Applications of Solvay ZEOSIL 125 Precipitated Silica Powder for Rubber in Industrial Manufacturing

Solvay ZEOSIL 125 Precipitated Silica Powder serves as a functional performance filler in advanced rubber compounding across multiple high-demand sectors. As a direct manufacturer, we supply this silica to global clients for precision applications requiring defined reinforcement, abrasion resistance, and processing optimization.

1. Passenger Car Tire Tread Formulations

ZEOSIL 125 acts as a primary reinforcing filler in passenger tire tread compounds, improving rolling resistance, wet grip, and wear performance. This grade is compatible with modern silane coupling agents, enabling compliance with fuel economy and safety standards in OE and replacement tire markets. Key process steps include dry mixing with SBR or BR polymers, sequential addition of silanes, and intensive Banbury milling to reach target dispersion before shaping and vulcanization.

Industry compliance standards

• UN ECE R117 Rolling Resistance and Wet Grip Regulation
• ISO 2006:2017 Rubber Testing Standard
• REACH Regulation (EC) No 1907/2006 Compliant Raw Material
• OEM Internal Quality Approval Protocols (Michelin, Bridgestone, Continental, etc.)

Typical usage ratio

• 30–80 phr (parts per hundred rubber) depending on required performance balance of rolling resistance and road grip
• Ratio adjusted for winter vs. summer tread, silica-silane coupling efficiency, and presence of carbon black

Downstream process integration

• Added as a dry powder during initial Banbury or internal mixer stage with rubber and plasticizer
• Blended with silane agents (TESPT, Si69) in main mixing step
• Incorporated before sheet-off and further open mill refinement
• Compound proceeds to extrusion, calendaring and tire building

Final product types

• Energy-saving summer tires
• All-season and winter car tires
• Performance and run-flat passenger car tires
• OE and aftermarket SUV tires

2. Truck and Bus Radial (TBR) Tire Production

Silica is increasingly used as a partial or full replacement for carbon black in truck and bus radial tire tread and cap compounds to reduce rolling resistance for fuel efficiency mandates. ZEOSIL 125 supports compounding for improved abrasion resistance and tear strength, while meeting stringent wear and load-bearing requirements in commercial fleet applications.

Industry compliance standards

• FMVSS No. 119 Tire Performance Standards (USA)
• UNECE R54 Truck Tires Regulation
• REACH SVHC Screening and Certification
• ISO 28580:2018 Rolling Resistance Testing

Typical usage ratio

• 20–60 phr in tread and cap compounds
• Ratio adjusted for on-road/off-road profiles and required heat build-up resistance

Downstream process integration

• Introduced during initial internal mixing with NR, BR, and SBR blends, along with coupling agents and processing oils
• Further milled and processed for pelletizing or direct calendering
• Compound advances to extrusion for tread strip production

Final product types

• Regional and long-haul truck tires
• City bus radial tires
• High-load dumper and trailer tires
• Retreadable truck tire casings

3. Silicon-Modified Rubber Compounds for High-Performance Footwear Soles

Precipitated silica enables the formulation of rubber outsole compounds with superior slip resistance, abrasion durability, and enhanced aesthetic finish in technical footwear. Our material is utilized in combination with silica-dispersing resins and UV-stable colorants to produce premium outsoles meeting global safety and sustainability demands.

Industry compliance standards

• EN ISO 20345:2022 Personal Protective Equipment Safety Standard
• REACH Annex XVII Restricted Substances Limits
• Prop 65 (California, USA) Compliance for Finished Footwear
• Eco-Labeling: OEKO-TEX Standard 100 for Footwear Components

Typical usage ratio

• 10–30 phr in footwear outsole rubber compounds
• Higher loading for safety footwear, lower for athletic soles emphasizing flexibility

Downstream process integration

• Fed into internal mixer with NR or SBR base, plasticizing oils, and color pigments
• Adjusted for dispersion via addition of surfactant or resin dispersants
• Sheeted and cut for sole molding or direct injection process

Final product types

• Protective industrial safety footwear soles
• Premium athletic shoe outsoles
• Slip-resistant hospitality or medical footwear soles
• Outdoor and hiking boot soles

4. Rubberized Conveyor Belt Cover and Skim Compounds

Manufacturers of industrial conveyor belts employ ZEOSIL 125 to reinforce cover and skim layers, targeting abrasion, tear, and chemical resistance for mining, aggregate, and bulk handling applications. The silica integrates into both cold- and hot-feed compounding systems, supporting the reproducibility required for OEM and end-user belt certifications.

Industry compliance standards

• DIN 22102 Abrasion Resistance for Conveyor Belt Covers
• ISO 10247:2017 Conveyor Belt Testing
• RoHS Directive 2011/65/EU for Restricted Substances
• REACH Compliance Documentation for Rubber Articles

Typical usage ratio

• 15–45 phr based on required abrasion resistance and flexibility
• Lower loading in thin covers, higher loading for heavy-duty industrial belts

Downstream process integration

• Incorporated during pre-mix with NR/SBR/BR blend and curing agents
• Processed via open mill mixing or internal mixer before final calendaring
• Spread onto fabric or steel cords prior to press vulcanization of finished belt

Final product types

• Heavy-duty mining conveyor belts
• Heat- and oil-resistant conveyor belts
• Sidewall and cleated conveyor belts for bulk material handling
• Industrial food-grade conveyor belts (non-food contact surfaces)

5. Sealing Systems for Automotive and Building Applications

Precipitated silica improves elastic modulus, weathering behavior, and color stability in EPDM- and SBR-based gaskets, automotive weatherstrips, and facade seals. Compounds are developed for consistent extrusion and molding, with compatibility for peroxide and sulfur curing systems to meet cycle time and end-use exposure requirements.

Industry compliance standards

• SAE J200 Rubber Material Specification for Automotive Seals
• EN 681-1 Elastomeric Seals for Water & Drainage Applications
• RoHS and REACH SVHC Declarations
• UL 94 Flame Classification for Building Components (when required)

Typical usage ratio

• 20–50 phr in sealing and weatherstrip formulations
• Ratio guided by extrusion profile complexity and target compression set

Downstream process integration

• Added to internal mixer during first phase with polymers and process aids
• Adjusted for flowability and surface finish with plasticizers and cure systems
• Sheets processed by extrusion or injection molding, then vulcanized in autoclave or tunnel ovens

Final product types

• Automotive door, trunk, and window weatherstripping
• Building facade gaskets
• Waterproof membrane edge seals
• HVAC and electrical enclosure grommets