Complete Tyre Processing Line: From Sidewall Cutting Through to Baling

By:     Conor Murphy

Expert review by:     Kieran Donnelly

Individual tyre processing machines work as standalone equipment, but they leave significant room for efficiency improvement when connected into an integrated processing line. A sidewall cutter on its own is a useful machine. A baler on its own is a useful machine. Put them together with the right conveying solution and a well-planned site layout, and the combined system outperforms the sum of its parts by a margin that matters operationally.

This guide explains the components of a complete car and truck tyre processing line, how each stage connects to the next, the layout principles that keep material flowing, and the output rates achievable at different configurations. It is written for operations at mid to high volume, typically 100 to 600 tyres per day, that are looking to move beyond ad hoc equipment arrangements and into a properly integrated processing sequence.

The Core Processing Sequence

A complete tyre processing line for car and truck tyres follows a defined sequence. Understanding each stage and its role helps when planning the layout and selecting the equipment for each position.

The sequence is straightforward, but the operational details of each connection determine whether the line runs smoothly or creates bottlenecks that limit throughput and frustrate operators. The most critical connection is between the sidewall cutter and the baler.

Sidewall Cutter Selection for an Integrated Line

The starting point for equipment selection is the tyre type mix that the operation processes. Car tyres and van tyres up to approximately 255 section width go through the car tyre sidewall cutter, which processes one tyre per cycle in under 12 seconds and achieves up to 400 tyres per hour with an experienced operator.

Operations processing truck tyres, or a mix of car and truck tyres, need the truck tyre sidewall cutter, which handles the larger tyre dimensions and heavier steel reinforcement of commercial vehicle tyres. Truck tyre processing rates are lower than car tyre rates due to the larger tyre mass and the additional cutting force involved, typically 90 to 180 tyres per hour depending on tyre size.

For mixed operations, the truck tyre sidewall cutter is usually the better choice because it handles both car and truck tyres, giving the line flexibility across different incoming tyre mixes. A dedicated car tyre cutter offers higher throughput when the operation is processing car tyres exclusively.

The Critical Link: Cutter to Baler

The connection between the sidewall cutter and the baler is where most integrated line designs either succeed or create problems. The sidewall cutter produces tread rings at a rate that, with a single operator, can outpace a baler running on a normal baling cycle. Without a buffer between the two machines, the operator ends up either waiting for the baler or leaving tread rings piled at the cutter output.

The inclined tyre baler conveyor solves this by transporting tread rings from the sidewall cutter output up to the baler chamber input, with enough conveyor length to act as a buffer for several tread rings at a time. The operator at the sidewall cutter loads tread rings onto the conveyor; the baler operator or an automated loading system takes them from the conveyor into the baler. Neither machine is waiting for the other.

The TBC8M tyre baler conveyor provides an alternative conveyor configuration for specific installation geometries where a standard inclined conveyor does not fit. The right choice depends on the building layout and the height differential between the cutter output and the baler input.

Baler Selection for an Integrated Line

The MKII tyre baler produces up to 6 PAS 108-compliant bales per hour from car tyres, with a bale mass of 650 to 900 kg when processing sidewall-cut tread rings. This is the flagship baler for car tyre operations and the most widely used Gradeall baler in the UK and internationally.

For operations processing truck tyres, the truck tyre baler handles the larger tyre sections and produces bales to the truck tyre bale specification. The MKII can also process truck tyre sections, but the truck tyre baler is specifically designed for higher truck tyre volumes and produces better output consistency for those tyre categories.

The MK3 tyre baler offers an alternative baler configuration for operations with specific throughput or bale dimension requirements. A Gradeall technical adviser can specify the right baler for your tyre mix and volume target.

Managing Sidewall Section Output

One of the most common oversights in processing line planning is failing to account for the volume of sidewall material the cutter produces. At 300 car tyres per hour, the sidewall output rate is around two sidewall sections per tyre, averaging 0.8 kg each, which is roughly 480 kg of sidewall sections per hour. This material accumulates quickly around the cutter if there is no collection system in place.

Position a collection skip directly at the sidewall cutter’s ejection point, sized for at least two hours’ production between empties. For higher-volume operations, a dedicated conveyor running parallel to the main tread ring conveyor can transport sidewall sections to a separate storage bay without requiring manual movement. Establish the sidewall section disposal arrangement before scaling up production: cement kilns and industrial furnaces accept tyre-derived fuel sections, and a pre-arranged supply agreement with a licensed TDF operator removes this as an ongoing operational concern.

Layout Principles for an Integrated Processing Line

A well-designed processing line layout serves three goals: linear material flow so that tyres move in one direction without backtracking; clear separation between the incoming whole tyre area and the outgoing bale area; and safe operator movement that does not require crossing active material flows or mechanical handling paths.

The most functional layout positions incoming tyre storage at one end of the building, the sidewall cutter in the middle third, and the baler at the far end adjacent to a loading door for bale collection. This left-to-right or back-to-front flow is intuitive for operators and minimises the distance that material must travel between stages.

Floor strength is a consideration at the baler position, where the machine applies significant downward force during the baling cycle, and at the bale storage area, where stacked bales of 700 to 900 kg each concentrate the load. Confirm floor loading capacity against the equipment and bale storage specifications before finalising the layout.

For incoming tyre reception, tipping skips at the building entrance allow lorry deliveries to be tipped directly into the reception area without manual handling. A sorting area adjacent to the tipping point separates tyre categories before they enter the processing line.

Throughput Rates by Configuration

These figures are for car tyre processing. Mixed car and truck tyre streams reduce overall throughput because truck tyre cycle times are longer. The most accurate throughput projection for a specific operation requires knowing the actual tyre mix by category.

Connecting the Line to the Wider Site Operation

The processing line does not operate in isolation from the rest of the site. Incoming tyre deliveries, bale collection logistics, and sidewall section removal all affect how the line runs in practice. Designing the line without accounting for these external flows creates pinch points that limit throughput even when the equipment itself is capable of more.

Plan the site traffic flow so that incoming tyre deliveries do not block bale collection access. In most facilities, a single loading door that serves both functions creates a queuing problem at peak times. Where possible, separate the delivery entrance from the bale dispatch exit, even if both use the same building. For advice on site layout planning specific to your building dimensions and tyre volumes, contact Gradeall International directly.

The tyre recycling equipment category at gradeall.com covers the full range of equipment available for integrated processing lines, including conveyors, cutters, balers, and handling equipment.

Conor Murphy, Director of Gradeall International

“The difference between a processing line and a collection of machines is the connections between them. We’ve seen operations running excellent individual pieces of equipment that are still limited to 80 tyres an hour because the layout forces the operator to carry tread rings from the cutter to the baler by hand. Getting the conveyor solution right and planning the layout before installation typically doubles the effective throughput without adding any more machines.”

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