If you want to process large volumes of tires and produce salable fuel and mulch, a used tire recycling plant of the TDS (Tire Derived Shred) type is the right solution. The tires are shredded mechanically, at ambient temperature, into TDF chips of 50 to 100 mm and wire-free chips of 20 mm, while the steel is extracted magnetically. No chemicals, no burning, no wastewater to treat.
A used tire recycling plant oriented toward TDS puts the emphasis on coarse fractions, the ones most sought after by cement plants and pyrolysis facilities, and on steel-free mulch for landscaping. It is a robust line, with high throughput and low energy use per ton. See the full range of recycling equipment and where each one fits in the line.
Key Advantages for Tire Derived Fuel
• High-quality TDF chips, a used tire recycling plant produces chips of 50 to 100 mm with low steel content, ideal as TDF for cement plants.
• Steel-free mulch, the wire-free 20 mm chips become rubber mulch for landscaping or feedstock for pyrolysis.
• Mechanical process, no pollution, everything at ambient temperature, with no chemicals and no burning, so no emissions and no wastewater to treat.
• High throughput, the line is optimized for industrial volumes of tires, with reasonable energy use per ton.
• Steel recovery, the magnetic separators extract the wire, supplying chips up to around 98% wire-free and salable steel.
• Lower initial investment, the focus on coarse fractions reduces the number of stages compared with a fine powder line.
• Expandable, you can later add rasping and granulation to produce rubber granules and powder.
• Fast payback, TDF and mulch have steady demand, and the feedstock, the worn tire, is abundant and cheap.
Technical Specifications, Used Tire Recycling Plant
| Parameter | Value |
|---|---|
| Process type | Mechanical recycling (TDS) at ambient temperature, no chemicals |
| Feedstock | Car, truck and OTR tires, whole or pre-cut |
| Main product | TDF chips of 50 to 100 mm |
| Secondary product | Wire-free chips of approx. 20 mm (mulch) |
| Metal separation | Magnetic separators (up to ~98% wire-free) |
| By-products | Recovered steel, textile fiber |
| Orientation | Coarse fractions, high throughput |
| Components | CE marked where applicable |
| Capacity | Configurable to the project |
Applications and Industries for Tire TDF
A used tire recycling plant of the TDS type serves high-volume recyclers and cement plants looking for cheap alternative fuel. The TDF chips of 50 to 100 mm, with low steel content, burn cleanly and replace a good part of the coal or coke in cement kilns. For an operator, that means a secure market and a stable contract with heavy industry.
Landfilling whole or shredded tires is banned in the European Union by Directive 1999/31/EC on the landfill of waste, which turns recycling into an obligation and creates a steady flow of tires toward processing. For integration into a complete line, see also the complete solutions by industry.
Beyond fuel, the steel-free 20 mm rubber mulch produced by a used tire recycling plant is used for landscaping, for protective surfaces and as feedstock for pyrolysis, which recovers oil, gas and carbon black. For an operator, the ability to deliver TDF and mulch at the same time, plus recovered steel, opens several revenue streams from the same robust line.
The volume of end-of-life tires grows year after year, while local processing capacity remains limited. A used tire recycling plant oriented toward TDS is the fastest way to enter the market with a lower initial investment, because it puts the emphasis on coarse fractions and high throughput, not on costly fine granulation. You can then gradually increase capacity and the product range.
For cement plants and pyrolysis facilities, quality TDF with low steel content is a strategic feedstock, cheaper and more stable in price than fossil fuels. A used tire recycling plant that consistently delivers uniform chips thus becomes a reliable long-term supplier, with contracts that justify the investment and ensure a predictable cash flow.
Compatible Materials
A used tire recycling plant processes practically all types of rubber tires. Very large tires are pre-cut before shredding, and those with steel beads first go through bead extraction. The better the input flow is sorted, the more uniform and salable as TDF the resulting chips are.
| Accepted material | Notes |
|---|---|
| Car tires | The main source, direct processing |
| Truck tires | Pre-cut if they exceed the feed size |
| OTR / machinery tires | Pre-cutting mandatory for large diameters |
| Industrial rubber | Belts, profiles and rubber waste |
How It Works
The flow on a used tire recycling plant of the TDS type is continuous, robust and mechanical:
1. The tires are fed and, if needed, their steel beads are extracted, then the large ones are pre-cut.
2. The twin-shaft primary shredder breaks the tires down into chips of 50 to 150 mm.
3. A magnetic separator extracts the steel wire freed from the chips.
4. A secondary stage calibrates the chips to 50 to 100 mm for TDF and to approx. 20 mm for mulch.
5. The additional magnetic separators raise the purity, up to around 98% wire-free.
6. The TDF chips and the mulch are screened, sorted by size and discharged separately, ready to sell.
Oversized material is recirculated, so the chips stay uniform. A continuously monitored used tire recycling plant keeps the fractions constant and quickly brings a new operator to stable results, a real advantage in plants with staff turnover. The control system signals overloads and allows planned maintenance without long production stops.
Frequently Asked Questions
What does a used tire recycling plant of the TDS type produce?
It mainly produces TDF chips of 50 to 100 mm for fuel and wire-free chips of 20 mm for mulch or pyrolysis, plus recovered steel. Unlike a fine powder line, a used tire recycling plant of this type focuses on coarse fractions, with high throughput and a lower initial investment, ideal for entering the market quickly.
Why TDF and not fine granules?
Because TDF has the largest and most stable demand, from cement plants, with a simpler and cheaper line. Fine granules bring a higher price per ton, but they require more stages and a larger investment. A used tire recycling plant oriented toward TDS lets you start with coarse fractions and expand later.
How clean is the recovered steel?
The magnetic separators supply chips up to around 98% wire-free, and the extracted steel is salable to steel mills. A TDF with low steel content sells better and is preferred by cement plants, so the purity of the separation directly influences the price of both fractions.
Is the delivered equipment new?
Yes. We deliver new, unused equipment, made to order, not reconditioned units. The build uses components from established suppliers, CE marked where applicable, and every plant goes through a full inspection before shipping. You receive the technical documentation and operating manuals in your language, for a commissioning without surprises.
What makes URSTAG a premium brand?
European design, top-tier components and experience. Every machine is designed by our engineering teams in Europe and built from components by industry leaders such as Siemens, Schneider Electric, ABB, WEG, SEW-Eurodrive, NORD Drivesystems and Bonfiglioli. The result is reliable, energy-efficient and durable equipment, backed by over 15 years of experience and by delivery, installation, training and service included.
How long does installation and commissioning take?
Transport, commissioning and operator training are included and carried out by a local team, in your language. Before shipping, the plant goes through a full inspection, so your unit becomes operational quickly, with no hidden installation costs.
Can I expand later toward granules and powder?
Yes. A used tire recycling plant of the TDS type is modular: you start with TDF and mulch, then add rasping, granulation and fiber separation to produce 1 to 5 mm granules and rubber powder. The stages are sized together, so the expansion can be done without redesigning the existing line.
Why URSTAG?
URSTAG is a premium brand of recycling equipment, with over 15 years of experience. You don't just get a machine, you get a solution engineered by specialists, built from top-tier components and backed by a team that supports you from design through commissioning.
• European engineering, every machine and every complete line is designed by our engineering teams in Europe, with a focus on reliability, safety and energy efficiency.
• Premium components, we build on motors and automation from industry leaders: Siemens, Schneider Electric, ABB, WEG, SEW-Eurodrive, NORD Drivesystems and Bonfiglioli.
• Over 15 years of experience, we know how materials and machines behave in real-world operation, and we configure each solution for your flow and volume.
• New equipment, configured for you, we supply new units, made to order for your application, with complete technical documentation.
• Delivery, installation and training included, we handle transport, commissioning and operator training, with support throughout the equipment's life.
As a premium brand, URSTAG relies on European engineering, top-tier components and experience. You choose a partner that supports your production long term, with equipment built to run reliably in demanding industrial environments.
