Reimagined tyres: the success of our ELT recycling project 

From playground surfaces to soccer fields, and even urban furniture like bike lane dividers, a common material is appearing across urban landscapes: recycled rubber from end-of-life tyres (ELT). Spain generates an estimated 300,000 tons of ELTs each year, making recycling and repurposing projects essential for advancing towards circular economy and protecting the environment.

The ELT recycling project led at our GRP (Granulated Rubber Project) plant in Manresa (Barcelona) represents a milestone in building a robust and sustainable circular economy. Since its establishment in 2016, this initiative has stood as a beacon of innovation and sustainability, providing real solutions to address environmental challenges and fostering more responsible industrial practices.

Cutting-edge processes for maximum efficiency

Equipped with the most advanced rubber crushing and screening technology, the GRP plant in Manresa operates two production lines that carry out a series of high-tech industrial processes, including primary and secondary crushing, magnetic separation, aspiration separation, particle size classification, and bagging into large bags for distribution.

The process begins with primary crushing to produce shredded ELTs. This shredded material is then transferred to the secondary section, where it undergoes further size reduction in the secondary mill, and textile fiber and steel are separated. After this, the rubber granules are classified by particle size, bagged, and stored.

Two distinct lines are prepared for the plant’s final products based on their end-use. Chips destined for energy recovery are transported in bulk to our cement factory, using containers and mobile floor trucks. These chips, a granulated rubber from ELTs, are tailored to a specific particle size—carefully determined through research to maximize combustion performance and energy efficiency in the cement factory’s kiln.

Transforming millions of tyres into valuable resources

With these high-tech facilities, we have processed over 20 million tyres in the last nine years. This achievement has been possible by the plant’s meticulous five-step process, which includes primary shredding, initial screening, secondary milling, secondary screening, and the final separation of components. Each step produces essential materials, such as shredded rubber, granulated rubber of various sizes, steel, fiber, and chips.

The use of end-of-life tyres as alternative fuel plays a crucial role in the decarbonization efforts of Molins’ operations. At the Sant Vicenç dels Horts (Barcelona) plant, 55% of the fuel used comes from alternative sources, including ELT, significantly reducing dependence on fossil fuels and lowering the carbon footprint of our solutions.

Meanwhile, rubber granules destined for material valorization are sorted by particle size according to customer needs, bagged, and dispatched via curtain-sided trucks. The granulated rubber finds a second life in diverse applications, including playground surfaces, sports tracks, and other industrial products.

Material and energy recovery with significant environmental impact

Our ELTs recycling project not only keeps waste out of landfills but also advances to circular economy model by transforming tyres into reusable resources. Energy and material recovery at the GRP plant aims to minimize natural resource consumption, reduce greenhouse gas emissions, and lessen landfill dependency.

Additionally, the plant’s energy-efficient design and location near the Sant Vicenç dels Horts (Barcelona) factory significantly reduces transportation costs and environmental impact, further underlining our dedication to a sustainable industry.

Commitment to circular economy and innovation

The project represents more than a corporate success story; it is part of our broader strategy to advance sustainability across the construction industry. The company’s vision goes beyond recycling tyres and aims to integrate recycled materials into all its production processes and final products.

One of our main projects is the establishment of an Alternative Raw Materials plant, located in Barcelona. This facility, launched in 2022, is dedicated to processing demolition and other industrial waste, giving a second life to materials that would otherwise end up in a landfill by transforming them into high-quality, sustainable products. By the end of 2024, the plant had reached the significant milestone of recovering more than 193,000 tons of construction, demolition, and other industrial waste since its inauguration. In 2024 alone, it recovered over 93,500 tons of materials, representing a 25% increase compared to the previous year.

Both Alternative Raw Materials plant and tire recycling project at the GRP plant stand as inspiring examples of innovation and commitment to sustainability, demonstrating the vital role of industry in fostering a circular, resilient economy. By confronting environmental challenges with determination and vision, we are setting the path for a more sustainable future. These projects exemplify not only a practical transformation of waste into resources but also a critical shift in how industrial development is conceived and approached in the 21st century.

Published in World Cement