ZY-DT Whole Tyre Shredder | Capacity 1–5 t/h, 3–8 cm granules, twin-motor PLC

The ZY-DT series whole tyre shredder is the specialised industrial equipment for fragmenting whole used tyres — without pre-shredding or prior cutting — into rubber pieces of 3–8 cm, with a twin-motor system, PLC control with automatic reversal on overload and re-sharpenable alloy steel blades.

The ZY-DT whole tyre shredder is available in three sizes: ZY-DT 1000 (60 kW total, 1–1,5 t/h, 8,5 t), ZY-DT 1200 (150 kW total, 2–3 t/h, 13 t) and ZY-DT 1500 (180 kW total, 4–5 t/h, 15 t) — the first step in the complete tyre recycling line for producing rubber granules, separating the steel wire and the textile fibre.

The ZY-DT whole tyre shredder is the first-processing equipment of authorised used-tyre recycling plants; the whole tyre — car, truck or machine — is fed directly into the cutting chamber without any prior preparation operation, the twin-motor system and the robust alloy steel blades fragment it into uniform pieces of 3–8 cm, and the resulting material is sent to the following stages of fine granulation, magnetic separation of the steel wire and air separation of the textile fibre for the separate recovery of each fraction. Key Advantages of the ZY-DT Whole Tyre Shredder

• Whole tyres directly into the chamber — zero pre-shredding, zero preparatory operations — the ZY-DT whole tyre shredder accepts whole car, truck and machine tyres without any cutting or prior pre-shredding; eliminating the pre-shredding operation halves the number of pieces of equipment needed compared with lines that require hydraulic shears or saws to prepare the tyres; the operator places the tyre directly on the feeder and the ZY-DT whole tyre shredder carries out the entire primary fragmentation operation automatically.

• Twin-motor system — double torque, resistance to jamming, continuous operation — the ZY-DT whole tyre shredder uses two shafts with blades each driven by a separate motor (30+30 kW on the ZY-DT 1000, 75+75 kW on the ZY-DT 1200, 90+90 kW on the ZY-DT 1500); the twin-motor system generates the combined torque needed to cut the reinforcing steel wire from truck and machine tyres — the most difficult material in the rubber waste category — and ensures continuous operation even at large variations in the density of the feed material.

• 3–8 cm output granules — standardised format for the second granulation stage — the ZY-DT whole tyre shredder produces rubber pieces with dimensions of 3–8 cm, the standardised format for feeding the secondary granulator in the recycling line; the uniform size of the output fractions optimises the productivity of the second-stage granulator and reduces energy consumption compared with feeding heterogeneous-size pieces produced by non-specialised shredders.

• Re-sharpenable alloy steel blades — reduced operating cost over the long term — the ZY-DT whole tyre shredder uses alloy steel blades that can be re-sharpened several times before replacement; re-sharpening the blades costs 5–10 times less than replacing a complete new set; producers who operate the ZY-DT whole tyre shredder under intensive conditions benefit from significantly reduced operating costs compared with shredders with non-sharpenable blades.

• PLC control with automatic reversal — zero jams resolved manually — the ZY-DT whole tyre shredder has a PLC system that monitors the motor current and detects overload; when the blades are jammed by a hard object (thick wire, residual rim), the PLC automatically reverses the rotation direction of the shafts to clear the jam and resumes cutting in the normal direction; the automatic reversal function eliminates the need to stop manually and for operator intervention at each jam, maintaining production continuity.

• Crushing chamber with a separable structure — easy access for maintenance and blade replacement — the ZY-DT whole tyre shredder has a crushing chamber designed with a separable structure that allows quick access to the blades for inspection, re-sharpening and replacement without complete dismantling of the equipment; blade maintenance is carried out in 1–2 hours compared with 4–8 hours on shredders with a non-removable one-piece chamber.

• Compact, space-efficient structure — installation in standard halls — the ZY-DT whole tyre shredder has an optimised power-to-footprint ratio compared with other equipment of the same capacity level; the compact design allows installation in recycling halls without building extensions or costly space-fitting works.

• Optimised energy consumption — maximum efficiency per tonne processed — the ZY-DT whole tyre shredder is sized to consume strictly the energy needed to process the feed material; the twin-motor system allows one of the motors to operate at reduced load when the material is lighter, reducing the total consumption compared with a single-motor system that is oversized and operates at nominal power regardless of the actual load.

Technical Specifications — ZY-DT Whole Tyre Shredder (All Models)

The Recycling Flow — The Place of the ZY-DT Whole Tyre Shredder in the Complete Line

The ZY-DT whole tyre shredder is the first stage of a standardised industrial used-tyre recycling flow that produces three separately recoverable fractions:

• Stage 1 — Primary fragmentation with the ZY-DT whole tyre shredder — the whole tyre is cut into pieces of 3–8 cm; at this stage, the rubber, the steel wire and the textile fibre remain bound in the same pieces; the ZY-DT whole tyre shredder produces the material throughput needed to continuously feed the granulators in the second stage.

• Stage 2 — Secondary granulation (separate equipment) — the 3–8 cm pieces are processed by fine granulators that reduce the size to 1–5 mm; at this stage, the rubber structure loosens sufficiently to allow efficient separation of the steel wire and the textile fibres in stages 3 and 4.

• Stage 3 — Magnetic separation of the steel wire (separate equipment) — a magnetic separator extracts the steel wire from the rubber granules; the recovered steel wire is recovered as scrap metal at smelters.

• Stage 4 — Air separation of the textile fibre (separate equipment) — a suction system separates the textile fibre (nylon or polyester cord) from the pure rubber granules; the textile fibre is recovered in the construction materials and insulation industry.

• Final product — pure rubber granules 1–5 mm — the recycled rubber granules are recovered in the sports surfaces, rubber paving, rubber-modified asphalt, sound and vibration insulation products and automotive industry materials sectors.

ZY-DT 1000 versus ZY-DT 1200 versus ZY-DT 1500 — Selecting the Correct Model

• ZY-DT 1000 (60 kW, 1–1,5 t/h) — small recycling plants, car service, local collection — the ZY-DT 1000 whole tyre shredder is sized for operators who process 8–12 tonnes of used tyres per 8-hour shift; the weight of 8,5 tonnes and the power of 60 kW allow installation in medium-sized halls with a standard three-phase connection; it is the solution for recycling firms at the start of their journey or for collection centres that wish to add value to the collected material through on-site primary processing.

• ZY-DT 1200 (150 kW, 2–3 t/h) — medium recycling plants, volume 15–25 t/shift — the ZY-DT 1200 whole tyre shredder serves recycling lines with flows of 100–200 tonnes of tyres per week; the weight of 13 tonnes requires a dimensioned foundation and a 150 kW electrical connection; it is the balance model between capacity and investment cost for professional tyre recycling operators.

• ZY-DT 1500 (180 kW, 4–5 t/h) — large industrial plants, 30–40 t/shift — the ZY-DT 1500 whole tyre shredder is the equipment for large recycling plants that process 200–400 tonnes of tyres per week; the weight of 15 tonnes and the power of 180 kW require a dedicated design of the foundation and electrical infrastructure; at the capacity of 5 t/h, the ZY-DT 1500 can feed 2–3 secondary granulators in parallel for a complete high-throughput line.

The ZY-DT Whole Tyre Shredder versus the ZY-S Scrap Metal Shredder — Complementary, Not Interchangeable Products

The ZY-DT whole tyre shredder and the ZY-S scrap metal shredder are equipment from the same industrial shredding category but designed for completely different materials and cannot be substituted for one another:

• The ZY-DT whole tyre shredder is specialised exclusively for vulcanised rubber reinforced with steel wire and textile fibre — the structure of the tyre requires specific blades and cutting geometry to simultaneously fragment the three composite materials without the shafts jamming on the wire; the twin-motor system is sized for the tensile strength of the reinforced rubber.

• The ZY-S scrap metal shredder is designed for ferrous and non-ferrous metals, cables, plastic and materials with high compressive strength — the Cr12MoV blades and the low speed of 75–80 rpm are optimised for cutting metals, not for elastic rubber which would absorb the cutting energy without being efficiently fragmented.

• Complementarity in the complete line — complex recycling plants can use both pieces of equipment in parallel: the ZY-DT whole tyre shredder for the tyre stream and the ZY-S scrap metal shredder for the metals and WEEE from the same stream of collected industrial waste; UZINEX supplies both pieces of equipment with integrated national service.

Applications and Industries — Who Uses the ZY-DT Whole Tyre Shredder

• Authorised used-tyre recycling plants — the ZY-DT whole tyre shredder is the base equipment of plants authorised under European legislation on the management of used tyres; authorised operators are obliged to process the collected tyres and cannot store or dispose of them in an uncontrolled manner; fragmentation with the ZY-DT whole tyre shredder is the first mandatory stage in the compliance flow.

• Producers of recycled rubber granules for sports surfaces — the ZY-DT whole tyre shredder feeds the production lines for the rubber granules used in artificial turf surfaces for football fields, athletics tracks, playgrounds and sports flooring; the 3–8 cm granules produced by the ZY-DT are reduced to 1–3 mm in the secondary stages to meet the technical specifications of certified sports surfaces.

• Producers of rubber-modified asphalt — the ZY-DT whole tyre shredder produces the raw material for the rubber granules used in noise-absorbing asphalt and asphalt with improved resistance to thermal fatigue; road administrations and motorway builders are the main users of granulated rubber from recycled tyres in the asphalt mix.

• Producers of sound and vibration insulation materials — the ZY-DT whole tyre shredder feeds factories making rubber panels and tiles for the sound insulation of industrial floors, machine foundations and building partitions; the material from recycled tyres has vibration-damping properties superior to virgin rubber at the same price.

• Authorised used-tyre collectors with their own processing — the ZY-DT whole tyre shredder allows used-tyre collectors to move from simple collection and transport to on-site processing and recovery of the material, eliminating the cost of transport to third-party plants and creating a source of revenue from the sale of the granules and the separated steel wire.

Frequently Asked Questions about the ZY-DT Whole Tyre Shredder

Can the ZY-DT whole tyre shredder also process large truck or machine tyres?

The ZY-DT whole tyre shredder accepts tyres of different sizes depending on the model; the ZY-DT 1200 and ZY-DT 1500 models with their wider chamber and total power of 150–180 kW also process large truck and machine tyres that do not fit into the ZY-DT 1000 chamber; UZINEX engineers confirm on request which model is suitable for the maximum tyre dimensions processed by the specific customer. What happens to the steel wire from tyres when processing with the ZY-DT whole tyre shredder?

The ZY-DT whole tyre shredder fragments the tyre together with the reinforcing steel wire; the wire remains mixed with the rubber pieces at the ZY-DT output and is separated in the subsequent magnetic stage of the recycling line; the steel wire recovered through magnetic separation represents 10–15% of the tyre weight and is recovered as scrap metal at smelters. How often must the blades of the ZY-DT whole tyre shredder be re-sharpened?

The re-sharpening frequency of the ZY-DT whole tyre shredder blades depends on the volume of tyres processed daily and on the dominant tyre type (car vs. truck); when processing 20–30 tonnes per day of car tyres, re-sharpening a set of blades is usually needed at 400–600 operating hours; UZINEX engineers establish at commissioning the recommended interval for checking blade wear for the customer's specific conditions. Does the ZY-DT whole tyre shredder require the tyres to be de-rimmed before feeding?

The ZY-DT whole tyre shredder is designed for tyres that are already de-rimmed — that is, tyres without an aluminium or steel rim; metal rims exceed the cutting strength of the blades and may damage the equipment; de-rimming the tyres is a simple operation carried out with a dedicated hydraulic tyre de-rimmer, available separately; UZINEX engineers can include the de-rimmer in the configuration of the complete recycling line on request. Why Choose UZINEX for the ZY-DT Whole Tyre Shredder

• Consultancy for the entire recycling line — not just the primary fragmentation equipment — UZINEX engineers advise the customer in the design of the complete recycling line: the ZY-DT whole tyre shredder for primary fragmentation, the secondary granulators, the magnetic separator and the air separator — to maximise the value of the final products (rubber granules, steel wire, textile fibre) and the profitability of the total investment.

• Transport and commissioning included — the ZY-DT whole tyre shredder (8,5–15 t) is delivered with specialised transport equipment to the customer's location anywhere in Romania; at commissioning, UZINEX engineers verify the installation, test all PLC functions on real tyres and calibrate the system for the tyre type dominant in the customer's flow.

• Extended 60-month warranty and spare parts in stock — the ZY-DT whole tyre shredder benefits from a 60-month warranty; sets of spare blades, shaft bearings and PLC components are kept in permanent stock at UZINEX for rapid intervention without waiting.

• Eligible for SEAP/SICAP public procurement and EU funding — the ZY-DT whole tyre shredder qualifies for funding through European support programmes for the circular economy and recycling; leasing and credit solutions additionally available for private financing of the investment.

• National service with intervention within 24–48h — the UZINEX service network intervenes on site anywhere in Romania; the critical parts available in stock minimise the downtime of the recycling plant.

• Complete range of recycling equipment — UZINEX offers complete solutions for shredding and crushing — the ZY-DT whole tyre shredder for rubber and the ZY-S scrap metal shredder for metals and WEEE — both with integrated national service and a 60-month warranty.

The ZY-DT whole tyre shredder, with a twin-motor system of 60–180 kW, a capacity of 1–5 t/h, output granules of 3–8 cm, whole tyres without pre-shredding, a PLC with automatic reversal and re-sharpenable alloy steel blades, is the primary fragmentation equipment of industrial used-tyre recycling lines for producing rubber granules, recovering the steel wire and separating the textile fibre.