Truck tyre baling is more technically demanding than car tyre processing, and the gap between doing it properly and cutting corners shows up fast in bale quality, equipment wear, and the prices you’re offered at the point of sale.
The core issue is construction. A truck tyre weighs five to seven times more than a car tyre, with thick steel-reinforced sidewalls and heavy bead wires that resist compression in ways standard baling equipment isn’t built to handle. Pre-processing with a truck tyre sidewall cutter solves this: removing both sidewalls before baling cuts compression time nearly in half, increases bale density to 1,200-1,500kg, and opens access to PAS 108-compliant construction markets paying £180-£250 per tonne. That’s a 50-80% price premium over whole truck tyre bales. Gradeall International has manufactured truck tyre processing equipment in Dungannon, Northern Ireland, for nearly 40 years and supplied operators across 100+ countries. The specifications and figures below are drawn from real operational data.
Truck tyres (commercial vehicles, HGVs, buses, coaches) are fundamentally different from car tyres in construction, size, and baling requirements. A standard car tyre weighs 8-12kg and measures 600-750mm in diameter. A truck tyre weighs 40-70kg and measures 900-1,200mm in diameter. This 5× to 7× size difference affects every aspect of processing.
Truck tyre construction includes:
These structural elements resist compression significantly more than car tyres. Attempting to bale whole truck tyres in equipment designed for car tyres produces poor results: low-density bales (600-800kg vs 900kg+ target), extremely long compression cycles (15-20 minutes vs 6-8 minutes), accelerated equipment wear, and frequent hydraulic system failures.
Proper truck tyre baling requires:
The truck tyre sidewall cutter addresses the primary bottleneck by removing rigid structural elements before baling. This single piece of equipment transforms truck tyre processing from impractical to efficient.
Gradeall International manufactures truck tyre processing equipment at our facility in Dungannon, Northern Ireland. We’ve supplied commercial tyre processors across 100+ countries over nearly 40 years. The specifications below reflect real operational requirements for truck tyre baling.
Every truck tyre category has different dimensions, steel content, and baling requirements. Getting the match right between tyre type and processing method is what separates efficient operations from costly ones.
OTR (off-the-road) tyres (construction, mining, agriculture):
This guide focuses on standard truck tyres (7.5-44 tonne commercial vehicles). OTR tyres require specialised processing beyond standard baling equipment.
Whole truck tyres resist compression in ways that make standard baling impractical. Removing the sidewalls first is the single most effective change you can make to your processing output, bale density, and bottom line.
Attempting to bale whole truck tyres in standard equipment encounters multiple issues:
Compression resistance: Thick sidewalls and steel beads create a rigid structure that resists hydraulic pressure. A 7.5kW motor producing 200 bar pressure compresses car tyres to 900-1,000kg bales in 6 minutes. The same equipment compressing whole truck tyres achieves only 700-800kg bales in 12-15 minutes.
Chamber capacity: Standard baler chambers (1,100mm × 1,100mm × 1,200mm depth) accommodate 80-90 car tyres or only 20-25 whole truck tyres before hitting volume limits. The resulting bales are light (600-700kg) and uneconomical.
Equipment stress: Forcing whole truck tyres through car tyre equipment accelerates wear. Hydraulic seals fail prematurely (18-24 months vs 36-48 months normal), motors overheat, and frames flex under excessive loading.
The truck tyre sidewall cutter removes both sidewalls in 45-90 seconds, leaving just the tread section. This eliminates 40-50% of tyre volume and removes the most compression-resistant components.
Results:
Total time: 90-120 seconds per tyre, including positioning and removal. One operator processes 30-35 tyres per hour continuously.
Choosing the right equipment for truck tyre baling comes down to tyre volumes, tyre size, and target bale markets. The specifications below cover sidewall cutters and balers across the full range of commercial tyre processing requirements.
Car tyre cutter: Processes tyres up to 800mm diameter
Truck tyre cutter: Processes tyres up to 1,200mm diameter
OTR tyre shear: Processes tyres up to 2,000mm+ diameter
Baler specifications:
Standard MKII handles pre-cut truck tyres adequately at volumes under 50 truck tyres daily. Above that threshold, a dedicated truck tyre baler justifies investment through faster cycle times and higher bale density.
Most operators process both car and truck tyres. Workflow optimisation depends on relative volumes.
Process car tyres normally in the MKII baler. Accumulate truck tyres until 40-50 are available, then batch-process:
This minimises equipment changeover and produces distinct car vs truck bales (easier to sell to specific end-markets).
Integrate cutting into daily workflow:
Mixed bales (car tyres plus cut truck tyres) are acceptable for most markets except construction (PAS 108 typically specifies car-only or truck-only bales, not mixed).
Invest in an integrated processing line:
One operator loads the cutter continuously. Cut tyres travel via conveyor to baler, second operator supervises baling. Throughput: 50-70 truck tyres per hour (continuous operation).
Equipment cost: £95,000-£135,000 total (cutter £18,000, conveyor £12,000, truck baler £85,000). For operations processing 50,000+ truck tyres annually, payback is 2-4 years through labour efficiency and improved bale revenue.
Truck tyre bale characteristics:
Standard bale dimensions: 1,200mm × 1,200mm × 900mm (larger than car tyre bales) Bale weight: 1,200-1,500kg (pre-cut truck tyres) Tyres per bale: 35-45 truck tyres (varies by tyre size and cutting quality) Wire requirements: 4.0mm high-tensile wire, 5-6 wraps minimum
PAS 108 compliance for truck tyre bales:
PAS 108 construction standard requires:
Only pre-cut truck tyres in a dedicated truck baler reliably achieve PAS 108 compliance. Whole truck tyres or mixed car/truck bales don’t meet the specification.
Market pricing by bale type:
Pre-cut truck tyres in PAS 108-compliant bales command a 50-80% premium vs whole truck tyres. At 10,000 truck tyres annually (100 tonnes), that’s £8,000-£15,000 additional revenue justifying sidewall cutter investment (£14,000-£22,000).
Sidewall cutting generates steel-rich waste: sidewalls (40-50% of original tyre weight) containing high steel content (beads and sidewall reinforcement). This has a separate value.
Sidewall composition:
Car tyre sidewalls: 10-12kg per tyre pair (both sidewalls), 30-40% steel by weight. Truck tyre sidewalls: 35-50kg per tyre pair, 35-50% steel by weight
Steel recovery options:
Option A: Sell sidewalls as-is to steel recyclers. Price: £50-£100 per tonne (low value due to rubber contamination) Revenue: 100 truck tyres × 0.04 tonnes sidewalls = 4 tonnes × £75 = £300
Option B: Further process sidewalls (debeading, shredding) to separate steel. Requires: Debeading equipment (£8,000-£15,000) or secondary shredding. Price: £200-£350 per tonne clean steel wire Revenue: 4 tonnes sidewalls × 40% steel content × £250/tonne = £400 Additional equipment and labour required
Option C: Bale sidewalls separately. Some markets purchase baled sidewalls for specialised applications (moulded products requiring high steel content). Bale sidewalls using the same equipment after processing tread sections.
Price: £80-£120 per tonne baled sidewalls Revenue: 4 tonnes × £100 = £400
Most small to medium operations choose Option A (sell as-is) for simplicity. Large operations (10,000+ truck tyres annually generating 400+ tonnes of sidewalls) justify debeading equipment for steel extraction.
Sidewall cutting labour:
One operator continuously cutting: 30-35 truck tyres per hour. Daily throughput (8 hours): 240-280 tyres Annual capacity (250 days): 60,000-70,000 tyres
Labour cost: 8 hours × £12/hour = £96 daily Cost per tyre: £96 ÷ 260 tyres = £0.37 per tyre cutting labour
Baling labour (pre-cut truck tyres):
MKII processes pre-cut truck tyres at a reduced rate vs car tyres:
Labour cost per truck tyre: £12/hour ÷ 55 tyres/hour = £0.22 per tyre baling labour
Total processing labour: £0.59 per truck tyre (cutting + baling)
Compare to whole truck tyre baling (no pre-cutting):
Wait, that suggests whole truck tyres are cheaper? The error is that whole truck tyre baling produces low-quality bales (700-800kg) selling at lower prices, whereas pre-cut bales (1,200kg) command a 50-80% premium. The revenue difference far exceeds the £0.15 additional labour cost:
Whole truck tyre bale revenue: 0.75 tonnes × £90/tonne = £67.50 per bale ÷ 25 tyres = £2.70 per tyre. Pre-cut truck tyre bale revenue: 1.25 tonnes × £180/tonne = £225 per bale ÷ 40 tyres = £5.63 per tyre
Net revenue advantage of pre-cutting: £2.93 per tyre (108% improvement) despite £0.15 higher labour cost.
Truck tyre processing equipment pays for itself faster than most operators expect. The figures below compare disposal costs, operating costs, and bale revenues across two equipment configurations for a real-world volume of 10,000 truck tyres annually.
Current state: No processing, pay for disposal. Disposal cost: 10,000 × £4.50 per tyre = £45,000 annually
Option A: Whole truck tyre baling (MKII only, £55,000)
Annual operating costs:
Revenue:
Net cost: £11,644 – £27,000 = -£15,356 (net profit) Improvement vs disposal: £45,000 cost → £15,356 profit = £60,356 benefit Equipment payback: £55,000 ÷ £60,356 = 0.9 years (11 months)
Option B: Pre-cut truck tyre baling (cutter + MKII, £75,000)
Net profit: £86,160 – £17,332 = £68,828 Improvement vs disposal: £45,000 cost → £68,828 profit = £113,828 benefit Equipment payback: £75,000 ÷ £113,828 = 0.66 years (8 months)
Despite a £20,000 higher equipment cost, pre-cutting delivers £8,472 additional annual profit (12% more than whole tyre baling) and faster payback due to premium pricing for PAS 108-compliant bales plus sidewall revenue.
Cutter efficiency improvements:
Position the cutter adjacent to the baler: Reduces material transport time. Pre-sort tyres by size: Allows continuous cutting without adjustment delays (large tyres grouped separately from small). Two-operator rotation: One operator cutting, one baling; switch every 2-3 hours to reduce fatigue
Result: Throughput increases from 30 tyres/hour (single operator, no optimisation) to 40-45 tyres/hour (optimised workflow).
Baler efficiency improvements:
Pre-stage cut tyres: Cut 40-50 tyres, then bale batch continuously (eliminates waiting for cutting between bales) Automatic wire system: Reduces wire handling from 3-4 minutes to 1 minute per bale (saves 40-60 hours annually at 1,000 bales) Optimize bale mix: Combine 30 cut truck tyres + 20 car tyres per bale (uses chamber capacity efficiently)
Result: Truck tyre baling rate improves from 50 tyres/hour to 65-70 tyres/hour.
Cutting hazards:
Hydraulic blade force: 25-35 tonnes. Cutting force presents severe crush and cut hazards. Tyre explosion risk: Pressurised tyres can explode violently if cut while inflated (always deflate tyres before cutting). Sharp steel wires: Exposed bead wires are sharp and spring outward during cutting
Controls:
Baling hazards:
Heavy manual handling: Truck tyre pieces weigh 15-25kg (vs 8-12kg car tyres). Wire hazards: 4.0mm wire is sharp and under high tension. Bale weight: 1,200-1,500kg bales require forklift handling (never manual)
Risk assessments are required under PUWER and the Health and Safety at Work Act 1974. Document hazards, controls, and training for both cutting and baling operations.
Truck tyre baling raises practical questions around equipment, processing rates, and bale values. Here are the answers operators ask us most.
Possible but not recommended. Whole truck tyres produce low-density bales (600-800kg vs 1,200kg target), take 2-3× longer to compress (12-15 minutes vs 7-9 minutes), accelerate equipment wear, and don’t meet PAS 108 requirements. Pre-cutting improves bale quality, processing speed, and market value by 50-80%. Equipment investment (£14,000-£22,000 sidewall cutter) pays back within 12-18 months at 5,000+ truck tyres annually.
Minimum: Truck tyre sidewall cutter (£14,000-£22,000) + MKII baler (£50,000-£65,000). Total: £64,000-£87,000. For high volumes (50,000+ annually): Dedicated truck tyre baler (£70,000-£95,000) instead of MKII improves throughput 30-40%. Integrated line with conveyor adds £12,000-£18,000 but eliminates manual material handling between cutting and baling.
35-45 pre-cut truck tyres per bale (1,200-1,500kg), depending on tyre size and cutting quality. Whole truck tyres: 20-25 per bale (600-800kg, not recommended). Car tyres: 80-90 per bale (900-1,100kg). Truck tyres are heavier individually but fewer per bale. Standard MKII accommodates 35-40 cut truck tyres; dedicated truck baler with larger chamber fits 40-50.
Sidewall cutting: 30-35 tyres per hour (one operator). Baling pre-cut tyres: 50-60 tyres per hour on MKII (vs 80 tyres/hour for car tyres). Combined rate for integrated operation: 40-45 truck tyres per hour start-to-finish. Daily throughput (8 hours): 320-360 truck tyres. Annual capacity (250 days): 80,000-90,000 truck tyres.
Yes, if pre-cut and PAS 108 compliant. Construction market: £180-£250/tonne truck vs £150-£200/tonne car (20-25% premium). Shredding: £120-£170/tonne truck vs £100-£140/tonne car. Premium reflects higher rubber content per tonne (less steel in tread-only sections vs whole tyres) and suitability for specific applications. Whole truck tyre bales sell at a discount (£70-£100/tonne).
Sell as-is to steel recyclers (£50-£100/tonne, simplest option), further process with debeading equipment to extract steel wire (£200-£350/tonne clean steel, requires additional equipment), or bale sidewalls separately for specialised markets (£80-£120/tonne baled). At 10,000 truck tyres annually generating 400 tonnes of sidewalls, revenue is £20,000-£30,000 from sidewall sales alone.
Yes for truck tyres. PAS 108 requires 1,200kg minimum bale weight for truck tyres. Whole truck tyres rarely achieve this (typical 700-800kg). Pre-cutting enables consistent 1,200-1,500kg bales meeting construction standards. Car tyres don’t require pre-cutting to meet PAS 108 (900kg minimum achieved with whole car tyres).
Sidewall cutter: 15-20 years with proper maintenance (hydraulic seals every 2,500 hours, blade every 10,000 cuts). MKII processing pre-cut truck tyres: 15-20 years (same as car tyre use; pre-cutting eliminates excessive equipment stress). MKII processing whole truck tyres: 8-12 years (accelerated wear from overloading). Dedicated truck baler: 20-25 years (designed for application).
Truck tyre baling requires sidewall cutting, pre-processing and appropriate compression equipment. The truck tyre sidewall cutter (£14,000-£22,000) removes rigid structural elements in 90-120 seconds per tyre, enabling effective baling.
Pre-cut truck tyres produce 1,200-1,500kg PAS 108-compliant bales commanding £180-£250 per tonne in construction markets (50-80% premium vs whole truck tyre bales at £70-£100/tonne). For operations processing 10,000+ truck tyres annually, pre-cutting equipment pays back within 8-18 months through improved bale revenue and sidewall steel sales.
Standard MKII baler processes pre-cut truck tyres at 50-60 tyres per hour. Dedicated truck tyre balers (£70,000-£95,000) increase throughput to 65-80 tyres per hour for operations exceeding 50,000 annual truck tyres.
Contact Gradeall to discuss truck tyre processing requirements. We’ll recommend optimal equipment configuration based on your truck tyre volumes, mix of car vs truck tyres, and target markets.
* The prices and running-cost figures below are based on real UK customer examples and are correct at the time of writing, but should be treated as indicative only.
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