Off-the-road (OTR) tyres are among the most physically demanding waste streams any recycling operation will encounter. Weighing anywhere from 300 to over 5,000 kilograms, measuring up to four metres in diameter, and reinforced with multiple steel belt layers, they bear no resemblance to the car or truck tyres that conventional processing equipment handles reliably. Mining sites, construction operations, and heavy industrial facilities accumulate these tyres at scale, yet most standard recycling infrastructure simply cannot touch them.
The volume of OTR tyre waste is growing. Global mining and infrastructure activity continues to expand, and the tyres worn out in those operations have to go somewhere. Traditional approaches, whether burial on-site, transport to distant specialist facilities, or long-term stockpiling, create costs that compound quickly and solve nothing in the long run.
Gradeall’s OTR Tyre Cutting Equipment Range was designed specifically for this problem. It transforms a disposal challenge that has historically required significant logistical effort into a manageable, on-site processing workflow that recovers valuable materials and eliminates unnecessary transport costs.
OTR tyres are not simply larger versions of conventional tyres. Their construction is fundamentally different, and that difference matters enormously when choosing processing equipment.
Standard tyre processing machinery is rated for the forces involved in cutting passenger car or truck tyres. OTR tyres routinely exceed those force thresholds by a significant margin. Attempting to process them through equipment not designed for the task risks blade failure, hydraulic system damage, and serious safety incidents.
The internal structure of an OTR tyre combines multiple steel belt layers, heavily reinforced bead sections containing high-tensile bead wire, and rubber compounds formulated to withstand extreme heat, impact, and abrasion from mining and construction environments. Many OTR tyres are also foam-filled to prevent blowouts in remote operating environments, adding both weight and complexity to the processing challenge.
Size alone creates handling problems. A tyre measuring three to four metres in diameter cannot be moved, positioned, or processed with the same material handling approaches used for conventional tyres. Specialist clamping, positioning, and cutting systems are required at every stage of the workflow.
The economic case for proper processing is straightforward. Conventional disposal of a large OTR tyre, including transport to a specialist facility and handling fees, can exceed £1,000 per unit. On-site processing eliminates those fees while recovering steel content that may exceed 100 kilograms in a single large mining tyre, along with hundreds of kilograms of rubber material with viable end-use applications.
Gradeall has developed a portfolio of specialist cutting equipment that addresses each stage of OTR tyre processing, from initial size reduction through to component separation and preparation for downstream processing. The range is designed to work as an integrated system, with each piece of equipment preparing material efficiently for the next stage.
No single machine handles everything. The processing challenge is too varied for that approach to work reliably across the full range of OTR tyre sizes and construction types encountered in the field. Instead, the equipment portfolio provides dedicated tools for each processing stage, allowing operations to configure workflows appropriate to their material volumes and tyre types.
The OTR Tyre Splitter handles primary size reduction, cutting massive tyres in half along the tread section. This first cut is the most critical step in the entire workflow. It transforms an unmanageable whole tyre into two semi-circular components that can be handled, transported within a facility, and fed into subsequent processing stages.
The splitting operation also opens the tyre cavity, allowing removal of foam filling, dirt accumulation, or other contamination before the material moves further through the processing line. Removing contamination at this stage protects downstream equipment and improves the quality and value of recovered materials.
Hydraulic cutting systems in the OTR Splitter deliver high-pressure force application, rated to handle the steel belt layers and reinforced construction found across the full size range of OTR tyres. Blade design uses hardened steel alloys and heat treatment processes to maintain cutting performance through extended use on abrasive materials.
Once a tyre has been split, the sidewall sections present a specific challenge. These areas contain the most heavily reinforced construction in the entire tyre, including the bead wire and the thick rubber compounds that support the tyre’s structural integrity under load. If left attached to tread sections, they create problems for downstream baling equipment and reduce material consistency.
The OTR Tyre Sidewall Cutter isolates and removes these heavily reinforced sections cleanly, separating the bead area from the tread and shoulder rubber. This separation serves two purposes: it protects baling and further processing equipment from components it is not designed to handle, and it allows different material streams to be directed to the most appropriate end-use applications.
Bead wire, once separated, is high-tensile steel with specific metallurgical properties that make it valuable for specialist applications. Separating it cleanly at this stage preserves that value rather than mixing it into a lower-grade combined steel stream.
After primary splitting and sidewall removal, the remaining tread and shoulder sections still require further size reduction before they can be processed through conventional baling equipment. The shear system addresses this, cutting the semi-circular sections into smaller components with consistent dimensions.
This secondary processing stage is where the workflow connects to standard material handling and baling infrastructure. The output from the shear system can be handled using conventional equipment, fed into standard baling systems, and transported using normal logistics. The specialist OTR processing has done its job; from this point, the material behaves like a conventional recyclate stream.
The forces involved in cutting OTR tyres, and the sheer mass of the materials being handled create inherent safety considerations that must be addressed in equipment design and operational procedures. A tyre weighing several tonnes, combined with cutting systems generating the hydraulic force needed to cut through multiple steel belts, requires comprehensive safety systems at every stage.
Gradeall’s OTR equipment incorporates multiple layers of safety provision, from the mechanical design of the cutting and clamping systems through to the control interfaces operators use to manage the process.
Emergency shutdown capability is built into every machine in the range, with immediate response systems that halt all mechanical and hydraulic action. These are not advisory stops; they are immediate, hard-wired shutdowns designed to respond faster than an operator can react to an unexpected event.
Hydraulic pressure monitoring runs continuously during operation, with automatic safety cutoffs that prevent the system from exceeding design limits. This protects both operators and equipment; an uncontrolled pressure event in a high-force hydraulic system is a serious incident waiting to happen, and the monitoring systems are designed to prevent it from occurring.
Operator positioning controls ensure that personnel maintain safe distances from the cutting zones during all active processing stages. The clamping and positioning systems that hold tyres secure during cutting also serve a safety function, preventing unexpected movement of materials that could injure operators or damage equipment.
Equipment safety systems are necessary but not sufficient on their own. The specialised nature of OTR processing requires operators who understand the characteristics of the materials they are handling, the limitations of the equipment, and the procedures to follow when conditions deviate from normal.
Gradeall provides training programmes that cover safe operation across the full range of OTR tyre types and sizes that the equipment is designed to handle. Training addresses not only standard operation but also the recognition of unusual conditions, such as tyres with unexpected internal features or contamination, that may require procedural adjustments.
Emergency response procedures are covered specifically, ensuring that operators know exactly what to do in the event of equipment malfunction, unexpected material behaviour, or other incidents. The goal is operators who can both prevent incidents and respond correctly when something unexpected occurs.
A structured processing sequence produces the best results in terms of both material recovery quality and operational efficiency. Moving through the stages in order, with appropriate checks at each transition point, prevents problems from compounding downstream and ensures that recovered materials meet the quality standards needed for end-use applications.
The initial assessment stage, before any cutting begins, establishes the appropriate processing approach for each tyre. Size, construction type, condition, and the presence of foam filling or other special features all affect the processing sequence and the settings required at each stage.
Primary splitting along the tread section creates the first manageable components and opens the tyre for inspection and contamination removal. Foam filling, if present, is extracted at this stage. Any significant contamination is cleared before the material moves further through the process.
Sidewall cutting follows, removing the bead sections and separating the steel bead wire from the rubber. At this stage, it is worth sorting the different material streams, as bead wire, tread rubber, and sidewall rubber have different compositions and different end-use applications. Mixing them at this point reduces the value of each stream.
Secondary size reduction through the shear system creates components with consistent dimensions suitable for baling or further processing. The target dimensions at this stage depend on the downstream equipment and the end-use specifications of recovered materials.
Final material sorting separates steel, rubber, and any textile reinforcement components into clean streams. The quality of this separation directly affects the value of recovered materials and the ease of finding appropriate end-use buyers or processors.
OTR tyres contain substantial quantities of valuable materials. Steel content in large mining tyres can exceed 15% of total tyre weight, and that steel has specific properties that give it value beyond standard scrap. Rubber content, whilst specialised in composition compared to passenger tyre rubber, is suitable for a range of applications.
The economic case for material recovery is strongest when recovered materials are directed to their highest-value applications, which requires clean separation and consistent quality. Mixing material streams or allowing contamination to carry through the process reduces both value and the range of viable end-use markets.
Steel recovered from OTR tyres includes two distinct material streams with different properties and applications. The bead wire is high-tensile steel with specific metallurgical characteristics; it is worth separating cleanly and treating as a distinct material stream rather than combining it with the belt wire and general steel content from the tread and shoulder sections.
Belt wire from the tread section is suitable for standard steel recycling, contributing to the scrap metal market. The volumes involved in processing large mining tyres make this a meaningful revenue stream, particularly for facilities processing significant numbers of tyres on a regular basis.
Processed rubber from OTR tyres serves several established markets. Construction and civil engineering applications use processed tyre rubber as lightweight fill material, drainage aggregate, and protective surfacing. These applications are well-established for conventional tyre rubber and extend to OTR material with appropriate processing.
Energy recovery through tyre-derived fuel provides an alternative for rubber material that does not meet the specifications for product applications. OTR rubber has a high calorific value, making it particularly suitable for this application. Facilities that process energy-from-waste streams regard OTR rubber as a valuable feedstock, especially given the volumes available from large mining operations.
Specialist rubber compounds used in OTR tyres have properties that may be of specific interest to manufacturing applications. The composition of OTR rubber differs from that of passenger tyre rubber, and some manufacturing processes specifically seek out this material for its particular characteristics.
The markets for OTR tyre processing equipment reflect the industries that generate OTR tyre waste at scale. Each sector has distinct operational characteristics that influence how processing equipment is configured and deployed.
Mining operations represent the largest single source of OTR tyre waste globally. Open-cast mining using large haul trucks, loaders, and specialist mining vehicles generates consistent volumes of worn OTR tyres throughout the year. The remote location of many mining operations makes on-site processing particularly attractive; transport to distant processing facilities is both expensive and logistically complex.
Large-scale mining operations often generate sufficient volumes of OTR tyres to justify a dedicated on-site processing capability. The economics are particularly favourable where disposal costs are high, which is typically the case for remote mining sites far from specialist waste facilities.
Processing on-site allows mining operations to recover valuable steel and rubber materials that can offset processing costs, and in some cases generate net revenue. The reduction in disposal transport creates both cost savings and a reduction in the environmental impact associated with moving large, heavy waste items over long distances.
Major construction and infrastructure projects generate OTR tyres from heavy earth-moving equipment, including bulldozers, scrapers, and large articulated dump trucks. The volumes generated on individual projects vary considerably, and construction operations are often more intermittent in their OTR tyre output than mining sites.
Regional processing facilities serving multiple construction clients represent an efficient model for this sector. A well-equipped processing operation can serve several major construction projects within a reasonable transport radius, offering processing services as an alternative to each project operating its own equipment.
Port operations and large logistics facilities also generate OTR tyre waste from the heavy handling equipment used in container movements and bulk materials handling. These operations tend to be in fixed locations with relatively consistent tyre volumes, making them good candidates for on-site processing capability.
Getting OTR processing equipment working effectively requires more than simply delivering machines to a site. The facility must be configured to handle the material flow, the power and hydraulic supply must meet equipment requirements, and operators must be trained and confident before production processing begins.
Gradeall provides site assessment services that evaluate all of these factors before installation, identifying any facility modifications needed and designing a material flow that supports efficient, safe operation. This assessment stage prevents problems that would otherwise only become apparent after installation.
Installation and commissioning services ensure that equipment is set up correctly and performing to specification before handover. Commissioning includes running test cycles with representative material, verifying that all safety systems are functioning correctly, and adjusting settings to match the specific tyre types the facility will be processing.
Operator training delivered on-site during commissioning combines theoretical knowledge with hands-on practice on the actual equipment in the actual facility. This approach produces operators who are confident and competent from the start of production, rather than learning on the job after formal training has ended.
Ongoing support through Gradeall’s global service network covers technical assistance, spare parts supply, and maintenance services throughout the equipment lifecycle. OTR processing equipment operates under demanding conditions; access to reliable technical support and genuine spare parts is an important factor in long-term operational performance.
“OTR processing is one of the most technically demanding areas of tyre recycling, but it is also one of the most rewarding,” notes Conor Murphy, Director at Gradeall International. “When we install equipment for a mining operation and see it eliminating disposal costs whilst recovering significant material value, that is exactly what this equipment was designed to do.”
OTR tyres that are not properly processed create long-term environmental challenges. Their size and the durability of their materials mean that poorly managed disposal, including landfill disposal or uncontrolled stockpiling, creates problems that persist for decades. Regulatory frameworks in many markets are increasingly restrictive about how waste tyres, including OTR tyres, may be disposed of.
Proper processing addresses both the regulatory compliance requirement and the underlying environmental challenge. Steel recovered through processing reduces the demand for virgin steel production. Rubber directed to construction applications or energy recovery keeps the material in productive use. The volume of material involved in OTR tyres means that each tyre processed correctly represents a meaningful environmental benefit.
Lifecycle thinking applied to OTR tyre management recognises that the cost of responsible processing, when offset against disposal costs and recovered material value, is often lower than the cost of disposal. Operations that reach this conclusion typically find that investing in processing capability pays for itself within a defined period, after which the ongoing cost savings and material revenues represent a genuine financial benefit.
The combination of specialist cutting technology, comprehensive safety systems, structured processing workflows, and reliable long-term support makes Gradeall’s OTR Tyre Cutting Equipment Range a practical solution for operations facing OTR tyre disposal challenges at any scale.
Processing OTR tyres raises practical questions about equipment, facility requirements, and material recovery. The answers below cover the most common concerns from operations considering on-site processing for the first time.
The range handles tyres from approximately 1.5 metres up to 4 metres in diameter, covering everything from large agricultural and construction tyres through to heavy mining haul truck tyres. Specific capacity details for individual machines are available on request.
The machines are designed to work together, but the right configuration depends on your tyre volumes and types. Many facilities start with the OTR Splitter and add further capability as volumes grow. A site assessment will identify what your operation actually needs.
Yes. The primary splitting operation opens the tyre cavity, allowing foam to be removed before sections move to further processing. Operators are trained in the specific procedures for handling foam-filled tyres safely.
Requirements vary by machine, but you’ll typically need heavy-duty flooring, adequate overhead clearance, sufficient electrical supply for the hydraulic systems, and enough floor space for safe material flow. Gradeall’s site assessment covers all of this before installation.
All prices and figures in this guide are indicative UK examples and correct at the time of writing; use them as a benchmark rather than fixed quotations.
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