How a Tyre Baler Works: The Complete Baling Process Explained

Updated on: 22nd February 2026 By:     Conor Murphy
Expert review by:     Kieran Donnelly

A tyre baler compresses waste tyres into dense, uniform bales, reducing their volume by up to 80 percent and transforming them from a difficult-to-handle waste stream into a stable, transportable material with a range of end-use applications.

The practical effect is significant. A pile of loose car tyres takes up several times the floor space of an equivalent baled stack. Loose tyres are awkward to move, a fire risk when stockpiled in large quantities, and expensive to transport to processing facilities. A baled tyre stack can be handled by forklift, stored efficiently, and transported in standard containers or on flatbed vehicles at a fraction of the cost per tyre of loose loading.

Understanding how the baling process works helps operators get the most from their equipment, troubleshoot problems when they arise, and make informed decisions about process configuration and maintenance priorities.

Gradeall International manufactures tyre balers at our facility in Dungannon, Northern Ireland, and has been producing tyre recycling equipment for nearly 40 years. The process described below reflects how Gradeall’s machines operate in the field.

The Core Components of a Tyre Baler

Before walking through the process, it helps to understand the main components and what each one does:

Baling chamber: The enclosed steel box where tyres are compressed. Chamber dimensions determine bale size and, for PAS 108 applications, the bale must meet the standard’s dimensional and density requirements. The chamber is constructed from heavy-gauge steel plate with replaceable wear liners on the internal surfaces.

Hydraulic ram (compression platen): A steel platen driven by a hydraulic cylinder that compresses the tyres loaded into the chamber. The platen moves vertically in a vertical baler. The force generated by the hydraulic system determines the compressive load applied to the tyre stack.

Hydraulic power unit: The motor, pump, reservoir, valves, and associated pipework that generate and control the hydraulic force. On the MKII Tyre Baler, the hydraulic motor is rated at 7.5kW, providing the power needed for consistent bale production across a full working day.

Loading doors: The access points through which tyres are loaded into the chamber. Gradeall’s tyre balers use a four-door loading design, allowing access from multiple sides to suit different site layouts and operator preferences.

Wire tying system: The mechanism that feeds baling wire through the chamber and around the compressed bale to hold it in its compressed state after the platen retracts. The number of ties per bale, the wire gauge, and the tying sequence all affect bale stability and compliance with PAS 108 requirements.

Ejection system: The mechanism that pushes the completed bale out of the chamber ready for collection. Ejection systems use a hydraulic push or gravity-assisted slide depending on the machine design.

Control system: A PLC-based controller that manages the cycle sequence, monitors position via limit switches, and provides the operator interface for controlling the machine and adjusting parameters.

The Baling Process: Step by Step

Step 1: Loading

The operator opens the loading doors and places tyres into the baling chamber. For car tyres, this is typically a manual operation. For truck tyres or high-volume operations, a conveyor feed system automates this stage.

The number of tyres loaded per cycle depends on tyre size and the target bale specification. For a standard PAS 108-compliant car tyre bale, the chamber is loaded with a defined quantity of tyres stacked in a specific orientation. Orientation matters: vertically stacked tyres compress more consistently and produce better bale geometry than randomly loaded tyres.

For operations processing both car and truck tyres, a truck tyre sidewall cutter is commonly used before baling. Cutting the sidewall allows the tyre to compress more effectively, increasing bale density and improving output rates. Whole truck tyres are significantly harder to compress and produce lower-density bales that may not meet PAS 108 specifications without pre-processing.

Once loaded, the operator closes and secures the loading doors.

Step 2: Compression

With the doors closed and secured, the operator initiates the compression cycle from the control panel. The PLC controller activates the hydraulic pump, which pressurises the circuit and extends the hydraulic cylinder.

The cylinder drives the compression platen downward (on a vertical baler) with substantial force. The platen compresses the tyre stack progressively, forcing the air out from between the tyres and deforming the tyre carcasses against each other and the chamber walls.

Compression force is the key variable in producing a dense, stable bale. The MKII Tyre Baler generates the hydraulic force needed to achieve the density specifications required for PAS 108 compliance. The PLC monitors system pressure and platen position throughout the compression stroke.

At full compression, the platen holds the load while the tying system engages. On modern balers, the control system manages this sequence automatically; the operator does not need to intervene between compression and tying.

Step 3: Wire Tying

With the tyre stack held at full compression, the wire tying system feeds baling wire through channels in the baling chamber, around the compressed bale, and forms a secure tie.

The number of ties per bale is a critical specification. PAS 108-compliant tyre bales require a specific number of ties at defined positions. Under-tying produces a bale that may partially decompress after ejection, affecting both density and dimensional compliance. Over-tying is not a significant problem but wastes wire.

Gradeall’s tyre balers use a semi-automatic wire tying system. The machine feeds and positions the wire; the operator cuts and fastens each tie. This gives the operator direct control over tie quality and allows visual inspection of each tie as it’s formed.

Wire gauge is specified for each machine model. Using the correct gauge, from a quality supplier, is important for consistent tie performance and minimising wire breaks during the tying cycle. See Gradeall’s baler consumables range for wire specifications matched to each machine in the range.

Step 4: Platen Retraction

Once all ties are in place, the operator signals the control system to retract the platen. The hydraulic cylinder retracts, drawing the platen back to its home position at the top of the chamber.

The bale remains in its compressed state, held by the wire ties. A well-formed bale with correct tie tension will retain close to its compressed dimensions after the platen retracts. A bale that noticeably expands after retraction indicates either under-tying or insufficient compression force.

Step 5: Bale Ejection

With the platen retracted, the ejection system activates to push the completed bale out of the chamber. On Gradeall’s tyre balers, ejection uses a hydraulic push mechanism to move the bale clear of the chamber.

The ejected bale lands on the floor in front of the machine or, where a conveyor is used, onto a discharge conveyor. Bales are then collected by forklift and added to the storage stack.

The ejection stage also presents the opportunity to inspect the bale before it leaves the machine. Check tie tension visually: ties should be tight against the bale surface with no visible slack. Check bale geometry: dimensions should be consistent from bale to bale and within PAS 108 tolerances if compliance is required.

Step 6: Reset and Next Cycle

With the bale ejected, the baling chamber is clear and ready for the next load. The operator opens the loading doors and the cycle repeats.

Cycle time varies by machine, tyre size, and bale specification. The MKII Tyre Baler is capable of producing up to 6 PAS 108-compliant bales per hour under normal operating conditions, making it the standard choice for mid-to-high volume tyre recycling operations.

PAS 108: What It Requires and How the Baling Process Delivers It

PAS 108 is the British standard for tyre bales used in civil engineering and construction applications, including land drainage, slope stabilisation, retaining walls, and embankment fill. A bale that meets PAS 108 can be sold or supplied for these applications; a bale that doesn’t meet the standard cannot.

The standard sets requirements for bale dimensions, mass, density, and the number, type, and positioning of ties. The baling process must be consistent enough to meet these requirements across every bale produced, not just test bales.

Key process requirements for PAS 108 compliance:

• Tyres must be of known and consistent type (car tyres, truck tyres, or OTR tyres are not mixed in a single bale under the standard)
• Loading quantity per cycle must be controlled to achieve target bale mass
• Compression must be sufficient to achieve the density specification
• Tying must meet the number and positioning requirements
• Bale dimensions must be within the tolerances specified

For operators supplying tyre bales to construction projects, the baling process is a quality-controlled production operation, not just a volume-reduction exercise. Consistent operator training and a well-maintained machine are both necessary conditions for reliable PAS 108 compliance.

Tyre Types and Their Effect on the Baling Process

Not all tyres bale in the same way. Understanding how different tyre types behave in the baler helps operators manage output quality and equipment wear.

Tyre Type	Processing Consideration	Pre-Processing Recommended?
Car tyres	Bale well whole; standard process	Not usually required
Van/light commercial tyres	Bale well whole; slightly harder to compress than car tyres	Not usually required
Truck/lorry tyres	Significantly harder to compress whole; lower bale density	Sidewall cutting strongly recommended
Agricultural tyres	Wide variation in size; large OTR types need pre-processing	Sidewall cutting or splitting for large sizes
OTR (off-the-road) tyres	Very large; cannot be baled without pre-processing	Splitting and sidewall cutting essential

For truck tyre operations, a truck tyre sidewall cutter fitted alongside the baler significantly improves both bale density and output rate. For larger OTR tyres, an OTR tyre splitter reduces the tyre to a manageable size for baling or further processing. For the full range of tyre pre-processing equipment, see the tyre recycling equipment category.

Conveyor Integration for Higher Volume Operations

At higher processing volumes, manual loading becomes the bottleneck. An inclined tyre baler conveyor automates the loading stage, feeding tyres from a ground-level collection point up to the baler’s loading chamber without manual handling.

Conveyor integration does several things simultaneously: it removes the physical effort of manually loading each tyre, allows a single operator to manage a higher throughput, and creates a more consistent loading rate that smooths out cycle times.

For sites with high daily volumes or limited staffing, the productivity improvement from conveyor integration is usually sufficient to justify the capital cost within the first year of operation.

Frequently Asked Questions

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