Gradeall Empowering Sustainable OTR Tyre Recycling with Advanced Cutting Technology

By:     Kieran Donnelly

Gradeall, a frontrunner in waste management technology, has pioneered an innovative solution for managing the disposal of Off-The-Road (OTR) tyres, particularly those used in quarrying and mining. Recognising the lack of cost-effective methods for dealing with these large, cumbersome tyres, We have introduced a specially designed series of machinery tailored to this challenge.

This development is a new 3-pronged solution to dealing with OTR (Off The Road) equipment tyres. The OTR Cutting range designed to Downsize OTR tyre waste.

Identifying that affordable solutions for dealing with Scrap OTR Tyres such as those fitted to quarry and mining equipment are few and far between. Gradeall developed an affordable range of machines for dealing with these tyres.


A sample range of the OTR tyres that can be cut with this equipment

Tackling the OTR Tyre Waste Dilemma

OTR tyres, notable for their colossal size and heft, present substantial logistical and environmental quandaries. Each tyre, tipping the scales at around 600 kilograms, demands extensive storage space and is impractical, if not impossible, to manoeuvre manually. Their unwieldy nature inflates transportation costs, as a mere handful of these tyres can be accommodated on a standard trailer. This inefficiency in handling and transportation exacerbates the OTR tyre waste issue, with growing piles of these tyres accumulating at mining and construction sites globally.


Gradeall OTR Recycling Equipment Range


The Gradeall OTR Cutting Range: A Comprehensive Three-Stage Process

Gradeall’s OTR cutting range consists of three distinct machines that collaboratively process OTR tyres:

1: OTR Splitter: This machine commences the downsizing by bisecting the tyre along its tread, dividing it into two halves. This initial step also facilitates the removal of any internal water or debris.

2: OTR Sidewall Cutter: The second stage involves the OTR sidewall cutter, adeptly separating the sidewalls from the tyre halves, focusing on the bead area. The cutter’s adaptability allows for various cuts, effectively isolating the sidewall from the bead and producing rings of different diameters as required.

3: OTR Shear : Completing the process, the OTR shear deals with the tread sections and sidewalls. Its formidable cutting power seamlessly slices through the tyre’s thickest parts, significantly reducing segment size.

The current problem is that these huge tyres take up a lot of space and are very heavy at approximately 600Kg per tyre making them take up a lot of space, they are impossible to move by hand and costly to transport due to how few tyres will actually fit on a trailer. OTR downsizing is crucial to get rid of this space consuming OTR tyre waste.


A range of the OTR tyres which the Gradeall equipment can deal with shown in the image above

Using the Gradeall OTR cutting range these large tyres can be cut down into easy to manage segments weighing under 25Kg which means they can be lifted and moved around by anyone. These segments can be baled, shredded, sent for pyrolysis or any of the further recycling methods that are available to conventional tyres.


The sub 25Kg segments are easy to handle and move around

The 3 machines work in sequence to deal with these tyres.

Advantages and Applications of Gradeall’s OTR Tyre Downsizing Strategy

Gradeall’s OTR tyre downsizing solution brings forth a myriad of benefits:

  • Diminished Storage Needs: By transforming bulky OTR tyres into smaller segments, Gradeall’s strategy drastically cuts down on storage space requirements, fostering more efficient space utilisation.
  • Streamlined Transportation: The compact tyre segments are more manageable, curbing transportation costs and promoting more effective movement of OTR waste.
  • Broadened Recycling Opportunities: The reduced tyre segments fit a variety of recycling processes, such as baling, shredding, and pyrolysis, thus expanding the horizons for OTR tyre recycling.
  • Mitigated Environmental Footprint: Gradeall’s solution aids in curtailing environmental impacts, reducing reliance on landfills and furthering resource conservation.

An Overview of the Tyre Splitting Process With Gradealls Machinery

OTR Tyre Splitter


An OTR Tyre Loaded onto the OTR tyre splitter


The OTR Splitter cutting the tyre in half

Firstly the tyre is brought to the OTR tyre splitter which cuts the tyre in half along its tread section, at this stage any water or debris inside the tyre will fall out of the tyre. The tyre is now in two halves.


The OTR Tyre is cut into two halves by the splitter

OTR Sidewall Cutter


One of the halves of an OTR Tyre in the sidewall cutter

The second stage is to bring the halves of the tyre to the OTR Sidewall cutter, this machine cuts the sidewalls out of the tyres, isolating the bead section ( It is the thick bead section which typically causes the most problems for shredders).


The sidewall and tread section have been expertly separated, demonstrating a precise and effective division of the tyre components.

It is possible to cut the sidewalls twice to give a ring of sidewall without any bead and a small sidewall cut close to the bead itself.

Gradeall’s Ongoing Pursuit of Excellence and Customer Feedback

Committed to perpetual enhancement, Gradeall continuously refines its OTR downsizing system, valuing customer insights and feedback. This dedication to innovation is exemplified in their success with baling OTR tyres, showcasing the system’s efficacy. In-house trials have indicated that the system can effectively process up to six OTR tyres per hour, rendering it a feasible and economical option for managing OTR tyre waste.


The OTR sidewall cutter can cut into the sidewall more than once and is adjustable to give sidewalls of different diameters to suit specific requirements.

OTR Shear


A section of OTR tread section being cut in the shear

The final stage is to use the OTR shear to cut the tyre down into smaller segments, the tread sections first which are the easiest to cut. This is followed by the sidewalls; the shear is sufficiently strong to cut through the bead of these tyres. Even when cut in half they are now much easier to handle.


The tread section of an OTR tyre being chopped by the shear


The shear chops the tyre into segments that can be easily carried around

It is entirely at the discretion of the operator how small to cut the segments of the OTR tyres, sub 25Kg pieces are optimal as this means that they can still be moved easily by hand.


4 OTR tyres which have been cut using Gradeall OTR Equipment

Gradeall has had success in baling these OTR tyres, and in-house testing found that it was possible to deal with 6 OTR tyres per hour. While it is still a labour-intensive process it provides the market with a viable and affordable way to deal with these tyres. Gradeall as with the original sidewall cutter will continue to develop this system with the help of customer feedback to refine the process in order to make it as streamlined as possible.


The Gradeall MK2 tyre baler being loaded with OTR Tyre segments


A bale made from OTR tyres


5 OTR tyres were compacted into this bale, showing the volume reduction

Innovating OTR Tyre Recycling with Gradeall’s Cutting-Edge Equipment

Q: What unique solution has Gradeall developed for managing OTR tyre disposal?

A: Gradeall has introduced a specialised range of machinery designed to address the challenges of disposing of Off-The-Road (OTR) tyres, particularly those from quarry and mining operations. This innovation presents a cost-effective, three-pronged approach to managing the large and cumbersome scrap OTR tyres.

Q: What are the challenges associated with OTR tyre waste?

A: OTR tyres pose significant logistical and environmental challenges due to their immense size and weight, typically around 600 kilograms. They require extensive storage space, are difficult to move manually, and their bulky nature increases transportation costs. This leads to inefficient handling and a growing issue of tyre waste at mining and construction sites.

Q: Can you describe the three stages of Gradeall’s OTR Cutting Range?

A: Certainly. Gradeall’s OTR cutting range includes:

  • OTR Splitter: Slices the tyre in half along its tread, dividing it into two halves and allowing for the removal of internal water or debris.
  • OTR Sidewall Cutter: Separates the sidewalls from the tyre halves, isolating the bead section. It’s adjustable to create sidewall rings of different diameters.
  • OTR Shear: Cuts the tyre into smaller segments, including the tread sections and sidewalls, even through the thick bead sections.

Q: What are the benefits of Gradeall’s OTR Tyre Downsizing Solution?

A: Gradeall’s solution significantly reduces storage needs by downsizing bulky OTR tyres into smaller segments. This simplifies transportation, opens up broader recycling opportunities, and reduces the environmental footprint. The smaller tyre segments are more manageable and fit a variety of recycling processes.

Q: How does Gradeall’s equipment prepare OTR tyres for recycling?

A: Using Gradeall’s cutting range, large OTR tyres are cut into manageable segments weighing under 25Kg, making them easy to handle and move. These segments can then be processed further through baling, shredding, or pyrolysis, just like conventional tyres.

Q: How does Gradeall ensure the continual improvement of its OTR tyre processing system?

A: Gradeall is dedicated to continuous innovation and refinement of its system, relying on customer feedback and in-house testing. This has led to the successful processing of up to six OTR tyres per hour and the development of efficient baling methods for these tyres.

Q: What kind of volume reduction is achieved through Gradeall’s OTR tyre baling process?

A: The Gradeall MK2 tyre baler can compact significant volumes of OTR tyre segments into a single bale. For instance, five OTR tyres were compacted into one bale during in-house testing, showcasing the substantial volume reduction and efficiency of the process.


Upgrade you facilities with Gradeall

To explore how Gradeall’s OTR Cutting Systems can drive circular tyre economies while maximising efficiency and cost savings, contact a tyre waste specialist at 02890844567.

The team can advise on the ideal baler model and capacity for your tyre volumes and assist with installation, operator training, and maintenance planning.

Gradeall Offers a Wide Range of Waste Management Innovation:

Transform tyre waste from an environmental liability into an asset with Gradeall’s baler driving your circular economy program. Follow Gradeall on Facebook and LinkedIn for more waste management insights.

Portable Compactors

  • GPC P9 – Ultra-compact 9 yard portable compactor
  • GPC S9 – 9 yard self-contained portable
  • GPC S24 – 24 yard hooklift portable
  • GPC P24 – 24 yard portable compactor

Static Compactors

Alternative Waste Treatment: Next-gen solutions from bio-drying to thermal hydrolysis

Continue leading the future of sustainable waste management alongside Gradeall by connecting with us today. Stay updated on the latest landfill innovations by following us on Facebook and LinkedIn.

OTR Cutting Video Preview

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