission Electric Vehicles Enabled by Harmonized Circularity” and brings together 28 partners, with Continental participating as the only tire manufacturer in the consortium. The concept tire includes recycled tall oil, steel, rubber from end-of-life tires and polyester fibers made from recycled PET bottles. Continental said the development highlights what is technically possible today while also showing that industrial-scale use of recycled materials requires reliable regulatory frameworks, sufficient supply of high-quality recycled raw materials and scalable recycling technologies. The tire also achieved the highest rating for the EU rolling resistance label, demonstrating the company’s aim to combine sustainability with performance.

ZEvRA project focuses on circular electric vehicles

The EU-funded ZEvRA project is designed to optimize the circular economy of electric vehicles across the value chain. The two-year project is scheduled to conclude in 2026 and includes 28 partners. Continental said its role as the only tire manufacturer in the project gives it an opportunity to demonstrate how tire materials can contribute to wider vehicle circularity.

Concept tire uses several recycled material streams

The ZEvRA concept tire consists of around 43% recycled materials. Continental said these include recycled tall oil, steel, rubber from end-of-life tires and polyester fibers produced from recycled PET bottles.

The company also uses pyrolysis-related technologies to recover materials such as recovered carbon black from end-of-life tires. Continental said recovered carbon black has been used at its Korbach site in all newly produced solid rubber tires since 2023, primarily for forklift truck applications.

Recovered carbon black supports tire circularity

Recovered carbon black is one of the recycling solutions highlighted by Continental as already being used effectively. The material can help replace virgin carbon black in selected applications when quality, consistency and performance requirements are met.

For the tire recycling sector, rCB is an important pathway for increasing the value of end-of-life tire processing. Its development is closely linked to tire pyrolysis, material recovery and efforts to return tire-derived materials to industrial production.

Alternative silica made from recycled sand

Continental said the project also uses sand residues, such as foundry sand, in a recycling process to produce an alternative silica variant. Silica is an important reinforcing filler in tire compounds, especially where rolling resistance and wet grip performance are critical.

Using recycled inputs for filler materials can help keep resources in circulation and reduce demand for primary raw materials, supporting broader circular economy objectives in tire manufacturing.

Tire performance remains central

Continental emphasized that tires are complex technical products made from many high-performance materials that must be precisely balanced for safety, efficiency and durability. The company said incorporating a high share of recycled materials into such a safety-critical product while maintaining performance standards is a significant development.

The ZEvRA concept tire achieved the highest EU rolling resistance label rating. Continental said this shows that sustainability and performance can be compatible when recycled materials are properly developed and integrated.

Regulatory clarity needed for industrial scale-up

Dr. Andreas Topp, Head of Platform Development and Industrialization for passenger-car tires at Continental, said circular materials can help save resources and energy while reducing greenhouse gas emissions. He said the concept tire demonstrates what is technically possible today and can act as a catalyst for future innovation.

Topp also said technological progress can achieve full impact only when reliable and aligned frameworks provide planning certainty and support market ramp-up. Continental called for standard European definitions for recycled materials, clear criteria for when processed substances qualify as recycled raw materials, technological openness and further development of recycling infrastructure.

Supply chains and reporting also highlighted

Continental said resilient supply chains and internationally coordinated procedures for material flow allocation are important for broader use of recycled materials. Jorge Almeida, Head of Sustainability for Continental’s Tires group sector, said innovative recycling technologies need to be established at industrial scale and closed material flows must be created.

Almeida also said a standardized approach to calculation and reporting should be developed through dialogue between policymakers and stakeholders. He said any regulation should be simple, transparent and easy for consumers to understand.

More than 80% from recycled, renewable or certified sources

In addition to the roughly 43% recycled material content, the concept tire contains around 13% renewable raw materials and a further 25% mass-balance-certified materials. Together, Continental said more than 80% of the materials used in the ZEvRA concept tire come from recycled, renewable or mass-balance-certified sources.

Continental has been increasing the share of recycled and renewable materials in its tires. Since 2022, polyester casings made from recycled PET bottles have been used in selected passenger-car tires. In 2023, the company launched the UltraContact NXT production tire with up to 65% renewable, recycled and mass-balance-certified materials. Continental said the share of purchased renewable and recycled production materials in its tire portfolio reached 28% in 2025 and is intended to rise to at least 40% by 2030.

Press release source: Continental.