Tire recycling has multiple stages, each designed to transform scrap tires from bulky waste into valuable materials. Whether you’re producing tire-derived fuel, crumb rubber, or upcycled products, having a clear process flow is vital for efficiency and profitability. This article provides a step-by-step overview of the tire recycling journey, highlighting where specific machinery—like sidewall cutters, balers, and shredders—plays a crucial role.
- Collection & Sorting
- Collection Points
- Tire shops, auto dealerships, and local waste facilities gather end-of-life tires.
- Many states impose fees on new tire purchases to fund collection programs.
- Initial Sorting
- Separate passenger car tires from truck or OTR tires.
- Check for rims, which must be removed or handled by a rim separator.
Machinery Tip: Rim Separators are invaluable at this stage if rims haven’t been removed beforehand, recouping scrap metal revenue and streamlining further processing.
- Primary Size Reduction
- Sidewall Cutting
- Removes sidewalls from truck and passenger tires.
- Simplifies subsequent shredding or baling, and allows for separate processing of the bead wire.
- Tire Shredding
- Breaks whole tires or sidewall-removed tires into smaller pieces or strips, usually 2–12 inches in size.
- In many states, partial shredding is mandatory before landfill disposal.
Machinery Tip: Tire Shredders come in various configurations—low-speed, high-torque or high-speed, lower-torque. The choice depends on throughput goals and final material requirements.
- Secondary Processing (Refinement)
- Steel & Fiber Separation
- Additional screening or magnetic separators pull out steel wires.
- Air classifiers or cyclones can remove loose textile fibers.
- Further Size Reduction
- Chips can be ground into crumb rubber or powder, typically below 1 inch in size.
- Cryogenic or ambient grinding are two main methods, each offering different product qualities.
Machinery Tip: Granulators with fine screens produce consistently sized crumb rubber, needed for high-value markets like playground surfaces or rubberized asphalt.
- Specialty Treatments
- Devulcanization
- Chemical or thermal processes break sulfur bonds in rubber, allowing it to be re-vulcanized into new tyres or rubber products.
- Pyrolysis
- Heats shredded tires in an oxygen-free chamber, yielding oil, syngas, and carbon black.
Machinery Tip: Although pyrolysis units and devulcanizers are still emerging, some advanced recycling plants integrate them to maximize material recovery and diversify product lines.
- Baling for Storage or Transport
- When to Bale
- If you plan to ship or store large volumes of tires or semi-processed rubber, baling reduces the bulk significantly.
- Some construction projects utilize whole tire bales for engineering applications (e.g., retaining walls).
- Baler Types
- Vertical balers are common in smaller operations. Larger facilities may opt for horizontal or fully automatic systems.
Machinery Tip: Tire Balers save considerable logistics costs by densifying material, crucial for facilities shipping cross-country or overseas.
- End Markets for Processed Tires
- Tire-Derived Fuel (TDF)
- Shredded tires are burned in cement kilns or power plants.
- Provides consistent BTU value, though emissions must be carefully managed.
- Crumb Rubber Applications
- Playground mulch, sports turf infill, rubberized asphalt, and molded rubber products.
- Steel Scrap
- Removed steel beads and wires can be sold to scrap metal buyers, offsetting recycling costs.
Quality Control & Contamination Issues
- Contamination Sources
- Dirt, rocks, or moisture can interfere with shredders or degrade crumb rubber quality.
- Textile fibers left in the rubber cause inconsistencies in final products.
- Inspection & Testing
- Regularly test crumb rubber for particle size and purity.
- Store processed materials in dry, clean areas to maintain quality.
Unique Quote from Conor Murphy, Gradeall
“Understanding each stage of the tire recycling process is half the battle. The other half is deploying machinery that keeps your operation efficient from start to finish. A well-planned setup saves time, reduces waste, and ultimately maximizes profit.”
– Conor Murphy, Gradeall
Regulatory & Environmental Considerations
- State Requirements
- Some states demand that tire recyclers maintain clear documentation of each stage—from collection to final sale or disposal.
- Permitting
- You may need separate permits for shredding vs. pyrolysis or devulcanization.
- Environmental Impact
- Properly stored shredded rubber or crumb is far less likely to pose fire or vector hazards than whole tires.
Building a Successful Operation
- Map Your End Products
- Decide early which markets (TDF, crumb rubber, etc.) align with your capacity and local demand.
- Synchronize Machinery
- Match the throughput of your shredder to that of your granulator or baler to avoid bottlenecks.
- Operator Training
- Skilled staff can handle minor mechanical issues, reducing downtime.
- Maintenance Regimen
- Regularly scheduled checks on hydraulic fluids, blades, belts, and screens keep machines running at peak efficiency.
https://www.youtube.com/watch?v=jzYUkdrClxY
Recycling tires into profitable materials relies on following a structured step-by-step process: collection, cutting or shredding, refining, baling, and final product manufacturing. At each stage, the right machine—from sidewall cutters to granulators—ensures efficiency, compliance, and maximum revenue.
Looking to optimize your tire recycling lineup?
Contact Gradeall for expert guidance. From entry-level balers to advanced shredding solutions, we’ll help you design a streamlined process that delivers real returns on every tire you handle.
