A tyre recycling plant is an industrial facility that takes used, end-of-life tyres and processes them into reusable materials. Specifically, the process generally includes:
1- Taking used tyres and shredding them into smaller pieces/chips; and/or
2-Separating the steel and fibre from the rubber within the used tyres and/or
3-Reprocessing the material into products such as crumb rubber and/or rubber powders, pyrolysis oil, carbon black, etc.
As part of overall waste tyre management in India, tyre recycling not only helps reduce landfill space consumed by tyres but also produces commercially viable by-products.
The following is a description of each stage of the tyre recycling process. Understanding each operation's order will help when planning your capital investment needs and production capacity.
Tyre Recycling Process – Step-by-Step
Step 1 – Collect and Sort
Waste tyres are collected from various sources such as garages, collectors and distributors.
Step 2 – Pre-Cut
Tyres will be prepped for shredding by using ring and strip cutters.
Step 3 – Shred
Tyres will be processed into chips by using a tyre shredding machine.
Step 4 – Strip Steel and Fiber
Non-rubber strips of fibre and metal from the tyre will be removed using magnetic and fibre-separating machinery.
Granulation / Powdering
Rubber pieces obtained from shredding are further processed to get crumb rubber or powder.
Optional Pyrolysis
In continuous plants, rubber can be thermally decomposed into fuel oil and carbon black.
Cost Breakdown: What You Should Budget
Investment for a tyre recycling plant in India is quite different depending on capacity, technology, automation, and compliance requirements.
1. Small to Medium Scale Recycling (Crumb Rubber Focused)
For a small to medium-scale setup focused on crumb rubber production, the tyre shredding machine and separators typically cost between 20 to 30 lakh INR. Infrastructure and shed development may require around 5 to 15 lakh INR. Supporting machines such as screening systems and dust collectors generally cost between 5 to 10 lakh INR. Working capital and miscellaneous expenses may range from 5 to 10 lakh INR.
Overall, the total investment for this type of plant usually falls between 30 to 60 lakh INR. This setup processes tyres into crumb rubber and related products without pyrolysis.
2. Medium to Large Scale with Pyrolysis
For plants that also recover pyrolysis oil and carbon black, land and civil works may cost approximately 40 to 60 lakh INR. Machinery and installation expenses generally range from 100 to 150 lakh INR. Pollution control systems may require an additional 25 to 40 lakh INR. Utility and electrical setup costs are usually between 15 to 20 lakh INR.
The cost in the market for a standard 10 tons capacity waste tyre recycling plant machinery can be in the range of approximately ?60 lakh (6 million rupees), depending on the supplier and features of the machinery.
To avoid any issues, please remember that regulatory compliance costs (pollution control board approvals, factory licensing), installation costs, and safety costs are separate. You should plan for these additional expenses early in your project.
The cost in the market for a standard 10 tons capacity waste tyre recycling plant machinery can be in the range of approximately ?60 lakh (6 million rupees), which is dependent on the supplier and features of the machinery.
To avoid any issues, please remember that the following costs are separate: Regulatory compliance (with respect to pollution control board approvals, factory licensing), installation costs and safety costs. You should plan for these separate costs early in your project.
Tyre Recycling Machinery
There are many key machines in a tyre recycling Business that are essential to the tyre recycling process:
a) Tyre Shredders – Provides the initial size reduction of entire tyres into chips.
b) Steel and Fibre Separators – Remove the steel and textile components from the tyres.
c) High-Speed Crushers / Granulators – Reduce the size of rubber into crumb or powder.
d) Dust Collectors and Related Screening Equipment – Provide a higher quality of end product(s) than without them.
e)Pyrolysis Reactors (optional) – Equipment to generate both oil and carbon black from the tyre.
Carefully reviewing the production requirements and goals for the end products from the machinery will help in selecting machinery that will meet your objectives.
Tyre Recycling Company and Market Context in India
There are many tyre recycling companies and tyre recyclers in India located in different regions such as Ahmedabad, Ghaziabad, Pune, Jaipur, and Ludhiana. These companies are supplying machines and helping to set up complete plants for tyre recycling.
The tyre recycling sector is linked with various consumer market forces:
1) The government imposition of Extended Producer Responsibility (EPR) on tyres.
2) The rising need for recycled rubber in the making of construction materials, streets, and flooring.
3) High prices of pyrolysis oil and recovered carbon black.
So, tyre waste recycling is a structured sector having both environmental and economic importance.
Practical Considerations Before You Invest
Regulatory Compliance
Make sure you get all the environmental clearances, trade licenses, and pollution approvals before the arrival of machinery.
Land & Utilities
Select industrial zones where power and logistics are easily accessible.
Raw Material Supply
There must be a continuous and regulated supply of waste tyres.
Market for Products
You need to know who your buyers are for crumb rubber, oil, and carbon products.
Tyre Recycling Plant FAQ in India
Q: What are the costs for a used tire recycling plant in India?
A: It depends on the type of equipment, type of technology, and how big the plant is. Small tire recycling plants cost between ?30 lakh to ?60 lakh to start up; however, integrated pyrolysis facilities can cost ?2 crore to ?3 crore or more.
Q: Is it possible to profit from recycling tires?
A: Yes, there are several ways to generate revenue, including selling crumb rubber, pyrolysis oils, carbon blacks and steel. With proper and consistent operations, you can break even within a few years.
Natural gas and other utility costs will be incurred by all of your utility-sucking machines, which is why you need to purchase a feasible business license, a GST registration number, a trade license, a factory license, an environmental consent to operate (CTE or CTO), and a number of relevant NOCs to run your own tire recycling plant.
Q: What types of machines do I need?
A: The basic equipment to operate a tire recycling plant includes a shredder/cutter, a separation machine, a crusher/granulator, and a dust-control system/treatment plant. If you would like to recover tires' oils through pyrolysis, you will require a pyrolysis reactor.
If you're interested in getting customized cost estimates or assistance with licensing for your tire recycling business, I create a model and checklist based on the capacity of your recycling plant and where you work.
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