Industry Overview
Reclaimed or regenerated rubber is produced from ground vulcanized scrap rubber tires, tubes, and miscellaneous waste rubber articles through the application of heat and chemical agents followed by intensive mechanical working. The process partially de-vulcanizes the rubber, restoring much of its plasticity and enabling the material to be compounded, processed, re-vulcanized, or reused in rubber products.
Reclaiming generally involves grinding suitable scrap, treatment with heat and chemical peptizers or reclaiming agents, and high mechanical shear. Partial de-vulcanization selectively breaks some sulphur cross-links, while thermal-oxidative degradation and mechanical forces can also promote polymer-chain scission. The resulting reclaimed rubber offers processing and economic characteristics that make it useful as a secondary raw material in natural and synthetic rubber compounds.
Reclaimed rubber was developed in response to the historical need for additional rubber resources as the rubber industry expanded and crude rubber supplies were insufficient to meet demand. It also provides a productive use for vulcanized rubber waste, including end-of-life tires. Its applications include cycle tires, rickshaw tires, battery boxes, automobile tires, and other molded rubber goods, where processing efficiency, energy conservation, cost reduction, and desired compound properties are important considerations.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 24 Ton/Day |
| Land & Building (2 Acres) | Rs. 4.08 Cr |
| Plant & Machinery | Rs. 5.50 Cr |
| Working Capital for 1 Month | Rs. 1.60 Cr |
| Total Capital Investment | Rs. 11.65 Cr |
| Rate of Return | 36% |
| Break Even Point | 55% |
Content Index
- INTRODUCTION
- FIGURE: VULCANIZED NATURAL RUBBER (WITH SULPHUR)
- WHAT HAPPENS DURING RECLAIMING
- USES APPLICATION AND ADVANTAGES
- ADVANTAGES OF RECLAIM RUBBER
- RAW MATERIALS
- RUBBER WASTE (USED TYRE AND TUBE SCRAP):-
- B.I.S. SPECIFICATIONS
- 1. SCOPE:
- 2. REQUIREMENTS:
- RECLAIMED RUBBER
- 3. PACKING:
- 4. MARKETING:
- 5. SAMPLING:
- MARKET OVERVIEW FOR RECLAIM RUBBER
- SO WHAT EXACTLY IS RECLAIM?
- DIFFERENT MANUFACTURING PROCESS OF RECLAIM RUBBER
- DIGESTER PROCESS
- PAN PROCESS
- HIGH PRESSURE STEAM PROCESS
- BANBURY PROCESS
- RECLAIMATOR PROCESS
- CRUMB RUBBER AND RECLAIM RUBBER PROCESS
- TIRE BEAD SEPARATOR
- TIRE SHREDDER
- CRACKER MILL
- MAGNETIC METAL & NYLON FIBER SEPARATOR
- FIBER SEPARATOR
- RUBBER CRACKER MILL WITH MAGNETIC METAL SEPARATOR, BELT CONVEYER AND VIBRATING SIEVE
- SEQUENCES IN CRUMB RUBBER AND RECLAIM RUBBER FROM WHOLE SCRAP TYRE
- DEVULCANIZER (AUTOCLAVE)
- KNEADING MIXING MILL
- TWO ROLL MIXING MILL
- STRAINER EXTRUDER
- STRAINER EXTRUDER HEAD
- REFINING MILL
- EXTRACTION OF RUBBER SCRAPS FROM WASTE TYRE
- TYPICAL COMPOUNDING RECIPES FOR INCORPORATING RECLAIMED RUBBER
- MANUFACTURING PROCESS IN DETAILS OF RECLAIMED RUBBER
- METHOD OF RECLAIMING RUBBER
- FLOW DIAGRAM FOR PRODUCTION OF RECLAIMED RUBBER
- TESTING & EVALUATION OF RECLAIMED RUBBER
- A) CHEMICALS
- B) PHYSICALS
- RECLAIM RUBBER PRODUCTION FOR CROSS PLY TYRES
- PROCESS FLOW DIAGRAM OF CRUMB AND RECLAIM RUBBER FROM TYRES /TUBES
- ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
- DETAILS OF RECLAIM RUBBER MACHINERY
- RUBBER GRINDER MILL
- RUBBER REFINER MILL
- PRE - REFINER MILL
- DE-BEADER MACHINE
- STRAINER
- AUTOCLAVES
- PRESSURE RATING:
- TYPES OF DOOR:
- TEMPERATURE INDICATION:
- FORCED AIR CIRCULATION:
- STANDARD ACCESSORIES:
- COMPLETE PLANT AND MACHINERY SUPPLIERS FOR RECLAIM RUBBER
- SUPPLIERS OF RUBBER PROCESSING MACHINERY
- SUPPLIERS OF RUBBER MIXING MILL
- SUPPLIERS OF VIBRATING SCREENS
- SUPPLIERS OF AUTOCLAVE, OVENS
- SUPPLIERS OF CONVEYOR BELT
- SUPPLIERS OF CHOPPER MACHINE
- SUPPLIERS OF MERIT INDUSTRIES LIMITED
- SUPPLIERS OF BOILERS
- SUPPLIERS OF PORTABLE GENERATOR
- SUPPLIERS OF CHEMICAL STORAGE TANKS
- SUPPLIERS OF RECLAIMED RUBBER
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF RUBBER MANUFACTURING CHEMICALS
- SUPPLIERS OF COAL TAR PITCH
- SUPPLIERS OF SODIUM HYDROXIDE
- SUPPLIERS OF BENZENE
- SUPPLIERS OF CARBON BLACK
- SUPPLIERS OF ZINC OXIDE
- SUPPLIERS OF CHINA CLAY
- BUYERS OF RECLAIM RUBBER
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Reclaimed rubber is a partially de-vulcanized rubber material produced from vulcanized rubber waste.
It is manufactured by treating ground scrap rubber from tires, tubes, and other rubber articles with heat and chemical agents, followed by intensive mechanical working. The treatment restores substantial plasticity to the rubber, allowing it to be compounded and processed for reuse. Reclaimed rubber can serve as a secondary raw material in natural and synthetic rubber compounds and is particularly useful where processing efficiency and economical material utilization are important.
Reclaimed rubber is manufactured by grinding vulcanized rubber waste and subjecting it to controlled heat, chemical treatment, and mechanical shear.
The process begins with preparation and size reduction of scrap rubber. The ground material is then treated to promote partial de-vulcanization, after which intensive mechanical working further modifies the rubber structure. Depending on the selected manufacturing route, equipment such as devulcanizers, mills, extruders, and refiners may be used. The resulting material can subsequently be tested, compounded, and processed into rubber products.
The primary raw materials for reclaimed rubber production are vulcanized rubber waste such as used tires, tubes, and other discarded rubber articles.
The report describes ground vulcanized waste or crumb rubber as the basic feedstock for reclaiming. Depending on the selected process and formulation, chemical peptizers, reclaiming agents, and other compounding materials may also be used. Scrap preparation can include removal of tire beads, metallic components, and fibers before the rubber is processed further. Proper segregation and preparation of the incoming waste stream are important for consistent reclaimed-rubber quality.
Reclaimed rubber can improve processing efficiency while providing an economical way to reuse vulcanized rubber waste.
The report identifies shorter breakdown and mixing times, reduced power consumption during breakdown and mixing, lower calendering and extrusion temperatures, improved tack, reduced sulphur bloom, and lower swelling and shrinkage during processing as important advantages. Reclaimed rubber can also support energy conservation and cost-effective formulation. Its suitability depends on the required properties of the finished compound and the quality and characteristics of the reclaimed material.
A reclaimed rubber plant can use equipment for scrap preparation, separation, devulcanization, mixing, extrusion, and refining.
The report lists equipment including tire bead separators, tire shredders, cracker mills, magnetic metal and nylon fiber separators, fiber separators, devulcanizers or autoclaves, kneading and two-roll mixing mills, strainer extruders, and refining mills. Auxiliary systems such as conveyors, vibrating sieves, boilers, generators, and chemical storage equipment may also form part of the plant. The exact equipment configuration depends on the selected reclaiming process and product requirements.
Reclaimed rubber is used in products such as cycle tires, rickshaw tires, battery boxes, automobile tires, and other molded rubber goods.
Its application depends on the grade and characteristics of the reclaimed material as well as the performance requirements of the finished product. Reclaimed rubber can be incorporated into natural and synthetic rubber compounds and subsequently processed and re-vulcanized. Compounders consider factors such as processing behavior, cost, energy requirements, cure characteristics, and the desired physical properties when determining the appropriate level and application of reclaimed rubber.
Reclaimed rubber provides a productive route for converting vulcanized rubber waste into a reusable industrial raw material.
End-of-life tires and other vulcanized rubber products present disposal challenges because conventional vulcanized rubber is not readily reused in its original form. Reclaiming transforms prepared rubber waste into a material that can be compounded and processed again. This supports material recovery while reducing dependence on virgin rubber in suitable applications. The approach also aligns with the report's historical rationale for reclaiming: meeting demand for secondary rubber resources while making productive use of waste rubber.
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