Turn End-of-Life Tyres into Recoverable Products
Tyres contain rubber, steel and textile materials that require multiple processing stages to separate and recover effectively. The appropriate system depends on the tyres entering the plant and the type, size and quality of material the operation intends to produce.
Waste Initiatives can develop an individual processing stage, expand an existing line or integrate a complete tyre recycling plant. Solutions may incorporate tyre preparation, primary shredding, classification, secondary size reduction, metal separation, granulation and recovered-material handling.
A tyre recycling system should begin with the required processing outcome rather than a predetermined equipment configuration.
The Tyre Recycling Process
1. OTR Tyre Pre-Processing
Large mining and earthmoving tyres may need to be prepared before entering the primary shredder.
Eagle OTR processing equipment can be incorporated to remove bead wire and cut large tyres into sections that can be handled by downstream equipment. This preparation reduces the size of the incoming material while allowing valuable bead steel to be recovered separately.
Equipment may include
- OTR tyre debeaders
- Sidewall cutters
- Tyre shears and sectioning equipment
- Material-handling equipment
This stage is optional and generally applies to large OTR tyres rather than standard passenger and truck tyre processing.
Eagle OTR Tyre Debeader
The Eagle OTR Debeader is a cutting-edge solution for processing end-of-life (EOL) OTR tyres. It can remove bead bundles from massive tyres up to 4m outside diameter (OD) or 63″ rim diameter. Ideal for EOL tyres from mining sites, key features include wireless controls and powerful hydraulic performance.
Eagle Titan OTR Tyre Cutter
The Eagle Titan OTR Cutter handles tyres up to 8ft diameter and 38” wide. Hydraulic rollers and probe ensure fast, safe cuts. Diesel or electric options available.
Eagle Super Slicer Sidewall Cutter
The Eagle Super Slicer removes sidewalls from tyres up to 44″ OD. With optional tread cutter, it’s perfect for repurposing and downsizing car and truck tyres.
Eagle Mobile Tyre Punch Cutter
The Eagle Mobile Punch Cutter splits OTR tyres up to 14ft diameter. Precision-cutting with PLC control, 10” blade, and auto-turning for unmanned operation.
2. Shredding to TDF - Low to Medium volumes
Primary shredding reduces whole or prepared tyres into rough shred suitable for classification, further size reduction or tyre-derived fuel production. The appropriate shredder depends on the tyre types, required throughput and expected input volumes.
Low to Medium Input Volumes
WastePac tyre shredders provide a practical primary size-reduction solution for operations processing low to medium tyre volumes. Whole tyres are reduced into manageable pieces that can be collected as rough shred or transferred to downstream screening, separation and secondary processing equipment.
Wastepac GL32120
The Wastepac GL32120 is a mid-sized industrial shredder for tyres, e-waste, and bulky waste. Customisable for high-throughput and heavy-duty applications.
3. Shredding to TDF - High Volumes
Barclay has built its reputation around heavy-duty tyre shredding equipment designed for demanding, high-volume recycling operations. Manufactured in the United States, Barclay primary shredders combine high throughput, low energy consumption and efficient blade changeovers to help processors minimise downtime and maintain consistent production.
Barclay primary tyre shredders are designed for high-volume, continuous processing and can handle most tyre types with the bead intact. Larger OTR tyres must first be debeaded and cut into manageable sections. The shredder can form the primary stage of an integrated system incorporating classification, recirculation, secondary shredding and material separation.
Barclay Primary Tyre Shredders are recognised as industry workhorses, designed to process whole tyres up to 1.8 metres in diameter. Combining high throughput with low energy consumption and efficient blade changeovers, they can process more than 12 tonnes per hour. Available in side-load and top-load configurations, the shredders produce cleanly sheared strips ranging from 124 mm to 254 mm.
The Barclay Secondary Tyre Shredders take pre-processed tyres and shred them down into smaller chips varying from 35mm to 91mm, depending on the shredder model. The top-feed design reduces pre-processed tyre material further, with cascading blade sizes ranging from 40-50 millimetres, perfect for producing chips for TDF.
Tyre Crumb
The WastePac Tyre Crumb plant is the second phase of the tyre recycling line that turns the TDF from the first production line into tyre crumb. It separates the rubber from the textile and steel, producing high-quality rubber crumb granules between 1mm – 4mm.
A rasper is an essential part of a tyre recycling plant. It is engineered to produce 10-15mm rubber granules from TDF rubber blocks. A magnetic separator removes metal contaminants. This process enables the recycling of tyres into valuable rubber crumbs used in various industries like rubber manufacturing, asphalt modification, sports surfaces, civil engineering, and rubberised products.
Rubber Powder
The third and final phase of the tyre recycling line is to take the rubber granules down to a high-quality rubber powder delivering a high commodity value. Vibrating screens and Classifiers segregate the granulated tire material based on particle size and segregate the fibres from the rubber. The rubber goes through the grinding mill that grinds the rubber particles from 5-15 mesh to 40-80 mesh using the relative motion of two grinding discs shearing the material to a super fine powder.
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