OTR Tire Splitter for Oversized Industrial Tires: Equipment Guide

By:     Kieran Donnelly

An OTR tire splitter is a piece of equipment that most recyclers never need. For those who do, it is the piece of equipment without which nothing else in their processing line can work. Oversized industrial and mining tires in the 35-inch and above diameter range cannot be processed through any standard recycling equipment in their whole form. They are too large to bale, too large for standard shredders, and too heavy to manage manually in any processing context. A splitter reduces them to sections that can be handled, transported, and processed further.

This article covers the OTR tire splitter in detail: what it does, which tire categories it is designed for, how it fits into an OTR tire processing line, and the US industrial and mining markets that generate the tires that make this equipment relevant.

What an OTR Tire Splitter Does

An OTR tire splitter divides the tread and belt section of a large OTR tire, after the sidewalls have been removed by a sidewall cutter, into segments. The splitting action uses hydraulic force to drive a blade through the heavy tread and belt assembly, producing sections that are physically manageable for loading into downstream processing equipment or for transport in standard containers.

The splitter is always used after the sidewall cutter in the processing sequence, not instead of it. The sidewall cutter removes the bead and sidewall sections, which are the structurally rigid elements of the tire. The resulting tread ring is then split into arc-shaped sections by the splitter. The final output of the two-machine sequence is a set of manageable sections, typically 2 to 4 sections per tire depending on tire size, that can be loaded into a shredder feed or accumulated for TDF or crumb rubber processing.

The Gradeall OTR Tire Splitter is designed to handle the tread sections from large OTR tires after sidewall cutting. Combined with the Gradeall OTR Tire Sidewall Cutter, it forms the core of an OTR tire size reduction capability applicable to mine site, quarry, and heavy industrial OTR tire processing.

OTR Tire Categories That Require a Splitter

Not every OTR tire requires a splitter. Smaller OTR categories in the 25-inch to 35-inch diameter range can in some cases be processed through heavy-duty sidewall cutters and then baled without splitting, depending on the specific tire weight and tread thickness. Larger categories from 35 inches upward, and all large haul truck tire formats from 46 inches to 63 inches, require splitting after sidewall cutting to produce sections manageable for downstream processing.

The primary OTR tire categories in US industrial and mining operations that routinely require an OTR splitter include: surface mine haul truck tires (46-inch to 63-inch), large loader tires (35-inch to 49-inch), quarry truck tires, and large dozer tires. Aggregates operations, large construction projects, and heavy industrial facilities also generate OTR tires in the size range that requires splitting.

Site Requirements for OTR Tire Splitting Operations

OTR tire splitting operations have specific site requirements that differ from standard tire baling. The equipment is significantly larger and heavier than a car or truck tire baler. The tires being processed weigh hundreds to thousands of pounds, requiring mechanical handling equipment (typically a front-end loader or telehandler) for positioning and movement. The processing area needs reinforced concrete capable of supporting both the equipment weight and the dynamic loads of the splitting process.

Overhead crane access is beneficial for positioning the largest OTR tires (57-inch and above) into the processing equipment, as manual or loader handling becomes impractical at the upper size range. Some OTR processing operations are designed around a pit or lower-level processing area where tires can be rolled in rather than lifted, reducing the crane requirement for initial positioning.

“Site design for OTR processing is a significant engineering exercise compared to a standard tire baling installation,” says Conor Murphy, Director of Gradeall International. “The equipment footprint, the structural requirements, the mechanical handling needs, and the material flow from whole tires to cut sections to transport all need to be planned together before the first machine arrives on site.”

Financial Case for OTR Tire Splitter Investment

Gate fees for large OTR tires reflect their processing complexity. Fees of $50 to $300 per tire are common for mid-size OTR categories; for the largest haul truck tires, fees of $300 to $1,000 per tire are possible in markets where processing alternatives are limited. At these rates, an operation processing 20 large OTR tires per week generates $1,000 to $6,000 in weekly gate fee revenue, producing a compelling return on the equipment investment for mines or quarries generating sufficient volume.

For US operators assessing the full range of OTR processing equipment, the Gradeall OTR tire cutting equipment range provides an overview of the complete product line from Gradeall. Contact Gradeall to discuss your specific OTR tire sizes and volumes and the equipment configuration appropriate for your operation.

Frequently Asked Questions

How large are OTR tires that require a splitter, and how much do they weigh?

OTR tires requiring a splitter typically start at 35-inch diameter and range up to 63-inch for the largest haul truck formats. Weights range from approximately 500 pounds for mid-size loader tires to over 12,000 pounds for the largest 63-inch haul truck tires. The Gradeall OTR Tire Splitter is designed for the range of tires after sidewall cutting; confirm the specific tire dimensions and post-cutting section weights for your tire mix when discussing equipment specification with Gradeall.

Can the OTR Tire Splitter process solid-fill OTR tires?

Solid-fill OTR tires (polyurethane-filled or other solid fill formats used in some mining applications to eliminate flat tires) have different processing characteristics from pneumatic OTR tires. The fill material affects cutting and splitting forces significantly. Consult Gradeall specifically about solid-fill tire processing before assuming the standard OTR Sidewall Cutter and Splitter configuration is appropriate. The type and hardness of the fill material is the critical variable in assessing equipment suitability.

What downstream markets accept OTR tire sections?

OTR tire sections from splitting operations are accepted by TDF buyers (cement kilns and industrial boilers accept large tire sections for energy recovery, often at attractive BTU-per-ton rates due to the high rubber content of OTR tires), by large shredding operations that have the input capacity for oversized sections, and by steel scrap dealers for the steel content in OTR tire belt and bead wire. The specific markets accessible depend on your location and the volume you can supply; a waste broker can help identify buyers in your region.

Does the OTR Tire Splitter work with any tire size after sidewall cutting?

The OTR Tire Splitter is designed for a specific range of post-sidewall-cutting tread ring diameters. Confirm the diameter range of the tread rings from your OTR tire categories with Gradeall before specifying the splitter. For very large haul truck tread rings from 57-inch and above tires, additional splitting passes may be required to reduce sections to a manageable size for downstream processing. Gradeall can advise on the number of splits typically required for your specific tire sizes.

Is specialist training required to operate the OTR Tire Splitter?

The OTR Tire Splitter is hydraulically operated with operator controls designed for industrial use. Gradeall provides operational training and safety documentation with every machine. The primary safety considerations are the significant forces involved in the splitting process, the weight of the tire sections being handled, and the requirement for mechanical handling equipment for larger tire formats. A risk assessment specific to the processing of your OTR tire sizes should be completed before operations begin.

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