The MineCycle project addresses the challenges of recycling end-of-life off-the-road (OTR) tires, a significant global waste issue with traditionally low recycling rates (10-30%) and quantities exceeding 800,000 tonnes annually. Current recycling methods are energy-intensive, yield low-quality rubber, and involve high logistics emissions. MineCycle solves this by deploying Ultra-High-Pressure Waterjetting (UHPW) and mechanical methods for efficient near-site tire downsizing, reducing transportation costs and environmental impact of the overall process. It enables advanced cryogenic micronization and AI-driven quality control to produce consistent, high-quality rubber powder for industrial composites. The high added-value product development is supported by AI-enhanced modelling, which accelerates composite formulation, promoting rapid market entry of products containing up to 30% recycled rubber. These innovations significantly reduce energy consumption and carbon emissions, aligning with environmental regulations and supporting sustainable industrial practices.