Gradeall, a renowned Northern Ireland-based manufacturer of tyre baling and recycling equipment, is introducing the Gradeall OTR Tyre Splitter, specifically designed to process puncture-proof OTR (off-the-road) tyres filled with polyurethane foam.

These heavy-duty tyres, measuring up to 2.2 metres in outside diameter and 1 metre in tread width, present a unique recycling challenge due to their dense, foam-filled cores.

The Gradeall OTR Tyre Splitter efficiently cuts large OTR tyres into two segments. Once split, the sidewalls can be removed using the complementary Gradeall OTR Sidewall Cutter, facilitating further processing or recycling.

Polyurethane foam filled puncture proof

To meet the growing demand for sustainable solutions in handling flat-proof OTR tyres, Gradeall has developed a dedicated add-on for the OTR Splitter. This new enhancement includes a wider solid idler wheel that provides additional support for polyurethane-filled tyres during processing. The clamping and blade system continues to operate in the same manner, rotating the tyre around its circumference to deliver a clean, precise cut — all without any increase in cycle time or changes to the loading process.

The polyurethane core, once separated from the tyre, can be ground down to crumb size and mixed with virgin material for reuse in new tyre applications. Gradeall sees strong potential in this material, citing its high recyclability and potential for circular reuse in the industry.

Gradeall OTR TYRE Splitter on Polyurethane/Foam filled tyres. | Video by Gradeall.

Complete OTR Tyre processing system from Gradeall

While the newly introduced Gradeall OTR Splitter Add-on for puncture-proof, polyurethane-filled tyres is a significant advancement, it is part of a broader, purpose-built system for efficiently downsizing and preparing OTR tyres for further processing.

Gradeall OTR Splitter & Sidewall Cutter. | Video by Gradeall.

Stage I: OTR Splitter – Halving the tyre

The process begins with the Gradeall OTR Splitter, which cuts through the center of the tread section in a single pass. This initial step reduces the tyre to two halves, significantly decreasing weight and making them easier to handle. The design is tailored to accommodate the most common sizes of OTR tyres in the industry.

Stage II: OTR Sidewall Cutter – Isolating problematic components

Following the initial split, the halves are lifted onto the Gradeall OTR Sidewall Cutter. This machine removes the sidewalls from the tyre and isolates the heavy bead section — often the most problematic component for shredding equipment. The outcome is four manageable segments, greatly simplifying downstream processing.

Gradeall Gradeall OTR Tyre Splitter & OTR Sidewall Cutter. | Video by Gradeall.

Post-Processing Options – Shredding, baling, and transport

Once split and sectioned, the processed OTR components can be sorted for shredding or compacted into bales. Baling facilitates efficient transport, reducing the space required on semi-trailers and significantly lowering transport and disposal costs.

For visual reference, see Gradeall’s OTR system in action in the following video:

Cutting OTR Tyres for Shredding

This complete, modular approach reflects Gradeall’s commitment to improving tyre recycling technology and operational efficiency across the board.

To learn more about Gradeall's products, please proceed to the company's website.