How to Enhance Waste Tire Recycling Efficiency with a Rubber Granulation System

Waste tire recycling is a complex process, but with the right system, you can transform “black pollution” into valuable resources. In this guide, we’ll walk you through how to set up and optimize a rubber granulation and fiber removal system to maximize your recycling efficiency.

What is a Rubber Granulation and Fiber Removal System?

A rubber granulation and fiber removal system is a comprehensive solution designed to:

• Shred whole tires into manageable pieces
• Separate steel wire from rubber
• Remove light fibers like nylon
• Granulate rubber into uniform 0.04–0.2 inch (1–5 mm) particles

Output materials: Clean rubber granules, recycled steel wire, and separated fibers.

Capacity: 1,100–22,000 lbs (500–10,000 kg) per hour, depending on the model.

Step 1: Powerful Shredding

Start by feeding whole tires into a tire shredder. This machine breaks down passenger car and truck tires into 2–6 inch (50–150 mm) rubber chunks.

Key features of an effective tire shredder:

• High-strength, wear-resistant rotating cutters
• Powerful shearing force to handle tough tire carcasses
• Consistent particle size for optimal downstream processing

Step 2: Steel Wire Separation

Next, feed the shredded rubber chunks into a tire rasper. This machine uses high-speed rotation and physical friction to separate steel wire from the rubber matrix.

For best results:

• Ensure the rasper has sufficient torque and speed
• Regularly inspect and replace worn components
• Optimize feed rate to maintain separation efficiency

Step 3: Fiber Removal

After steel wire separation, the rubber still contains small amounts of light fibers. Use a fiber separator to remove these using air separation or vibratory screening.

Tips for efficient fiber removal:

• Adjust air flow or vibration frequency based on material type
• Regularly clean filters and screens
• Monitor fiber content in the final rubber product

Step 4: Fine Granulation

Finally, feed the purified rubber into a tire granulator. This machine uses extrusion and die-cutting to produce uniform 0.04–0.2 inch (1–5 mm) rubber granules.

To optimize granulation:

• Use high-quality dies and cutting blades
• Maintain proper temperature and pressure
• Regularly calibrate particle size

Technical Features and Advantages

A well-designed rubber granulation system offers several key benefits:

1. High Efficiency and Output: Automated production lines ensure continuous, stable operation.
2. Pure Products: Multi-stage separation processes result in high-purity, low-impurity rubber granules.
3. Fast Return on Investment: Convert waste tires into directly marketable products.
4. Durable Construction: Core components made from high-strength, wear-resistant materials.

Applications and Materials

The system can process a wide range of materials, including:

• Passenger car tires
• Truck tires
• Off-the-road (OTR) tires
• Bicycle tires
• Tire beads
• Other rubber products

End products find use in:

• Rubber floor tiles and running tracks
• Molded items
• Recycled rubber goods

Conclusion

A rubber granulation and fiber removal system is a game-changer for waste tire recycling. By following these four key steps, you can significantly enhance your recycling efficiency, reduce waste, and create valuable products from what was once considered pollution.