Overview of Tyre Recycling Plant Setup in India

• Waste Management: Supports the environmentally acceptable disposal of scrap tyres and cutting out landfill waste.
• Resource Recovery: Contributes to the most effective utilization of such raw materials as rubber, steel, and oil.
• Environmental Protection: Helps minimize pollution from dumped tyres and open air burning of tyres as they emit toxic gases.
• Circular Economy Support: Recycles waste tyres into material that embraces crumb rubber, fuel oil and reclaimed rubber.
• Energy Conservation: From the recycling processes, energy in form of pyrolysis oil and gas can be produced.
• Job Creation: Offers opportunity for employment in operation, logistic, and waste disposal.
• Compliance with Regulations: Closely relates to government schedules of waste management and EPR measures.
• Carbon Footprint Reduction: Reduces the amount of virgin rubber and oil which are extracted, thus reducing the amount of environmental damage.
• Market Demand: Increasing consumer consciousness about environment and health and trends of new demand in the production of construction materials and manufactured rubber goods with recycled rubber.
• Profitability: Provides revenues from product recycling and carbon credits with the potential to expand into the sector of ecological businesses.

Types of Tyre Recycling Plant Setup in India

Crumb Rubber Plant

• Process: Waste tyres are shredded and ground into small granules or fine powder (crumb rubber). This process includes removing steel and fibre from the tyres.
• End-products: Crumb rubber is used in road construction (rubberized asphalt), playground surfaces, sports fields, and moulded products like mats.
• Advantages: Reduces landfill waste, offers high market demand for eco-friendly infrastructure, and promotes a circular economy.

Retreading Plant

• Process: Old tyres are inspected, buffed, and fitted with new rubber treads, extending their usable life.
• End-products: Retreaded tyres, commonly used for commercial vehicles like trucks and buses.
• Advantages: Cost-effective, reduces tyre waste, conserves resources, and decreases demand for new tyres. Retreading also saves energy compared to producing new tyres.

Pyrolysis Plant

• Process: Tyres are heated in an oxygen-free environment (pyrolysis) to break them down into pyrolysis oil, carbon black, steel, and gas.
• End-products:
• Pyrolysis oil: Used as fuel in industries or further refined.
• Carbon black: Reused in tyre manufacturing or pigments.
• Steel: Sold to metal recycling companies.
• Advantages: Efficiently converts waste into fuel and raw materials, reduces environmental impact, and provides energy recovery.

Tyre Waste Registered Recyclers Can Issue EPR Certificates-

Tyre waste recyclers in India significantly contribute to fulfil producers or importers EPR targets. End of life management is a policy approach that seeks to make those who design products, import them as well as those who own a brand accountable for their products at their disposal. CPCB registered tyre recyclers can also provide EPR certificates to these stakeholders certifying that they have treatment/ disposal of a specific quantity of waste tyres. Such certificates serve as evidence that producers and importers deliver the set EPR for recycling of tyre waste. The legal risks are an indication that working with certified recyclers will actually help avert the realization of such a situation.

Requirements for Tyre Recycling Plant Setup in India

Land and Infrastructure

• Adequate, and preferably urbanized, industrial site that would meet the provisions of zoning ordinances.
• A large garage with enough space for installing machines, storing inputs and keeping outputs.
• Standardization of electrical and water system to facilitate organizational requirements and working apparatuses.

Machinery and Technology

• Crumb Rubber Plant: Tyre shredders, granulators, magnetic systems (for steel), and fibre rejection systems.
• Pyrolysis Plant: Reactor, oil condenser, gas scrubber, cooling tower, collection system for carbon black and polluting materials and devices.
• Retreading Plant: Rubber buffing machines, rubber extruding machines, curing chambers and inspection equipment.
• Equipment such as scrubbers, dust collectors and exhaust emission control systems.

Licenses and Permissions

• Consent to Establish (CTE) & Consent to operate (CTO) from state pollution control board under the air and water Act.
• Obtaining CPCB registration for the implementation of waste tyre management norms.
• Where necessary, consent from the Ministry of Environment, Forest and Climate Change (MoEFCC) for big projects and or those proposed in sensitive ecosystems.
• Local public consultation through Public Hearings especially for Environmental Impact Assessment (EIA) approval on specified categories of works.

Compliance with Regulations

• Compliance with the Hazardous Waste Management Rules rendering safe processes for the pyrolysis by-products and other wastes.
• ALL tangible / physical, including fixtures and installations intended to reduce fire risks or contain the spread of fire such as. Fire extinguishers Fire alarms Emergency exits.
• Sanitary treatments that involve individual protection devices for workers and their trainings.

Raw Material Supply

• The other are reliable supply linkages of waste tyres, scrap dealers and municipal solid waste departments, tyre shops etc.
• Suppliers relations where the organization has agreed with suppliers on how they will supply the organization’s raw materials in the future.

Manpower and Expertise

• Skilled technicians to operate the machinery and handle maintenance.
• Trained staff for sorting, loading, unloading, and quality control.
• Environmental and safety officers for monitoring compliance and handling regulatory inspections.

Pollution Control Measures

• Proper dust and fume control systems to prevent air pollution.
• Wastewater treatment facilities to manage industrial discharge.
• Regular monitoring of emissions and waste disposal methods to comply with SPCB and CPCB standards.

Financial Investment

• Capital investment for land, equipment, construction, licenses, and operational setup.
• Budget for working capital, including raw materials, labour, and utilities.
• Consideration of financial support through government schemes or bank loans targeting green industries.

Waste Management and Recycling Efficiency

• Effective handling and storage of by-products like pyrolysis oil, carbon black, and scrap steel.
• Implementation of a recycling process with high recovery rates to minimize waste and optimize efficiency.

Market Analysis and Product Distribution

• Research on demand for recycled products like crumb rubber, fuel oil, and retreaded tyres.
• Establishment of a distribution network to market the recycled products to relevant industries, including construction, manufacturing, and energy sectors.

Personal/Basic Documentation:

• Identification and address verification of the applicant
• Documentation demonstrating ownership or a lease agreement

Technical Documentation:

• Comprehensive project report including layout designs and waste management plans
• Specifications regarding recycling technology and equipment
• Environmental Impact Assessment (EIA) report, if relevant

Regulatory Compliance:

• Form 1 submission in accordance with the Hazardous Waste Regulations
• Evidence of adherence to safety and environmental regulations
• Consent to Establish (CTE) issued by the State Pollution Control Board (SPCB)

Local Authority Approvals:

• No Objection Certificate (NOC) from the relevant local authorities
• Approval for power connection from the local electricity authority

Step 1: Business Registration

• Register company with Ministry of Corporate Affairs (choose business structure)
• Obtain PAN and GST registration
• Register business name in compliance with legal norms

Step 2: Location and Land Requirements

• Identify suitable industrial land following zoning laws
• Get Land Use Conversion Certificate (if using agricultural land)
• Secure permissions from municipal/development authorities

Step 3: Environmental and Pollution Control Approvals

i. State Pollution Control Board (SPCB):

• Apply for Consent to Establish (CTE)
• Submit project report, layout plans, and production details
• Obtain NOC for construction

ii. Central Pollution Control Board (CPCB):

• Register as authorized tyre recycler
• Submit recycling technology and capacity details
• Register for EPR compliance if applicable

iii. Ministry of Environment (MoEFCC) :

• Submit project details and environmental management plans
• Obtain Environmental Clearance for large-scale projects
• Conduct and submit Environmental Impact Assessment (EIA)

Step 4: Operational Permits

• Apply for Consent to Operate (CTO) from SPCB
• Register under Factories Act, 1948
• Obtain Hazardous Waste Management registration (if applicable)
• Secure Fire Safety Certificate

Step 5: Infrastructure Setup

• Install machinery and pollution control equipment
• Set up safety measures and emergency protocols
• Establish proper waste storage and handling facilities
• Arrange power supply and other utilities

Step 6: Final Compliance and Launch

• Schedule inspection with SPCB/CPCB
• Obtain final operational license
• Implement labour compliance measures
• Set up system for annual compliance reporting

Step 7: Ongoing Compliance

• Submit regular environmental compliance reports
• Maintain proper documentation
• Prepare for periodic regulatory inspections
• Update permits and licenses as required

Growing Market: Tap into India's expanding tyre recycling sector with expert guidance

Environmental Impact: Contribute to sustainable development while building a profitable business

Proven Success: Join our community of successful plant owners

Future-Ready: Stay ahead with regular updates on industry trends and technological advancements

Our Commitment: We are committed to making your tyre recycling plant not just operational, but exceptionally successful. We combine technology, expertise, and dedicated support to ensure your venture thrives in this growing industry.

Get Started Today: Take the first step towards establishing your tyre recycling plant. Connect with us for a free consultation and discover how we can make your vision a reality.