Plastic Energy unveils Tacfiller to replace traditional carbon black

UK – London-based Plastic Energy has introduced Tacfiller, a sustainable carbon black substitute derived from post-consumer plastic waste. 

This product emerges as a byproduct of the company’s TAC chemical recycling process, which transforms hard-to-recycle plastics into TACOIL, a recycled feedstock for new plastic production.

The initiative targets the packaging industry’s reliance on carbon black, a pigment that strengthens materials but originates from fossil fuels.

Carbon black’s manufacture generates significant environmental impact, with global output linked to 29 to 79 million metric tonnes of CO₂ emissions annually. 

In contrast, Tacfiller’s production cuts these emissions by up to 89%, based on a Life Cycle Analysis performed by Plastic Energy. 

The material maintains the durability benefits of conventional carbon black while supporting circular economy goals. It also avoids the sorting disruptions that carbon black can cause in recycling streams.

A key milestone for Tacfiller came with its registration under REACH, the European regulation governing chemical substances in Great Britain. 

This approval marks it as the first such product to achieve this status, paving the way for broader market adoption. 

“Tacfiller represents a practical step forward in reducing the carbon footprint of essential packaging components,” said Carlos Monreal, CEO of Plastic Energy, in a recent statement. 

He added that the company’s recycling technology processes over 30,000 tonnes of plastic waste yearly, yielding materials that displace virgin fossil resources.

Earlier this year, Unilever committed to incorporating 50% recycled content in its flexible packaging by 2025, including alternatives to high-emission additives like carbon black. 

This move supports similar innovations, as reported in industry updates. Plastic Energy plans to scale Tacfiller production, targeting partnerships with packaging converters across Europe.

Initial trials have shown seamless integration into polyethylene and polypropylene films, common in food and consumer goods packaging.

The European Commission’s recent push for 55% recycled plastic use in packaging by 2030 provides a regulatory tailwind. 

Plastic Energy’s process not only lowers emissions but also diverts waste from landfills, processing mixed plastics that mechanical recycling often rejects.

Monreal emphasized the economic viability, stating indirectly that Tacfiller costs align with traditional options while delivering verifiable sustainability gains.

As global plastic production nears 400 million tonnes per year, solutions like Tacfiller gain urgency. 

The product enters a market valued at over US$20 billion for carbon black, where demand for eco-friendly variants rises. 

Plastic Energy aims to supply major brands seeking compliance with Scope 3 emission targets. Early adopters report improved recyclability in downstream applications, further enhancing the material’s appeal.

This development signals progress in chemical recycling, a method projected to handle 6 million tonnes of plastic annually by 2028. 

With Tacfiller now available, packaging firms have a tangible tool to trim emissions without compromising performance.

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