2. “A society is defined not only by what it creates, but by what it
refuses to destroy.” – Recycle!!
PICS providing you the ultimate solution for recycling
scrap into valuable commodities year after year, at the
same time helping to protect the environment.
4. Tire recycling or rubber recycling is the process of recycling tire that are
no longer suitable for use.
These tires are among the largest and most problematic sources of
waste, due to the large volume produced and their durability.
Tire is one of the most re-used waste materials, as the rubber is very
resilient and can be reused in other products.
Material recovered from waste tires, known as "crumb."
Tires can be recycled into, among other things, the hot melt asphalt,
typically as crumb rubber modifier—recycled asphalt pavement.
Tires can also be recycled into other tires.
6. Tires are not desired at landfills, due to their large
volumes and 75% void space, which quickly
consumes valuable space.
Landfill Tires can trap methane gases, causing them to
disposal become buoyant, or 'bubble' to the surface.
This 'bubbling' effect can damage landfill liners
that have been installed to help keep landfill
contaminants from polluting local surface and
ground water.
7. Shredded Tires are now being used in landfills,
replacing other construction materials, for a
lightweight backfill in gas venting systems,
leachate collection systems, and operational
liners.
Shredded tire material may also be used to cap,
close, or daily cover landfill sites.
Scrap Tires as a backfill and cover material are
also more cost-effective, since Tires can be
shredded on-site instead of hauling in other fill
materials.
8. Tire stockpiles create a great health and safety
risk. Tire fires can occur easily, burning for
months, creating substantial pollution in the air
and ground.
Recycling helps to reduce the number of Tires in
storage. An additional health risk, Tire piles
provide harborage for vermin and a breeding
Stockpiles and ground for mosquitoes that may carry diseases.
illegal Illegal dumping of scrap Tires pollutes ravines,
dumping woods, deserts, and empty lots; which has led
many states to pass scrap tire regulations
requiring proper management.
Tire amnesty day events, in which community
members can deposit a limited number of waste
Tires free of charge, can be funded by state scrap
tire programs, helping decrease illegal dumping
and improper storage of scrap Tires.
9. Besides being unsightly and taking up valuable
land space, Tire dumps and stockpiles present
many environmental concerns.
When waste Tires are buried they have a
tendency to “wiggle” their way to the surface
over time causing problems for landfill sites.
When Tires are stockpiled above ground they
form mountainous piles that are at high risk of
catching fire.
10. When fires do break out – usually caused by
lightening strikes – they can be extremely difficult
to extinguish, sometimes burning for several
months.
Stockpile fires cause pollutants being released
into the environment.
Oil as a result of the burning Tires enters the
groundwater and nearby rivers and thick black
clouds of smoke full of toxic gases are released
into the atmosphere.
Even when fires don’t break out, Tire stockpiles
are breeding grounds for pests such as
mosquitoes and rodents.
11. Scrap tires are generated when consumers buy new tires for their vehicles or
dispose of their old vehicles. These are newly generated scrap tires.
Old scrap tires also enter the recycling chain when they are eliminated from
existing stockpiles.
Scrap tires from consumers are collected by generators who are either tire
retailers or vehicle recyclers.
Haulers pick up the tires from generators and hand them over to processors
who convert the tires into crumb rubber, shred rubber, tire-derived fuel and
other materials that are suitable for end-markets.
Municipalities can also collect scrap tires, and in certain cases, haul them to
processors.
13. •Tire A tire is made of natural rubber (also called virgin
composition rubber), Stirene-Butadienubber (SBR),
and stages in Polybutadiene Rubber (PBR), Carbon black, Nylon
tire cord, rubber chemicals, steel tire cord and
recycling Butyl rubber.
14. Crumb:
Rubber Crumb is the material resulting from granulating scrap tires into
uniform rubber granules. It can be mixed with asphalt for road surfacing and
making children’s playgrounds.
Reclaimed Rubber:
Reclaimed Rubber is the recycled old tire rubber.
It can be used as a substitute of natural & synthetic rubber. It is mixed with
virgin rubber to further make new tires of automobiles, bicycles and other
low-cost products like footwear and mats.
Virgin rubber, 90 percent of which is produced in Kerala is sold for as high Rs
140-150 per kg.
Reclaimed rubber is sold for Rs 25-30 per kg and India being one of the
voluminous reclaim rubber producers, the production is growing by ten
percent per year.
15. With the PICS recycling equipment you will be able to process whole car and
truck Tires (including super singles) without prior debeading being required.
You can also process earth mover tires, OTR etc.
The tire recycling systems offered by PICS is modular systems enabling you to
invest as much or as little as you wish in the certain confidence that it will
always be possible to add to the system as required.
The flexibility of this modular approach means that a large number of
combinations can be obtained, ranging from a single machines for shreds or
chips to a complete System for granules.
16. With the PICS
tire recycling
equipment you
will be able to
process whole
car and truck
tires including
super singles,
earth mover
tires, OTR etc.
17. The PICS system is a "multi-size" system, which means that the output size
easily can be changed by merely changing the screens (i.e. larger or smaller
holes).
By production of rubber granulate, flexibility is an very important factor since
the market demands of various fraction sizes will vary.
18. Shreds are the largest of
the output material.
The Tires are chopped
down to shreds with size of
50-300 mm in the
powerful PICS single-shaft
Super Chopper.
The maximum size of input
material is approximately
1900 x 550 mm.
Shreds are for example an
useful size when
transporting used Tires.
They need less space, and
therefore the transporting
costs are reduced.
19. By putting either whole car
Tire or pre-chopped Tires
into the PICS medium-
speed, dual drive Multi
Purpose Rasper chips with
sizes down to
approximately 12 mm can
be produced.
At this stage it will also be
possible to remove up to
98% of the liberated steel
from the rubber granulate.
The chips can be used for
TDF (Tire Derived Fuel)
which is a fuel used for
heat plants and cement
owns or for “Equestrian”
(i.e. rubber mixed with
sand or sawdust used in
the horse industry as
ground in the stable or at
the tracks).
20. The fine-granulation is a two stage
operation which is primarily used
for liberating and removing as much
textile as possible from the rubber
granulates.
This keeps the capacity high since
the textile otherwise will block the
screens and thereby reduce the
capacity.
After the fine-granulation and
separation of steel and textile a
rubber granulate with a purity of up
to 99,9% can be ensured.
The final size distribution depends
upon your specific requirements.
It can for instance be 0,8 to 1,6 mm
and 1,6 to 3,2 mm.
Granulate are for example used for
Rubber Mats and to Moulded
products. It is also used for Sports
fields and Artificial Turfs in for
example soccer, golf and athletic
tracks.
21. With the above mentioned
granulate from the PICS
tire recycling plants,
powder with sizes ranging
from 10 to 50 Mesh can be
produced in the PICS
Powder Plant.
Mesh is the number of
openings per linear inch of
a screen (i.e. the higher
number, the smaller
particles.
The powder from the PICS
Powder Plant comply with
ASTM D 5603-96.
The powder is for example
used in the asphalt
industry for “Rubber Paved
Asphalt”.
22. The standard setup includes a Super Chopper, Tumble Back Feeder, Multi
Purpose Rasper, Eddy Current Separator, Heavy Granulator, Fine Granulator
and a Separation Table.
We have standard plants with capacities ranging from 3.000 - 8.000
kgs/production hour.
This is also the starting point when plants are tailored to suit specific
customer requirements.
Within Tire recycling we often talk about Plant A to E. Plant E is the entire
line, and Plant A to D are parts of that line. All these plants give different
outputs.
23. A – plant: up to 20.000 kg/ hr *
Standard B – plant: up to 6.000 kg/ hr*
plants: C – plant: up to 5.000 kg/ hr *
D – plant: up to D3000T: 3.000 kg/ hr &
D4000T: 4.000 kg/ hr *
E – plant: up to E3000T: 3.000 kg/ hr &
E4000T: 4.000 kg/ hr *
Powder Plant: 2.500 kg/hr*
E4000T + Powder Plant: up to 4.000 kg/
hr (it can run up to 2.5 ton/ hr output i.e.
4.000 kg/ hr input) *
25. Plant A consists merely of the Super Chopper.
This is a hydraulic driven powerful pre chopper capable of processing
complete car and truck tires (including super singles) down to shreds size
(approximately 50-300mm).
It is low-speed with either single or dual shafts. The torque is with its 30 – 40
ton cutting force per knife!
Other advantages with Plant A are low running costs, few spare parts, easy
access to knives, very few wear parts to change and high capacity.
The dimensions of the tires to be chopped has a maximum diameter of 1200
mm and width of 450 mm.
De-beading of the tires will not be required prior to processing in the PICS
Super Chopper.
The machine is delivered with a Disc Pusher to occasionally assist by feeding
of truck tires to the Super Chopper.
26. The multifunctional Super Choppers (SC1408/90, SC1412/160 and
SC2118/250) process most non-ferrous materials and tyres.
Unique single rotor design.
Low speed, high torque rotor.
Powered directly by a Hägglund hydraulic motor and power unit.
Automatic reverse for overload protection.
Large triangular knives are resistant to cracking or breaking.
Adjustable knife clearance.
Knives available in different steel qualities providing the optimum solution for
processing of your specific material.
Special tool-steel knives can be reground multiple times on a »flat-bed«
grinder to ensure long life and low operating costs.
Starts when fully loaded with material.
Inlet hopper with large opening enabling very easy grab loading.
Reliable After-Sales-Service.
27. Standard Plant B is designed for recycling of
Standard Plant whole car Tires or pre-cut car and truck Tires with
a maximum car Tires 300 mm. The input material
B is turned into Tire chips with a size from 75 mm
down to approximately 12 mm. The chips are up
to 98% free of liberated steel content!
The Tumble Back Feeder is the machine ensures a
continuous flow into the Multi Purpose Rasper -
thus ensuring an optimum load/utilization of the
Multi Purpose Rasper.
The Multi Purpose Rasper is the first granulation
which means that it reduces the Super Chopper
shred input (50-300 mm) down to 12 mm in a
single pass. The majority of the steel is removed
and the chips are almost free from steel.
The chips are then used for example TDF (Tire
Derived Fuel) or further processed in the
granulation plant.
28. The machine is an effective Rasper designed for tire recycling.
The MPR is medium-speed and has dual drive. This machine is capable of
processing whole passenger car Tires or pre-chopped car and truck tires.
The machine is equipped with exchangeable screens and the output size will
be determined by the actual screen size installed in the machine.
It ensures individual size reduction down to approximately 12 mm chips and
liberation up to 98% of the steel content.
30. The Multi Purpose Rasper (MPR120, MPR160 and MPR200) has a standard
rotor is made from wear-resistant, hardened steel.
The main rotor housing is equipped with replaceable wear plates to increase
the durability of the machine.
Special tool-steel knives can be reground multiple times on a »flat-bed«
grinder to ensure long life and low operating costs.
Adjustable knife clearance.
The rotor can be turned automatically when changing knifes and doing
maintenance or inspection.
Serrated knife design available in different steel qualities.
Screens available with different hole sizes and different steel qualities.
31. Hydraulic opening of rotor housing for easy access to rotor and knives.
Hydraulically operated swinging cradle will permit cleaning or exchange of
screen.
Screen segments can be turned.
Friction clutches protects the drive system from momentary overload.
The machine is belt driven x 2, each side being individually adjusted.
Components used in each drive side – from axle journal to belt/flywheel are
alike thus reducing maintenance costs.
The high inertia gives a more even load of the machine.
Reliable After-Sales-Service by PICS Recycling.
32. Standard Plant
Plant C is designed for recycling of complete Truck
C and Car Tires (including Super Singles & Tractor
Tires) and size reduction from Tire chips of 75 mm
to 12 mm. The output chips are up to 98% free of
liberated steel content.
The Super Chopper is a hydraulic driven powerful
pre-chopper capable of processing complete car
and truck Tires (including super singles) down to
shreds size (approximately 50-300mm).
It is low-speed with either single or dual shafts.
The torque is with its 30 – 40 ton cutting force per
knife!
33. Other advantages with Plant A are low running costs, few spare parts, easy
access to knives, very few wear parts to change and high capacity.
The dimensions of the Tires to be chopped has a maximum diameter of 1200
mm and width of 450 mm. De-beading of the Tires will not be required prior
to processing in the PICS Super Chopper.
The machine is delivered with a Disc Pusher to occasionally assist by feeding
of truck Tires to the Super Chopper.
34. The Tumble Back Feeder is the machine ensures a continuous flow into the
Multi Purpose Rasper - thus ensuring an optimum load/utilization of the
Multi Purpose Rasper.
The Multi Purpose Rasper is the first granulation which means that it reduces
the Super Chopper shred input (50-300 mm) down to 12 mm in a single pass.
The majority of the steel is removed and the chips are almost free from steel.
The chips are then used for example TDF (Tire Derived Fuel) or further
processed in the granulation plant.
35. Plant D is designed for processing of pre-cut car
and truck Tires (maximum size approximately 300
mm) to high quality rubber granulate. The output
Standard Plant size of the rubber granulate varies, but is always
up to 99.9% free of liberated steel wire and
D textile.
The Tumble Back Feeder is the machine ensures a
continuous flow into the Multi Purpose Rasper -
thus ensuring an optimum load/utilization of the
Multi Purpose Rasper.
36. The Multi Purpose Rasper is the first granulation which means that it reduces
the Super Chopper shred input (50-300 mm) down to 12 mm in a single pass.
The majority of the steel is removed and the chips are almost free from steel.
The chips are then used for example TDF (Tire Derived Fuel) or further
processed in the granulation plant. The machine is an effective Rasper
designed for Tire recycling.
The MPR is medium-speed and has dual drive. This machine is capable of
processing whole passenger car Tires or pre-chopped car and truck Tires. The
machine is equipped with exchangeable screens and the output size will be
determined by the actual screen size installed in the machine. It ensures
individual size reduction down to approximately 12 mm chips and liberation
up to 98% of the steel content.
37. Silos
The Silo V4 ensures
continuous flow
through the first Fine-
Granulator and
ensures optimum
utilization of the
capacity.
38. For optimized operation and enhanced throughput
Buffer Silo (BFS5)
Between Super Chopper and Rasper
5 m3 Silo with slatted steel conveyor belt
Heavy rotating fl ail to control the feed rate.
Balances the output from the Super Chopper to the input rate of the Rasper.
Silo SMV
Between the Granulator and the Separation Equipment
Centred around an open rectangular storage vessel with a vibrating base
Balances the flow of granulated material to ensure that the Separation works
at maximum capacity, thus ensuring that the quality of separation is
maintained.
39. Silo V4
Between the Rasper and the Granulator
4 m3 Silo with vibratory base to control the feed rate
Balances the output from the Rasper the input rate of the Granulator.
40. The Fine-Granulators ensures fine granulation of the rubber granulate. These
machines are also equipped with exchangeable screen sizes to determine the
actual output size – if you want a different output size, just change the
screen.
Fine-Granulator 1 is a high-speed, single shaft Fine-Granulator used for the
first granulation stage enabling liberation of up to 50% of the textile
contained in the Tires. The liberated textile is then removed in the Classifier
PC10.
Fine-Granulator 2 high-speed, single shaft Fine-Granulator for the second
and final granulation stage. If there is still any textile or steel left in the
material it is liberated here. The steel is removed by magnets, and the textile
is removed by the Classifier PC15 (removes 40% of the textile).
42. PICS Fine Granulators (FG476, FG952 and FG1504) are ideally suited for the
modern world of today’s scrap processing. They have open rotor design
provides natural internal airflow keeping the cutting chamber and the
material cool.
The individual and adjustable flying and static knives are easy to change in a
quick change knife system. Special tool-steel knives can be reground multiple
times on a »flat-bed« grinder to ensure long life and low operating
costs. Main rotor housing has replaceable wear plates. Hydraulically operated
inlet hopper provides easy access to the cutting chamber for
maintenance. Hydraulically operated access to screen area for cleaning and
changing of screens.
Screens available with different hole sizes to suit your special requirements.
PICS has reliable After-Sales-Service to all plants and machines.
43. T H E A S P I R AT O R E N S U R E S T H E F I N A L S I Z E
D I S T R I B U T I O N O F T H E G R A N U L AT E A N D
R E M O V E S T H E R E M A I N I N G , L I B E R AT E D T E X T I L E
PROVIDING A HIGH QUALITY RUBBER
G R A N U L AT E W I T H A P U R I T Y O F U P T O 9 9 . 9 % .
45. The PICS Aspirators are designed to separate the
textile from the rubber granules and classify the
rubber granules into three sizes.
The Aspirators are precision cleaners, which
handle capacity requirements up to 4-6 ton/hour.
The Aspirators perform with high cleaning
efficiency on a wide range of rubber granules and
powder.
They work on the basis of two separate
separation devices, a dust suction system that
removes the dust fraction and a three screen
Classifier separating the textile and classifying the
rubber into three fractions.
The material is fed to the machine at the inlet,
where the feed roller distribute the material.
46. From the feed roller the material is led into a
»light particle« extractor channel, where the light
fluff particles are sucked away from the material.
The major part of the fluff is then separated out
in the aspiration chamber, where ventilators lead
the light fraction to a possible cyclone.
The material is now led to the screen section,
where the sizing takes place. The short upper
screen removes the remaining fluff particles. The
long screen removes the large rubber particles
and the small rubber particles passing through
this screen are divided equally onto each of the
two sorting screens in the bottom of the screen
section.
With the PICS Aspirators you also get our reliable
After-Sales-Service.
47. Plant E is designed for recycling of complete Truck
and Car Tires, including Super Singles & Tractor
Standard Plant Tires to a high quality rubber granulate of various
E sizes.
The output material is 99.9% free of liberated
steel wire and textile.
The dimensions of the input Tires can be
maximum diameter of 1200 mm and maximum
width of 450 mm. De-beading of the Tires will not
be required.
The Super Chopper is a hydraulic driven powerful
pre-chopper capable of processing complete car
and truck Tires (including super singles) down to
shreds size (approximately 50-300mm).
49. It is low-speed with either single or dual shafts. The torque is with its 30 – 40
ton cutting force per knife!
Other advantages with Plant A are low running costs, few spare parts, easy
access to knives, very few wear parts to change and high capacity.
The dimensions of the Tires to be chopped has a maximum diameter of 1200
mm and width of 450 mm.
De-beading of the Tires will not be required prior to processing in the PICS
Super Chopper.
The machine is delivered with a Disc Pusher to occasionally assist by feeding
of truck Tires to the Super Chopper.
The Tumble Back Feeder is the machine ensures a continuous flow into the
Multi Purpose Rasper - thus ensuring an optimum load/utilization of the
Multi Purpose Rasper.
50. The Multi Purpose Rasper is the first granulation which means that it reduces
the Super Chopper shred input (50-300 mm) down to 12 mm in a single pass.
The majority of the steel is removed and the chips are almost free from steel.
The chips are then used for example TDF (Tire Derived Fuel) or further
processed in the granulation plant.
The machine is an effective Rasper designed for Tire recycling.
The MPR is medium-speed and has dual drive. This machine is capable of
processing whole passenger car Tires or pre-chopped car and truck Tires.
The machine is equipped with exchangeable screens and the output size will
be determined by the actual screen size installed in the machine.
It ensures individual size reduction down to approximately 12 mm chips and
liberation up to 98% of the steel content.
51. The Silo V4 ensures continuous flow through the first Fine-Granulator and
ensures optimum utilization of the capacity.
The Fine-Granulators ensures fine granulation of the rubber granulate.
These machines are also equipped with exchangeable screen sizes to
determine the actual output size – if you want a different output size, just
change the screen.
52. Fine-Granulator 1 is a high-speed, single shaft Fine-Granulator used for the
first granulation stage enabling liberation of up to 50% of the textile
contained in the Tires. The liberated textile is then removed in the Classifier
PC10.
Fine-Granulator 2 high-speed, single shaft Fine-Granulator for the second
and final granulation stage. If there is still any textile or steel left in the
material it is liberated here. The steel is removed by magnets, and the textile
is removed by the Classifier PC15 (removes 40% of the textile).
The Aspirator ensures the final size distribution of the granulate and removes
the remaining, liberated textile providing a high quality rubber granulate with
a purity of up to 99.9%.
53. E5000T– plant: up to 5.000 kg/hr *
E8000T– plant, double line: up to 8.000
Special plants: kg/hr*
E1500T/MF: up to 1.500 kg/hr* (can be
modified to also recycle cable and WEEE)
Steel Cleaning Systems
54. T O A C H I E V E T H E R E Q U I R E D T Y P E O F E N D - P R O D U C T,
D I F F E R E N T S TA N D A R D T I R E R E C Y C L I N G P L A N T S A R E
AVA I L A B L E .
T H E S E S TA N D A R D P L A N T S A R E A L S O T H E S TA R T I N G
P O I N T W H E N P L A N T S A R E TA I L O R E D T O S U I T
SPECIFIC CUSTOMER REQUIREMENTS.
AVA I L A B L E O P T I O N A L M O D U L E S F O R S P E C I F I C
R EQ U I R E M E N T S W I T H I N T I R E R EC YC L I N G A R E :
55. The Car Tire Feeder automatically ensures a
continuous feeding of the Super Chopper.
•Car Tire The tumbling effect reduces the content of
Feeder foreign bodies in the tires.
The feeding capacity of the Car Tire Feeder is 5-6
per hour, and it can contain approximately 10-50
car tires at the same time (depending on the type
of machine).
56. Due to the growing demand for cleaning of the
steel we have developed systems to meet specific
•Steel Wire customer requirements for upgrading of the steel
fraction originating from PICS Tire Recycling
Cleaning Plants.
System The syThe Steel Wire Cleaning Systems reduces
the rubber content in the steel fraction down to
3-5%.
stems will be dimensioned and balanced to meet
specific customer demands.
Purities of 95 - 99% will be obtainable all
depending on the system chosen.
57. •Quality
The Quality Upgrading system ensures ultimate
Upgrading purity of 99,99% of the main size and under size
System rubber fraction.
Meets customer and market demands for powder
Powder Plant
down to 50 Mesh.
58. Excluding the use of whole tires, we can categorize the uses of tires in the
following way:
Rubber Crumb - Floor mats, belts, gaskets, shoe soles, dock bumpers, seals,
muffler hangers, shims, and washers.
Reclaimed Rubber in Vehicles:
a) Automotive Industry - Crumb (three to five percent) and Reclaimed rubber
(up to ten percent) is particularly used in automobile tires. However, since the
volume of tires is very high, the quantity of these rubbers used also goes up.
New tire industry uses approximately 58 percent of the natural rubber of
India, including imports of more than 80000 tones (according to ATMA
figures)
b) In tire carcasses in substantial volume and other automotive parts
c) Bicycle tire industry produces a massive 6-7 lakh tires/day, out of which
more than 80 percent are produced in Ludhiana.
59. Molded products – These include mats, hose pipes, conveyor belts, v-
belts, footwear, tiles, adhesives, sound dampers, rubber sheets,
battery containers and other rubber molded goods
Footwear industry - Shoe soles
Cement Industry - "This is the most perverse use of old tires causing
only pollution", says Dr. Chakravarty . However, in some countries,
respective cement industries have developed technology where the
tire is burnt at a temperature that destroys most toxic emissions, the
exhaust is scrubbed and filtered and little escapes the cement kiln. The
usage of tires for burning in cement kilns in India is up to 20000 tones
per year, according to Imbrose, a small tire trader.
60. Retreading – Tires in India are retreaded as much as three to six times.
One thing to note here is that it’s the truck tires that are retreaded,
and not the car tires. There are 100-odd firms engaged in tire
retreading in India with prominent names being MRF, Apollo, ELGI,
Midas and Indag.
Whole tires are used as highway crash barriers, furniture, boat
bumpers on marine docks, etc but it is a negligible amount.
Land filling or burning tires for energy has limited prospects as
environmental authorities are acknowledging the need for its greener
alternatives.
On the other hand, mass-market end products like continuous rolls of
cost-effective recycled rubber used for noise insulation now complete
the 'big picture' for investors to consider recycling tires commercially.