KwaZulu-Natal-based radial truck tyre recycler, Mathe Group, has processed its one-millionth radial truck tyre, bringing the total amount of rubber crumb produced for re-use in industrial and construction applications to around 38 500 t, says CEO Dr Mehran Zarrebini.

Based on an infill of 100 t of rubber crumb per full-size artificial football field, this equates to 385 football fields or 700 hockey fields – based on 55 t needed to create the elastic layer underneath the artificial grass.

The amount of rubber crumb produced would also have provided the asphalt and seal needed to pave at least 8 000 km of roads.

Zarrebini, a British investor who initially acquired KwaZulu-Natal-based carpet manufacturer, Van Dyck, discovered Mathe Group as a small operation with 20 employees operating in New Germany in 2016.

He was looking for rubber crumb to manufacture acoustic underlays and acoustic cradles for flooring in high-rise buildings – products that he has since improved and continues to export.

Having acquired a 49% shareholding in the Mathe Group, he relocated the company to its present site in Hammarsdale.

From here he boosted production through continuous re-investment in the plant over the past eight years.

Today, the Mathe Group recycles around 700 radial truck tyres a day to produce 30 t of rubber crumb.

Seventy per cent of each 55 kg truck tyre becomes rubber crumb, and 30% is waste steel, which is exported via the Port of Durban.

Through its own research and development, or, through working with partners, the Mathe Group’s product list has grown to include non-slip paving and flooring for agricultural use, ballistics products, gym mats, rubber pavers, and infill for sports fields.

Various sizes of rubber crumb are also key ingredients in bitumen for road resurfacing, non-slip paints, the parts moulding process for the automotive industry, the retreading of tyres, and the production of brake linings.

Challenging Environment
Zarrebini says there have been a number of challenges hindering the Mathe Group in achieving its millionth-tyre milestone far sooner.

These include the Covid-19 pandemic, which shut down the plant for 18 months, loadshedding, water shortages, and the delayed implementation of the Industry Waste Tyre Management Plan.

The Mathe Group is also awaiting the renewal and expansion of its tyre quota from the Department of Forestry, Fisheries and the Environment’s Waste Bureau.

In the meantime, half of a tranche of new equipment needed to replace existing plant will arrive in South Africa early this year, with the remainder ready to be shipped during the second quarter.

Zarrebini says ongoing replacement of equipment that comes into contact with abrasive hard rubber and steel is essential.  

In addition, he notes that the Mathe Group is finalising external funding for additional upgrades to the existing line, which will enable the company to diversify.

“For phase-two investment, we designed the equipment to have the flexibility to process radial steel truck tyres, as well as a variety of other tyres.

“Although nylon truck tyres are few and far between now because trucking companies prefer to use radial steel tyres that are of a higher quality and retreadable, this gives us the security of more variant tyre supply.”

Waiting in the wings – and dependent on the delivery of more tyres for recycling – is a phase-three investment.

The Mathe Group has already been granted a waste management licence for the installation of a new line to complement its existing one.

Zarrebini says although the Mathe Group’s growth from 2016 to 2019 showed a steep upwards curve, this has levelled off on the back of loadshedding, high energy costs and the factory’s closure during the pandemic.

Given a more stable business environment and energy supply, however, output again increased last year as the factory was able to operate 24/7.

Should the group’s upcoming investment programme come to fruition, Zarrebini is optimistic that business will soon reach its two-millionth-tyre milestone.