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Tyre stacks beside the rotary reactor - YUGA rubber-to-fuel pyrolysis unit
Product · YUGA PMC

Rubber-to-Fuel (Tyre Pyrolysis)

Waste tyres into Tyre Pyrolysis Oil (TPO), carbon black, steel & gas

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Overview

What is Rubber-to-Fuel (Tyre Pyrolysis)?

Tyre pyrolysis (rubber-to-fuel) thermally decomposes end-of-life tyres into Tyre Pyrolysis Oil (TPO), recovered carbon black (rCB), steel wire and combustible gas. India generates large volumes of waste tyres, making feedstock plentiful.

Operations must follow the CPCB SOP for TPO units (latest revision), including PLC automation, Zero Liquid Discharge and EPR registration. Newer norms favour continuous-type, higher-capacity, well-controlled plants.

Tyre pyrolysis plant - interior view
Why this business

Benefits

  • Four revenue streams — TPO oil, carbon black, steel wire and gas
  • Abundant feedstock — millions of end-of-life tyres each year
  • Strong margins — payback frequently in ~12–24 months when optimised
  • Environmental value — removes a hazardous waste-tyre stockpile
  • EPR aligned — supports tyre producers' recycling obligations
Demand

Applications & buyers

  • TPO sold as industrial fuel or further refined
  • Recovered carbon black for rubber, plastic, masterbatch, pigment uses
  • Steel wire scrap sold to steel/foundry units
  • Gas recycled to heat the reactor, reducing running cost
Technical

Specifications

FeedstockEnd-of-life tyres / shredded rubber
OutputTPO ~40–45%, carbon black ~30–35%, steel ~10–15%, gas ~10%
RegulationCPCB SOP for TPO units; PLC + Zero Liquid Discharge
Land (typical)Larger continuous units need sizeable plots (e.g. ~7,000 m²+)
ApprovalsSPCB/CPCB consent, EPR, factory & fire NOC
Setup

Plant & machinery

Capacity to showCommon 10 TPD; Larger continuous 20–50 TPD
Area required10 TPD: ~3,000 sq m compliance base, practical 1–2 acres; 20–50 TPD: 2–5 acres (tyre yard, shredding, reactor, TPO tanks, char, steel, green belt)
Approx. cost (without land)10 TPD compliant ₹2.5–5 Cr; 20 TPD ₹5–9 Cr; 50 TPD ₹12–25 Cr (compliant continuous/APC costs more than basic batch)
UtilitiesElectricity, process fuel/gas reuse, cooling water, scrubber, compressed air, fire water, forklift/loader
ApprovalsCPCB waste-tyre EPR / TPO registration, CPCB SOP compliance, SPCB CTE/CTO, factory & fire, storage permission, authorized buyer records
Best-use statesCompliance-first continuous design; Gujarat, Maharashtra, Tamil Nadu, Punjab, Rajasthan
Tyre receiving, weighing & storage yardTyre debeader/cutter or shredderConveyor & feed-preparation systemContinuous pyrolysis reactor with sealed feedingHeating furnace / thermic systemCondenser train & oil collectionPyro-gas cleaning & reuse systemChar cooling, handling & baggingSteel-wire magnetic separation & storageTPO storage tanks, transfer pumps, loading bayScrubber, stack, monitoring provisionFire safety, gas detection, emergency systemsLab for oil, char & compliance records
YUGA founder Prince Shah consulting at a tyre/rubber-to-oil pyrolysis plant
Tyre pyrolysis plant - hero product moment
Tyre pyrolysis plant - hero product moment
Feedstock & Output

What goes in, what comes out.

Per 10 TPD waste-tyre input

Input
Waste tyres / shredded rubber
10 tonnes/day
Output
Tyre Pyrolysis Oil (TPO)
~4–4.5 tonnes/day (40–45%)
Recovered carbon black
~3–3.5 tonnes/day (30–35%)
Steel wire
~1–1.5 tonnes/day (10–15%)
Gas (reused)
~10%
Quality & Compliance

Standards & testing.

IS (BIS)
TPO — follows CPCB SOP for TPO units; no single BIS product std
ASTM
ASTM D7544/D240/D445 fuel references; carbon black D1765
MSDS / SDS
MSDS/SDS mandatory for TPO, carbon char (flammable/dusty)
Investment & Returns

Cost, output & payback.

Indicative for a ~5–10 TPD tyre pyrolysis unit (continuous, CPCB-compliant scale varies).

Rubber-to-Fuel

Cost & ROI

Investment (CAPEX)
₹2.5–5 Cr
Output / year
1,000–1,400 MT TPO/yr (+ carbon black & steel)
Revenue / year
₹3–6 Cr
Profit / year
₹0.6–1.5 Cr
Land required
1–2 acres
Payback
1.5–3 yr

Indicative only — actual figures depend on capacity, location, raw-material price and utilisation. Contact us for an exact DPR.

Project investment (CAPEX)₹1.5 crore – ₹5 crore
Capacity basis~5 – 10 TPD waste tyres
Approx. annual revenue₹3 crore – ₹8 crore
Approx. gross profit (GP) margin30% – 45%
Approx. net profit / year₹60 lakh – ₹2 crore
Approx. payback period1.5 – 3 years

Figures are for plant supply only — land and working capital are separate — and reflect a batch / semi-continuous build. Fully-continuous, automated, premium-spec production plants cost more (roughly ₹0.8–1.2 Cr per TPD). Your exact cost is fixed in a site-specific DPR.

Where to build

Best Indian states for this plant.

Gujarat, Maharashtra, Tamil Nadu, Punjab, Rajasthan

Transport hubs = waste-tyre supply; Gujarat allows continuous units; industrial fuel demand.

Site & Footprint

How much land you'll need.

Indicative plot size by capacity — we lock the exact figure to your layout and feedstock plan during feasibility.

Capacity
10 TPD
1–2 acres
Capacity
20 TPD
2–3 acres
Capacity
50 TPD
3–5 acres

Indicative footprint per capacity tier. Actual plot size depends on layout, feedstock storage, effluent/ZLD provisions, future expansion and statutory setbacks — finalised in the feasibility / DPR stage.

Regulatory

Licences & permissions you'll need.

Core approvals plus the extras specific to this plant — pick your state to see the nodal authority. We handle the full filing as part of PMC.

Licences & permissions

Gujarat PCB + Investor Facilitation Portal (single-window) under the Gujarat Industrial Policy.

Udyam (MSME) registrationMinistry of MSMESetup
GST registrationGST DepartmentSetup
Company / firm incorporationMCA / RegistrarSetup
Factory licenceState Factories & Boilers DeptPre-build
Fire NOCState Fire ServicesPre-build
Consent to Establish (CTE)State Pollution Control BoardPre-build
Consent to Operate (CTO)State Pollution Control BoardPre-commissioning
PESO licence (storage of petroleum/flammables)PESO (Petroleum & Explosives Safety Org)Pre-commissioning
Trade / municipal licenceLocal municipal bodySetup
Electricity & power connectionState DISCOMPre-build
End-of-life tyre / EPR authorisationCPCBSetup
Hazardous-waste authorisationState PCBPre-build

Indicative — the exact licence set depends on product, capacity, category (red/orange) and the latest state norms. We handle the full filing as part of PMC. Verify on application.

Client couple at their commissioned YUGA plant - idea to income
Carbon & Market

Extra revenue, and where it's running.

Carbon
~0.35 t
CO₂ saved per MT of bio-bitumen
Carbon
₹2,500+
Indicative credit value / MT
Carbon
~2.5 MT
Crop residue diverted / MT output
Carbon
MRV
Puro.earth-style verified pathway

Indicative — actual eligibility, methodology, credit volume and price depend on the registry, feedstock and verification. We structure the MRV pathway as part of PMC; contact us for a project-specific assessment.

Approx plants running (India)
~90
Top states
Gujarat · Rajasthan · MP · TN
What You Get

Documents & deliverables we provide.

Reports, drawings, working procedures and compliance docs — the full pack that takes the plant from paper to production.

Reports & financials

  • Detailed Project Report (DPR)
  • Bank DPR + CMA data (bank format)
  • 5-year financial model — P&L, balance sheet, cash flow
  • ROI / IRR / break-even & sensitivity analysis
  • Feasibility & techno-economic report
  • Subsidy & loan eligibility memo

Drawings & engineering

  • Plant layout & general-arrangement drawings
  • Process flow diagram (PFD) & P&ID
  • Civil & foundation drawings
  • Electrical & utility layout
  • Equipment & machinery specification sheets
  • Site plan & location scoring

Working & process docs

  • Standard Operating Procedures (SOPs)
  • Production & blending process manual
  • Quality-control test protocols (penetration, softening, ductility)
  • Raw-material & input–output (mass balance) sheets
  • Operator training & safety manual
  • Vendor / OEM list with negotiated pricing

Compliance & market

  • Licence & permission checklist (product + state)
  • Standards pack — IS / ASTM / MSDS
  • Tender & empanelment documentation (NHAI / PWD)
  • Buyer network & sales-support pack
  • Carbon-credit MRV documentation (optional)

Exact deliverables are scoped per engagement and product. The full pack is provided as part of PMC — contact us for a project-specific document list.

Tyre pyrolysis plant - plant inauguration ceremony
Plant Views

One plant, four angles.

Front, both sides and the working floor — the same facility from every angle.

Tyre pyrolysis plant - one plant from four angles
Questions

Top questions, answered.

A process that heats waste tyres without oxygen to recover oil (TPO), carbon black, steel and gas.

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Plan your Rubber-to-Fuel (Tyre Pyrolysis) plant with YUGA.

From feasibility to first commercial production - and the capital to fund it.

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