YUGA
Vision · Strategy · Execution0%
YUGA
End-of-life tyres for rubber-to-oil pyrolysis
Product · YUGA PMC

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

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Overview

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.

Why this business

  • 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

  • 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

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

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
Feedstock & Output

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

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

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
Where to build

Gujarat, Maharashtra, Tamil Nadu, Punjab, Rajasthan

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

Questions

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

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