Every new recycling site has individual requirements for which we:
Deep rubber processing know-how
WIL draws on many years of hands-on experience in the tyre recycling business. Our know-how in the tyre recycling industry stems from being actively involved in tyre disposal, tyre shredding, rubber granulation, selling turn-key solutions and world-wide rubber product sales on a daily basis.
We specialise in processing scrap tyres for environmentally friendly applications and products. We avoid targeting End-of-Life-Tyres (ELTs) for energy recovery purposes. The rubber products fabricated at our own facilities as well as the tyre shredders and granulator systems our customers buy as complete recycling solutions are strictly intended for zero emission applications. The rubber derivative crumbs and powders produced at our customers’ waste tyre processing plants can be found in the construction sector, the sports facility sector, and the asphalt rubber sector. We help customers set up and run tyre processing machinery to produce moulded rubber products for applications in the automotive, as well as to provide a stable supply of high-tech cryogenically ground fine powders for chemical, paint, and other industries.
When we install a granulation system the customer will derive long term benefits from our packaged solution approach:
Holistic solutions. Many installations today deliver less than satisfactory results because the production design has not been properly conceived for the particular conditions of the target location. The dimensions, costs, as well as the functional and technical layout of a successful granulation plant must take into account a number of important parameters.
Having traded recycled rubber derivative products on world wide markets for over 10 years, WIL AG’ concept is that with each new recycling plant customer we aim to add a stable, economically viable supplier of predictable quality products to our list of approved vendors.
Long term partnerships. Price is only one factor contributing to profits. Economic viability of a recycling factory is derived from reliable operations and from long term relationships with the customers who buy granulates, powders or other rubber products. Consistency, reliability, availability, and quality of supply will always outweigh any pricing tactics and represent barriers to entry for new-comers or spot sellers.
Every new customer who installs a WIL AG recycling solution at his facility will enter the fold of long term partners with common supply. Our focus is on evolving in the markets together with our operations partners.
Parameters To Consider
Market specific adaptation. In planning each new facility we evaluate all design options and make choices based on the customer’s budget, the raw material supply of used tyres, the factory site, and the markets we plan to feed with recycled rubber products. Our Business Plan for the site will contain a balance trade-off of the financial, technical, functional, and market relevant parameters of the project.
Innovation. Continuous improvements of our process concepts and technology is a key factor of our success. Every rubber processing facility we install benefits from all the experiences we have gained on previous installations. Since conventional vendors of recycling equipment usually only deal with one particular aspect of the recycling value chain they cannot offer this broad know-how integrated into the overall system. Our technology is state-of-the-art, but we do not experiment with new concepts, equipment or process ideas that have not been well proven in a production environment.
Total-cost-of-ownership approach. Our systems are conceived keeping in mind the total cost of producing a given quantity of product output. Incremental initial capital expenditures are often outweighed by reductions in production costs achieved through increased production efficiency:
We encourage our customers to take these factors into account when comparing the acquisition costs for the complete system.
Technical superiority. Our systems offer a number of technical features that have been balanced from a system operator’s standpoint.
Our technology is constantly evolving. All our solutions are comprised of best of breed recycling technology and are designed into the overall system based on the following principles:
Integrated components. We hand over a turn-key recycling system guaranteed to provide continuous service at full capacity as specified. All machinery components of the system have been adapted and fully integrated into a coherent system, allowing optimized production with minimum operator intervention.
Automated Processes. A typical recycling plant can be run with a staff of two operators per shift. From a computer console the foreman can monitor all parameters of the process, adjust capacities of each station, and execute emergency procedures.
Industrial strength and reliability. All equipment, from conveyor belts to shredders, grinders and processed rubber filling stations are dimensioned with ample safety margin over the specified capacity.
Reduced operational and maintenance costs. Productivity of a plant is affected greatly by the procedures required for maintenance of the systems. The length of shutdown time required to exchange expendable parts such as rotor blades has a huge impact on the resulting production costs. In WIL AG’s systems great care has been taken to minimize down-time and the number of parts that have to be kept in stock. Blades, for example, can be refurbished at the plant site with standard tools.
Quality of output. In WIL AG solution designs we place special emphasis on the purity of the material entering each processing phase. This greatly enhances the consistency of the output and the reliability of the processes.
Reduced production cycles. All steps in the process have been optimized so that the number of repetitive process cycles are kept at a minimum.
Proven reliability and safety. All our systems have been proven to be reliable in continuous full capacity operations for many years. Experiences gained during these production times have allowed us to minimize accident risks and fire hazards.
WIL is focussed on ascertaining that starting a new recycling enterprise becomes a rewarding experience for our customers. Engaging WIL is a step-by-step process in which each step has its own success criteria and produces results as prerequisites for the next step.
Planning from A to Z. Our customers usually start with a concept and invite vendors to quote various components of a system. Pretty soon they are faced with questions that - without experience - are difficult to answer. In WIL’ approach we ask all the tough questions first. We will not offer solutions or make proposals unless all the questions have been answered satisfactorily. If too many unknowns remain we offer to first complete a research effort in which we evaluate the supply situation (collection business), as well as segment, characterize, qualify, and quantify the markets for the proposed projects. We then propose to develop a written Business Plan based on that research which will act as a bankable blueprint for all technical, financial, functional, and market related aspects of the overall recycling facility implementation. All fees for ordered Research, Business Planning and Financial Planning modules can be applied towards the eventual EPC contract.
Financing Services. Having helped a number of customers obtain financing for their facilities, we know what it takes to prepare a coherent Business and Finance Plan that will induce lending institutions to fund the project, or that can be used to apply for government grants. Our plans have achieved high marks from analysts of several banks for their clarity and plausibility. Let us assist you in choosing a lender, preparing all the documents (a typical submission is 220 pages long), and in convincing the decision makers of the viability of your project.
Engineering, Procurement, and Construction (EPC). Once all plans have been completed and the economic and technical parameters approved by the customer, WIL takes responsibility for engineering all systems as complete solutions. This often involves cooperation with the architectural and planners and construction companies. Installation at the customer’s site is always included in our price. Hand-over will only occur after several test operation cycles have been performed.
Hands-on training and operations. Our customers’ staff usually undergo a training period for every step in the process. To become proficient in the collection, sorting and pre-processing methods, we offer training programs at a large German disposal site. To become familiar with all the details of the equipment, personnel are also required to be present during installation of the systems. Usually the customer will only prepare the building and supply the infrastructure such as power systems, air, water and drainage systems. WIL will take on the responsibility of the rest.
Optionally, WIL can take over operation of the completed plant for an initial period to ensure smooth take-over by the customer’s team.
Marketing and distribution. All products that can be fabricated by WIL' equipment can be produced and distributed royalty free. Our customers can optionally market some products under the WIL's brand for a royalty fee. The trading division of WIL will also handle sales of the customer’s products at pre-agreed quantities and terms. Alternatively, marketing and distribution (both local and international) of the products can be fully outsourced to WIL. This service includes product planning, sales, and distribution, as well as a web-shop solution.
Each facility needs its own unique solution, adapted to the initiators’ intentions, budget, as well as to local scrap tyre supply, regulatory environment, site requirements, and local used rubber market conditions. When generating a concept for a specific situation WIL AG will base the design on one or more of the following basis solutions:
AGF 30 Ambient Granulation Facility. A complete factory capable of processing 4.8 tonnes of tyres per hour at ambient temperatures. With three shifts or 5,265 hrs of operation per year the plant will process 30,000 tonnes of scrap truck and car tyres per year, separating rubber from steel and fiber and resulting in approximately 20,000 tonnes of rubber granulates per year*).
AGF 18 Ambient Granulation Facility. A complete factory capable of processing 3.5 tonnes of tyres per hour at ambient temperatures. With three shifts or 5,265 hrs of operation per year the plant will process 18,000 tonnes of scrap truck and car tyres per year, separating rubber from steel and fiber and resulting in approximately 12,000 tonnes of rubber granulates per year*).
AGF 8 Ambient Granulation Facility. A complete factory capable of processing 1.5 ton of tyres per hour at ambient temperatures. With three shifts or 5,265 hrs of operation per year the plant will process 8 tonnes of scrap truck and car tyres per year, separating rubber from steel and fiber and resulting in approximately 5,200 tonnes of rubber granulates per year*).
MPF 4 Mat Producing Facility. An add-on module allowing the production of mats, bricks, and moulded parts in a great variety of thicknesses, colors, shapes and surface finishes. With three shifts or 5,265 hrs of operation per year the plant will produce approximately 4,000 tonnes of mats and bricks per year*).
CGM 6 Cryogenic Granulation Module. An add-on module allowing the production of high end fine powders from shreds and granulates, employing a cryogenic process in which the granulates are cooled to -200° C. Approximately 6,000 tonnes of fine powder per year*).
Planning Service Modules. WIL offers a complete set of services, usually starting with a research effort in which we evaluate the supply situation (collection/disposal business), as well as segment, characterize, qualify, and quantify the markets for the proposed projects. We then propose to develop a written Business Plan based on that research which will act as a bankable blue print for all technical, financial, functional, and market related aspects of the overall recycling facility implementation. All fees for ordered Research, Business Planning and Financial Planning modules can be applied towards the eventual EPC contract.