Beyond Compliance: Optimising Recycling Operations with Innovative Gradeall Solutions

By:     Kieran Donnelly

Compliance with regulations is no longer sufficient. Waste management is changing fast. Now, it’s not just about following the rules. Local councils, businesses, and communities want more – they’re looking for smart, forward-thinking ways to manage waste and recycle better. That’s where Gradeall comes in. We’re at the forefront of waste management technology, offering innovative solutions that do more than just meet the standards; they set new ones.

The Environmental Impact of End-of-Life Tires

  1. Cutting Waste Volume by 80%: Gradeall’s advanced tire recycling units, including the MKII Baler, MK3 Baler, Truck Tyre Baler, Agricultural Tyre Shear, Portable Tyre Bailing System, Car Sidewall Cutter, Tyre Baler Conveyor, and Tyre Rim Separator, efficiently compact tire volumes. By doing so, these machines enable more sustainable transportation and material recovery processing at lower costs.
  2. Transforming Waste Management: For instance, Gradeall’s G120 Compactors have been instrumental in transforming waste management for Newtownabbey Borough Council. These compactors efficiently handle bulky tires, significantly reducing their volume and making transportation more cost-effective.

Equipment for the job:

MK3 Baler

The Gradeall MK3 Tyre Baler is an advanced piece of recycling equipment designed specifically for handling and processing large volumes of waste tyres. It represents an evolution from the earlier MK2 model, incorporating several key improvements and innovations. Here are some of its notable features and aspects:

  • Designed for High-Volume Tyre Processing: This machine is specifically tailored for businesses that deal with significant quantities of waste tyres. It’s ideal for large tyre recycling plants or vehicle dismantlers.
  • Three-Ram Baling Mechanism: The MK3 features a unique three-ram system. This design is likely more efficient in compressing tyres into compact bales, making storage and transportation easier and more cost-effective.
  • Increased Power and Strength: With 75 tonnes of force exerted by its rams, the MK3 is more powerful than its predecessor. This increase in force means it can compress larger volumes of tyres more effectively. Additionally, the machine has been reinforced to handle these greater forces, ensuring durability and longevity.
  • Use of Finite Element Analysis in Design: The MK3’s design process included Finite Element Analysis, a sophisticated method of simulating physical behavior using mathematical models. This approach helps in optimising the design for strength and durability, ensuring the machine can withstand continuous use over many years.
  • Proven Track Record: Before its widespread release, the MK3 was tested extensively. Two test units were installed at separate sites in the UK in 2018, providing valuable data and feedback used to refine the design. The success of these tests and the positive reception from users across Europe underscore the machine’s reliability and effectiveness.
  • Global Availability: The MK3 is not just limited to European markets; it’s available for shipping to various countries worldwide, including Australia, France, Ireland, the United States, and the United Kingdom. This wide availability makes it accessible for international customers dealing with tyre waste.
  • Part of a Comprehensive Tyre Recycling Equipment Range: The MK3 Tyre Baler is part of a broader range of tyre recycling equipment offered by Gradeall. This suggests that the company provides holistic solutions for tyre recycling, potentially including other related machinery and support.

In summary, the Gradeall MK3 Tyre Baler is a robust, efficient, and globally available solution for high-volume tyre recycling. Its enhanced power, durability, and innovative design make it a significant tool for businesses in the tyre recycling industry.

MK2 Baler

  • High Output Design: The MK2 is engineered for maximum efficiency in tyre baling. It can produce up to 6 PAS108 compliant tyre bales per hour, making it a highly productive machine. This efficiency is particularly significant given that each bale can contain between 400-500 tyres.
  • Volume Reduction: One of the key benefits of the MK2 is its ability to reduce tyre volume by up to 80%. This reduction drastically improves the logistics of transporting and storing tyres, which is a major concern in tyre recycling processes.
  • PAS108 Compliance: The ability to produce PAS108 compliant tyre bales is critical. PAS108 is a specification for the production of bales of end-of-life tyres for use in civil engineering applications. Compliance with this standard ensures that the bales produced are of a consistent size and quality, making them suitable for various applications.
  • Versatile Applications: The compacted tyre bales from the MK2 are not just easier to transport but can also be used in various industries, including construction, civil engineering, shredding, pyrolysis, and energy recovery. This versatility adds value to the end product of the recycling process.
  • Global Distribution: The widespread availability of the MK2 across the globe is a testament to its effectiveness and demand. It is ideal for tyre collectors, recycling centers, vehicle dismantlers, and tyre depots, showcasing its adaptability to different scales of tyre recycling operations.
  • Reliability and User-Friendliness: The MK2 is known for its robust construction and reliable performance. Its design minimises downtime and maximises output, which is crucial for businesses that depend on continuous operation. The emphasis on reducing human error through a user-friendly design makes it accessible and efficient for operators.
  • Maintenance and Operation: The machine’s design simplifies maintenance and operation. This aspect is crucial in industrial equipment as it reduces operational costs and enhances productivity. The user-friendly nature of the MK2 ensures that it can be operated with minimal training, making it a practical choice for various businesses.

The Gradeall MK2 Tyre Baler stands out as a robust, efficient, and versatile machine in the tyre recycling industry. Its ability to produce high-quality tyre bales compliant with industry standards, along with its user-friendly design and reliable performance, makes it a valuable asset for businesses involved in the collection, processing, and recycling of end-of-life tyres.

Tackling the Transportation Challenge

Transporting end-of-life tires (ELTs) has historically been a logistical hurdle due to their bulky nature. Loose transport is prohibitively expensive, especially considering fuel costs. Gradeall’s tire recycling products address this challenge:

  • From car and lorry tires to agricultural tractor tires and massive off-the-road (OTR) tires, Gradeall offers a comprehensive range of solutions.
  • Our goal is to cater to as many tire types as possible, making tire recycling accessible and efficient worldwide.

The Environmental Impact of Recycling

  1. Resource Conservation:
    • Recycling helps conserve natural resources by reusing materials instead of extracting and processing new raw materials.
    • Gradeall’s tire recycling units, such as the MKII Baler and MK3 Baler, extend the life of tires, minimising waste and conserving valuable resources.
  2. Energy Savings:
    • Processing recycled materials typically requires less energy than manufacturing products from new materials.
    • Gradeall’s tire recycling machinery ensures that valuable materials are not wasted but reused, contributing to energy efficiency.
  3. Reduction in Greenhouse Gas Emissions:
    • By recycling, we reduce emissions of greenhouse gases like carbon dioxide, methane, and nitrous oxide.
    • Gradeall’s tire recycling solutions play a role in mitigating climate change by minimising the need for new tire production.
  4. Waste Reduction:
    • Recycling reduces the volume of waste sent to landfills, minimising environmental impact.
    • Gradeall’s G120 Compactors transform waste management, efficiently handling bulky items like tires.
  5. Pollution Reduction:
    • Proper waste management prevents pollution of air, water, and soil.
    • Gradeall’s tire balers and compactors contribute to cleaner environments by managing waste effectively.
  6. Protection of Wildlife:
    • Recycling reduces habitat destruction and pollution, benefiting wildlife.
    • Gradeall’s commitment to tire recycling helps protect ecosystems where wildlife thrives.
  7. Promotion of Sustainable Practices:
    • Gradeall’s tire recycling machinery promotes circular economy principles, encouraging sustainable practices.
    • By reusing materials, we reduce the need for raw material extraction and promote long-term environmental health.

At Gradeall, we are dedicated to supporting recycling methods through innovative waste management solutions. Our goal is to make recycling accessible and profitable for businesses worldwide.

Gradeall’s commitment to plastic recycling, upcycling, and the promotion of a circular economy reflects a deep-rooted dedication to sustainability and efficient waste management. Let’s delve into these aspects:

Plastic Recycling and Upcycling:

  • Innovative Equipment Design: Gradeall’s approach involves designing and creating equipment that simplifies waste management processes. Their range of balers, compactors, and tire recycling machinery plays a crucial role in effective plastic waste management.
  • Reducing Plastic Volume: The high-performance balers developed by Gradeall are key in condensing plastic waste into compact bales. This not only makes disposal more efficient but also significantly reduces the environmental impact.
  • Empowering Local Communities: In a manner akin to Precious Plastic’s open-source approach, Gradeall empowers communities by making recycling solutions more accessible. This approach enables local initiatives to participate actively in recycling efforts.

Circular Economy:

  • Longevity and Reusability: The principles of the circular economy are embodied in Gradeall’s tire recycling units. These units extend the life of tires through recycling, thus minimising waste and conserving resources.
  • Cradle-to-Cradle Design: Gradeall’s equipment, including tire balers and compactors, promotes the cradle-to-cradle concept. This means materials are continuously repurposed, reducing the reliance on new raw materials and fostering sustainable cycles.

Food Waste Reduction

With it advanced compactors and commitment to sustainable practices, Here at Gradeall, we’re making significant strides in addressing the complex issue of food waste. By transforming how we handle this often-overlooked aspect of waste, Gradeall is not only aiding in reducing the environmental footprint of food waste but also paving the way for more sustainable practices in waste management.


The Gradeall GPC P9 is a specialised piece of equipment designed for the efficient compaction of wet waste, which includes materials like food waste, medical waste, green waste, and other types with high liquid content. Here are the key features and benefits of the GPC P9:

Key Features of Gradeall GPC P9

  • Wet Waste Compaction: Specifically designed for wet waste, the GPC P9 addresses the challenges associated with the disposal and management of such materials. Wet waste often poses difficulties due to its high liquid content and potential to leak, which the GPC P9 is built to handle effectively.
  • Pendulum Head Design with Twin Ram Arrangement: This innovative design allows the machine to develop even pressure from both sides. The twin ram system is significant as it ensures balanced and effective compaction, reducing the risk of uneven loading or stress on the mechanism.
  • Higher and More Concentrated Pressure: The smaller surface area of the head in the GPC P9 means that the pressure exerted on the waste is higher and more focused. This design translates into more efficient compaction, as the waste is pushed into the container with greater force, leading to better volume reduction.
  • Leak-Proof Loading Area: One of the standout features of the GPC P9 is its leak-proof construction, particularly in the loading area. This is crucial for handling wet waste, as it prevents liquids from escaping, thus maintaining a cleaner, safer, and more environmentally friendly operation.

Applications and Benefits

  • Versatile Waste Management: The GPC P9 is suitable for a range of wet waste types, making it a versatile solution for various sectors, including food processing, healthcare, and landscaping or gardening businesses dealing with green waste.
  • Environmental and Health Safety: By effectively containing and compacting wet waste, the GPC P9 helps mitigate the risks associated with liquid waste, such as contamination or spillage. This is particularly important in sectors like healthcare, where waste might be hazardous.
  • Operational Efficiency: The effective compaction leads to better utilisation of container space, which means fewer collections are required. This not only reduces collection costs but also minimises the environmental impact associated with waste transport.
  • Ease of Use and Maintenance: The design of the GPC P9 likely takes into account user-friendliness and ease of maintenance, given the nature of the waste it handles. Easy cleaning and maintenance are essential for equipment dealing with wet and potentially messy waste.


The Gradeall GPC P9 portable compactor is a sophisticated solution for managing wet waste, providing an effective, safe, and environmentally friendly method of dealing with challenging waste types. Its specialised design and features make it a valuable asset for businesses and facilities that generate significant amounts of wet waste, ensuring efficient and hygienic waste management practices.

Efficient Waste Handling:

  • Compact Design for Food Waste: Gradeall’s waste compactors are specifically engineered to handle a variety of waste streams, prominently including food waste. These compactors are adept at reducing the volume of food waste efficiently.
  • Reduction in Transportation and Landfill Space: By compacting food waste, the volume is significantly reduced. This reduction is crucial because it lowers the frequency and costs associated with transporting waste to disposal sites. Additionally, less space is required in landfills, which is beneficial given the environmental impact and space constraints of landfill sites.
  • Improving Hygiene and Reducing Odors: Compacting food waste also helps in managing hygiene and odor issues often associated with decomposing food waste. This is particularly important in urban areas or locations where waste can’t be immediately processed.

Innovative Solutions:

  • Beyond Tire Recycling: While Gradeall has made a name for itself with tire recycling, its commitment to sustainability is demonstrated in its approach to managing other types of waste, including food waste. This diversification shows an understanding of the broader implications of waste management.
  • Contribution to Environmental Sustainability: By developing and implementing effective methods for food waste management, Gradeall contributes to broader environmental sustainability goals. Proper management of food waste is critical in reducing greenhouse gas emissions, particularly methane, which is released during the decomposition of organic waste.
  • Supporting a Circular Economy for Organic Waste: Gradeall’s technology can be seen as a step towards a more circular approach to organic waste. By compacting and efficiently managing food waste, there’s potential for this waste to be repurposed, for example, as compost or bioenergy, depending on the subsequent processing methods.

In conclusion, Gradeall’s approach to waste management is multi-faceted and forward-thinking. By focusing on reducing waste volume, empowering communities, and adhering to circular economy principles, Gradeall not only contributes to environmental protection but also encourages a broader shift towards sustainable practices in waste management. Their diverse range of equipment and solutions represents a significant step forward in tackling the challenges of modern waste management.

A new tyre bale sits in front of the Gradeall Truck Tyre Baler after ejection.

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