Equipment for the production of crumb rubber. Plant for recycling used car tires into rubber crumb Profitability of the rubber crumb painting business
Fractionated crumb rubber is the basic raw material for rubber tiles and flooring. This raw material is actually taken from waste, or rather, it is obtained by processing old worn tires from cars. Car tires are made from fairly expensive high quality components (various oils, synthetic rubber, fillers), as these products must withstand huge loads for a very long period of time.
Of all the existing types of rubber, tire rubber, in its structure, stands out for its high strength and durability. Such rubber easily tolerates the ingress of acid and alkaline solutions on its surface, is very elastic, does not stretch, does not bend and is able to withstand temperatures from -45 to + 60 degrees.
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raw material:
Automobile crumb (or crushed rubber - RD) - is mined as a result of the processing of worn tires of other rubber goods. Its price depends on such indicators as: quality, method of manufacture, dimensions, place of manufacture and sale. In Russia, the retail price per crumb fluctuates between 6-15 rubles per kilogram.
Places of rubber crumb production:
- factories that process car tires into crumbs as the main raw material;
- for side production at RTI factories
- factories that restore tires by roughening them (tread processing), as a waste product.
Used crumb rubber fractions:
Fractions of crumb rubber vary from 0.1 mm to 10 mm and directly depend on their purpose. Thus, fractions of a small type (0.1 - 4 mm) are mainly used in the production of colorless (black) or colored single-layer products. In the manufacture of the lower colored layers, mainly fractions of a larger nature (2-10 mm) are used. Most often, they are cheaper compared to smaller fractions, as they may contain textile or metal inclusions. The production of tiles with two layers (the upper thin colored layer, the lower dark layer with large crumb fractions) is acceptable and relevant when the initial thickness of the product exceeds 1.5 cm.
Layering allows you to reduce the cost of the product due to the following points:
. Inclusion in the composition of a cheap large fraction of crumbs. Such a crumb may contain textile or other inclusions.
. The housekeeper on the paint - the bottom layer remains black.
. Larger crumb fractions require a smaller amount of binder for their crosslinking, which is carried out by enveloping the surface of the crumb particle
. The absence of a dye allows the use of less binder for crosslinking the particles, since the mixture dries out in the colored crumb.
Equipment and raw materials (prices)
The line, which produces rubber coatings, has the following set of equipment:
Volcanic press with a capacity of up to 100 m² per day. Price - about 350 thousand rubles;
Press molds. Cost - 30 thousand rubles a piece;
Drying chamber (for a mini business, it is possible to make it yourself), price from 100,000 rubles.
Raw material:
Rubber crumb - black (17 thousand rubles per ton), colored (from 23 to 35 thousand);
. polyurethane glue - 140 rubles / kg;
. dyes - 7 rubles per kg;
Consumption of electricity by the line - 15 15 kW/h.
Coatings can be made:
- both soft and hard in density;
- waterproof, or with the passage of water (drainage);
- thin and thick;
- as colorless (black), colored, or black with patches of different colors;
- with good grip, and more slippery;
- with or without a pattern;
- single-layer or with several layers;
- for laying on a soft base (soil) or hard;
- with connections (sleeve, lock) or without them.
Paving rubber tiles are often laid in parallel with conventional paving slabs. It is for this combination that rubber coatings of similar sizes and shapes are created as ordinary pavement tiles.
A room for a mini tile production workshop.
The criteria for the production of rubber coatings (provided that the equipment is optimal and has an average level of performance):
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1. The area occupied by the technical line - 70-100 m² (not counting the warehouse); Equipment and materials are placed by sectors: |
General axioms:
1. Glue consumption.
§ The amount of binder is inversely related to the crumb fraction. The smaller the crumb, the more binder is needed for crosslinking. The larger, the smaller.
§ Dyes dry the glue. Because of this, its amount in the black coating is smaller.
§ The higher the density of the product, the less glue is needed.
2. The average consumption of glue for the manufacture of various coatings is from 4 to 12%, depending on the presence / absence of dye, the density of the materials, the quality of the adhesive, and the size of the tire crumb used.
For example, to make a color coating Mat 500 * 500 * 16mm (from crumbs of fine fraction), you need 6% dye and 5% glue from the amount of rubber crumb.
a) Black coating (crumb size - 4-10mm) - 4% glue.
b) Black coating (crumb size - 2-3 mm) - 5% glue.
c) Black coating (crumb size - 1.2-1.8 mm) - 6% glue.
d) Color coating (crumb size - 1.2-1.8 mm) - 7-9% glue.
3. Water resistance increases, the smaller the crumb rubber fraction and the higher the pressure.
4. The larger the crumb, the faster the color of the product will be lost due to abrasion.
5. The larger the crumb, the stronger the coating, but the thickness of the coating must be observed.
6. Thick coatings (2 cm or more) are best made in two layers. For the upper part, use a crumb of a fine fraction, for the lower part - a cheaper crumb of a large fraction (5-12 mm) with possible foreign inclusions. Each layer has its own proportions of glue. Each layer is kneaded in different containers.
7. It is recommended to produce products of the same thickness on the same pressing mechanism, regardless of the configuration, since the thickness affects the time of the press (the thinner the product, the faster its formation).
Additional accessories for production.
Trolley to transport raw materials (crumbs, dye).
- Trolley with a special stand to transport containers with glue.
- Scales to weigh components (preferably 50 kg electronic).
- Trowels for uniform laying of coverings.
- Special mugs and scoops for measuring, depending on the standard of the product.
- Mixing glue and dye drill with nozzles.
Price for the implementation of rubber plates:
One pack
100 tiles - 57 thousand rubles.
The cost of 1 m² is 1,584 rubles.
The price of 1 plate is 570 rubles.
The minimum lot is 100 slabs (25 m²).
Sales of products.
For coating on production lines, in warehouses, or as a rubber coating for garages;
- use in areas near ice rinks, locker rooms, playgrounds;
- in combination with paving slabs;
- as a covering for various sports complexes or children's playgrounds;
- on farms, livestock facilities;
- on roofs, terraces
- in baths and other places.
As you can see, the release of such products is part of an ecosystem, dealing in high-quality safety products - rubber tiles or crumb coating.
Production of crumb rubber tiles:
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Recycling not only helps to protect nature, but also allows you to make good money with less costs. An excellent example is the production of crumb rubber: how to open a business, its profitability based on financial calculations, market analysis in this area and help with choosing a work strategy in our today's article.
Let's analyze the business area
When opening a business in some area, it is worth immediately determining its relevance, complexity and profitability. In this case, the production of crumb rubber is a business idea that is not yet too developed, and therefore has many prospects.
Car tires are washed out very often, especially in the CIS countries, where the vast majority of residents of cities and villages drive around in cars. You can find entire landfills where only tires are stored, and they are excellent, and most importantly, free raw materials for useful products.
Rubber crumb, which can be obtained after recycling a tire, is used in many areas, which we will discuss later. And this means that getting into the production of such a material, receiving raw materials almost for free, will be an incredibly profitable idea. Undoubtedly, this will require a lot of effort.
Advantages of such a business idea
To make sure that the production of crumb rubber is a really profitable project, it is worth evaluating its advantages specifically as a business. The advantages can be called:
- The absence of powerful and large organizations involved in this activity.
- Low level of competition in the market.
- High demand for crumb rubber itself.
- Relatively low start-up costs.
- High payback.
- Prospects for expanding the scope of the manufactured product.
As a result, we have an excellent business option that does not have any particular problems with finding sales channels for products, competition in the market and the actual production of crumb rubber.
Where is the manufactured product used?
To start producing a product, it is important to understand what demand it has, or rather, where exactly it is used. In our case, the use of crumb rubber refers to the industry where this material is required:
- construction organizations;
- enterprises for the production of sports coatings;
- pavement manufacturers;
- rubber goods companies;
- oil production companies.
Also, rubber granules are produced for the further creation of bituminous mixtures and mastic, there is also demand from manufacturers of noise-absorbing and heat-insulating materials.
Here you can download ready-made as an example.
We prepare business documents
In order to properly organize the processing of automobile tires, the production of crumb rubber and the sale of manufactured products, you will have to formalize the legal form of the business. In our case, an Individual Entrepreneur is suitable, requiring a really minimal package of documentation, a small amount for the state fee and not much time for registration.
To work with organizations directly, as well as to form a partnership, it is necessary to register an LLC already, but this can be done in the future with the expansion of the project. A significant plus of this business is that you can open it without obtaining a license.
Finding a suitable site and requirements
To organize such a project, you will need to rent a fairly large site. According to the rules, any plant or enterprise of this type must be located away from residential buildings, besides, rent is much less outside the city. The main thing is that a developed transport system be laid to the site you have chosen.
It is highly desirable that the room has an area of at least 200 square meters so that it is possible to arrange the necessary equipment. Otherwise, the following requirements must be met:
- The height from floor to ceiling is at least 3 meters.
- Working industrial electrical network for 20 kW.
- Constant temperature not less than 15 degrees.
- Flat floor.
- Constant ventilation.
- Sewerage right in the shop.
Among other things, it is necessary to equip three different zones: a production workshop, a warehouse for raw materials and finished products, utility rooms for employees.
We buy raw materials for processing
Such a processing station will undoubtedly need a constant supply of raw materials for further production. Often, enterprises purchase already worn-out tires, tires and air chambers, as well as fabric or metal-reinforced rubber. The enterprise must independently organize collection points for obsolete and worn tires or other rubber materials, advertising it.
There are several more options:
- Cooperation with other manufacturing organizations that leave rubber in the course of manufacturing their products.
- Acquisition of raw materials from intermediaries collecting old rubber.
- Cooperation with car workshops and shops.
It is most convenient to create a collection point on the production site, but sometimes you will have to spend money on the delivery of raw materials from other places, and it is important to be prepared for this.
We buy the necessary equipment
To work in this area, you need to acquire special devices. In this case, you will have to buy both a processing plant and specifically equipment for the production of crumb rubber. The minimum set required for the enterprise must include:
- Machine for cutting boards.
- Ring processing machine.
- Ribbon cutting machine.
- Shredder for grinding raw materials into crumbs.
- Rotary crusher.
- Separator.
- Sieve.
All this equipment can be purchased individually or as a whole line. Often a similar line for recycling obsolete rubber and further production of crumb rubber is cheaper, and there is no chance that you will miss something. But sometimes it’s easier to buy some cheaper items, to find used ones.
Recruiting staff
To open a really good working project for the recycling, recycling and production of something, you need to enlist the help of at least a small staff of employees. For this business, people of extremely high qualifications are not needed, it is enough that they know their business.
To establish the use of equipment in the shop, the average enterprise will need about four workers. It is also necessary to take at least one manager who controls the stability of the supply of raw materials and the operation of the distribution channels for the manufactured product. Obviously, to establish the work of the enterprise itself, a mechanical technologist will be needed.
Still, from time to time, you will have to resort to the services of a driver so that the manufactured products and the material necessary for work can reach the desired location. It remains only to take one or two loaders to the warehouses. The owner of the business will become not only the chief director, but also the accountant of his enterprise.
It is very important to be able to advertise your services. It is necessary not only to think over a competent marketing campaign, but also to correctly find the potential audience for which you need to work. First of all, you simply have to create a business card website for your company.
Nowadays, it is much easier for customers to find out all the information about the organization itself, its services and order conditions on the Internet in one place. Be sure to create a separate discussion where each customer can leave their feedback to create a good picture for future interested buyers.
Try also to form a list of services in accordance with the capabilities of the enterprise, but also with an eye on competitors. For example, the right move would be to launch our own production of rubber crumb coatings if there are enough customers for this product. Advertise in the media, offer services to other organizations yourself and build your client base.
Video: crumb rubber quality, production stages, processing methods.
What is the profitability of the project?
In order to correctly assess your financial capabilities, as well as find out how profitable the enterprise will turn out, it is worth drawing up a business plan that takes into account the costs of processing raw materials and the production of rubber crumb, as well as the income of this business.
| Expense Line | Amount of expenses, thousand rubles | |
| 1 | Workshop rent | 100 |
| 2 | Purchase of all equipment | 1 500 |
| 3 | Repair of premises and installation of equipment | 400 |
| 4 | Public utilities | 5 |
| 5 | Registration of all documents | 10 |
| 6 | Salary of all staff | 200 |
| 7 | Purchasing additional inventory | 20 |
| 8 | Marketing Campaign | 30 |
| 9 | Purchase of raw materials for production | 20 |
| 10 | Fare | 40 |
| 11 | Taxes and contingencies | 100 |
| Total: | 2 425 |
With how to open such an enterprise, people with a sufficiently large collected capital will definitely not have problems. Many of these cost items can be reduced, besides, it all depends on the region and the capabilities of the entrepreneur himself. Income will also vary, but we will calculate the approximate profit.
The average cost of about 100 tons of crumb rubber on the market is 900 thousand rubles. The net monthly profit in this case will be approximately 400 thousand rubles. Thus, the profitability of the project will come after about six months of fruitful work.
Rubber crumb coating is the trend of this year. Moreover, the production of this coating is a very popular area that can bring serious profits. There is practically no competition in this niche, and there are no large monopolies either. In addition, there are more and more new directions where this coating is applied.
What are the benefits of crumb rubber coating? This modern material has a lot of positive qualities that attract consumers:
- The coating looks expensive, of high quality;
- Wide range of colors;
- Large size range;
- Various thickness;
- Impact resistant surface;
- Does not slip;
- Moisture does not accumulate on it;
- Does not lose the brightness of colors under the influence of solar radiation;
- Thermal stability;
- Long service life - more than 40 years.
The manufacturing technology is quite simple - a mixture of glue with crumb rubber and the desired color dye is heated to a certain temperature.
Sales market and features of coating production
Before starting to implement the idea, you need to analyze the demand and identify a potential market. Since the use of rubber crumb coating is quite versatile, sales can be found in different directions. So, the rubber coating will be in demand for:
- Creation of a covering on children's playgrounds;
- Landscaping of the local area in the private sector;
- Equipment of production sites with a non-slip surface, which reduces injuries;
- Floor coverings in washing and dressing rooms in saunas and baths;
- Covering blind areas and areas near ice rinks or pools;
- Farm floor coverings.
The production technology is so simple that special skills are not required. This direction can even be done as an extension of the service sector.
For example, tire fitting owners can use old and unnecessary tires to optimize their workspace and earn additional income from used parts. They are the basis for creating such a convenient product in the future.
The composition of the rubber coating is as follows:
- rubber crumb;
- polyurethane adhesive;
- powder dye.
Automobile tires and tires are crushed to obtain a homogeneous mass. This raw material makes up 85% of the total mass of the finished coating. It should be noted that there is another direction - the production of rubber tiles, but it is somewhat different from what is being considered now. Directly for the production of crumb rubber, you will need quite expensive equipment, but it quickly pays for itself.
To expand the range, as an option, rubber granules of different colors can be added in the form of patterns.
The production process is called pressing, and it looks like this:
- rubber crumb, polyurethane glue and dye of the desired color in the ratio of 85:10:5 are loaded into the bunker, everything is mixed;
- molds are filled with the mixture;
- the desired vulcanization temperature is set depending on the parameters of the tile;
- finished tiles are removed from the molds after cooling.
There is a second option for making a rubber coating from crumbs, vibrocasting: instead of molds, molds are poured in a vibrating table for two days.
Where to begin?
If you have 1.7 million rubles for the initial start, you can immediately rent a room for workshop equipment, buy molds or a vibrating table, equipment for crushing rubber, and start producing crumb coatings.
If you buy a grinder, it will be able to produce almost 2.5 tons of crumbs per day. The average price of a kilogram on sale fluctuates around 12 rubles.
Of course, attractive figures do not guarantee a successful development of events. Each step should be worked out, expressed in a business plan with a time period of at least 3 years. You will also have to rely on a certain sales market, that is, simply starting production without sales is an absolutely unsuccessful undertaking.
Costs and payback
If we talk about the payback time of a running production, everything is individual here and depends on the scale of the enterprise itself and on the success of the sale of finished products. On average, this figure ranges from one and a half to two years.
The calculation of costs (for the purchase of basic equipment for the organization of the workshop) will be approximately as follows:
- molds for the press - 30 thousand rubles. for one piece;
- press - about 300 thousand rubles;
- mixing hopper - approx. 200 thousand rubles;
- a chamber for drying the finished coating - it will require the cost of improvised materials, and so - you can do it yourself.
Where can I get money to start my own business? This is the problem faced by 95% of new entrepreneurs! In the article, we have revealed the most relevant ways of obtaining start-up capital for an entrepreneur. We also recommend that you carefully study the results of our experiment in exchange earnings:
In addition to the minimum necessary equipment, you will need to spend a certain amount of money on the purchase of raw materials: glue, the crumb itself, powder dyes.
The possibility of production using a two-layer technology should also be considered, which will increase the quality of the finished rubber crumb coating. The point is that the bottom layer of the coating will be made from large and cheaper crumbs, and the top layer will be made from a fine fraction of rubber crumbs.
The retail price per square meter of finished products reaches 1,500 rubles.
Coating production from free raw materials
Since obsolete rubber products are used for the production of crumb rubber, mainly wheel tires, it is not difficult to find raw materials for production - any tire shop will give away a bunch of tires and other rubber waste for free.
In general, the raw materials for production are free auto junk.
It should be emphasized the advantages of opening such a business in Russia. The free disposal of broken rubber products for cars determines the behavior of people - everything unnecessary is simply thrown away. Compared to European countries, the owner of the car must pay a commission for recycling unnecessary tires, and also deliver them to a special recycling center.
In our country, the car owner will be happy to give away tires for free, just not to waste his time on it. If the tires themselves are free, then to collect them you need to go around the city and nearby settlements. Depreciation on fuel and lubricants and payment to the driver are added to the expenses. Alternatively, you can conclude an agreement with large transport companies for the supply of tires - the flow of rubber for production will be stable.
Rubber tire grinding technology is one of two options:
- mechanical impact;
- shock wave effect.
The second option is more compact (in terms of installation dimensions) and economical in terms of electricity consumption, but the installation itself will require serious investments to purchase it. In addition, it will be necessary to supplement the shock-wave installation with refrigeration equipment. The tire will break into small pieces under the influence of a temperature of 90 degrees.
In order to locate the production, it is necessary to find and rent a room provided with electricity with a voltage of 380 kW versus the usual 220, this is due to the fact that the characteristics of the installation require an energy flow of 15 kW/h. The area sufficient for production is 60 square meters. m.
From the workforce, you can limit yourself to hiring a minimum number of employees, based on round-the-clock work without days off in three shifts - two operators per shift, and in general, a staff of 8 employees. Two storage rooms should be equipped - one large for raw materials, the second - 4 times smaller for finished products.
As already mentioned, a working seven-day round-the-clock week will be the most profitable and cost-effective. You should be prepared for fairly large expenses. For example, if the productivity of the workshop is 100 kg / hour, you will have to spend:
- $30,000 for the purchase of equipment (depending on the model and equipment of the instruments);
- 2,000 dollars for the execution of various documents, certificates;
- $3,000 monthly to pay rent for the premises;
- Approximately $5,000 should be payroll for staff, monthly.
At the indicated productivity, 72 tons of coating will be produced at the end of the month, with the implementation of which most of the costs will already be covered. And this is - if you sell crumbs, $ 500 per 1 ton of crumb rubber ($ 36,000 for the first month of work).
There will still be a small additional income to support the enterprise - 25% of the total mass of raw materials is metal released from tires, plus tires are often given away with broken metal parts of the wheel. The sale of metal will bring a small income, compensating for part of the costs.
If you organize the production of rubber tiles on your own, combining the processing and production of rubber coating, the cost of delivering raw materials will be equal to zero, increasing all the economic indicators of the company.
A working idea for the recycling of tires and the production of rubber crumb and coating from it can not only bring good income to the organizer, but also make the environment cleaner without harming nature.
It must be said that such an idea has already been put into practice in the production of pavement, to which the mentioned material is added - crumb rubber. Thus, the constructed roads become less expensive, and for crumb producers it is a fairly stable consumer, providing stable work orders for even a large enterprise.
At the moment, already operating enterprises offer to open their own franchise business. Don't be afraid to take action, grow and market your business the right way.
Rubber tile production is the most efficient way to recycle old worn tires. The final product is characterized by high strength and wear resistance. The production of such a material allows us to solve two important problems - to produce products with excellent performance and to safely dispose of unnecessary tires. This is a great idea for those who want to start a business from home.
Raw materials for the production of rubber tiles
If you plan to start producing rubber paving stones at home, the main raw material is crushed rubber, which can be purchased at the factory. Many domestic enterprises are engaged in the processing of old car tires, so there will be no problems with the purchase of raw materials.
Tire crumbs can be made with your own hands, but in this case you cannot do without special equipment.
Waste tires can be purchased for next to nothing or received free of charge, incurring only transport costs.
The composition of the mixture for the manufacture of rubber paving slabs includes:
- crumb rubber fractions;
- glue;
- pigments;
- modifying fillers.
This is a recycled material from old car tires, which is obtained by mechanical crushing, followed by the separation of unnecessary impurities such as textile fibers and metal cord. The composition of the crumbs includes synthetic rubber, various oils and fillers, so the feedstock is initially strong and wear-resistant. Tires are not afraid of exposure to acids and alkalis.
Automotive rubber is highly elastic and perfectly retains its shape. It is difficult to deform even at high temperatures.
The crumb size can vary between 0.1-10 mm. Raw materials 0.1-4 mm are used for the production of black or colored single-layer tiles. Larger fractions are intended for the manufacture of the lower layer. They may contain metallic inclusions.
Pigment dyes allow you to get finished products of different colors. The colorants are in the dry powder phase. They can be organic or inorganic. Outwardly, the pigments look like multi-colored flour. The coloring of the mixture for the manufacture of rubber crumb tiles occurs when the dye interacts with polyurethane adhesive. The coloring matter envelops the rubber crumb and gives it the desired color.
The basis of inorganic dyes can be:
- titanium dioxide - white;
- iron oxide - red;
- iron oxide hydroxide - yellow;
- cobalt blue.
Mixing primary colors allows you to get different shades.
polymer adhesive
The binder that is added to the tile mix is a non-toxic, polyurethane-based mass. It can be:
- one-component;
- two-component.
The second option differs in composition. It comes with a hardener. When choosing a glue, pay attention to its quality. It accounts for the entire load, so it is worth buying a binder in small quantities from several manufacturers and empirically choosing the appropriate option.
Modifying fillers
This component allows to increase the strength and wear resistance of secondary raw materials, and also gives elasticity to the finished product. At a low concentration, modifying fillers do not improve mechanical performance, and at a high concentration, the material becomes brittle, and therefore the mechanism of its destruction changes.
Tile molds
Rubber tile molds can be made by yourself. But this lesson will take you a lot of time and money, so it’s better to purchase finished products or order them to be made according to a sketch.
Before use, do not forget to treat the mold with soapy water or silicone so that the solution does not stick to it. After removing the finished rubber, non-metallic molds are treated with an acid solution to eliminate dust.
Equipment for the production of
Components for the production of tiles by cold pressing will cost more than for hot pressing. The most expensive option is the installation of an automated line. Such equipment is suitable for industrial production, so you need a large area.
Special equipment for the production of rubber tiles at home consists of the following units:
- raw mixer;
- volcanic press;
- Press forms;
- scales;
- conveyor trolleys;
- molding tables;
- drying chamber.
The components of the working mixture are loaded into a mixer with low-speed blades, which thoroughly mix them. Most often, the main raw materials and glue are mixed separately, so you will need another machine of this type.
The mixture is loaded into molds on special molding tables. After that, the molds are placed on trolleys and placed under a press. Loaded carts are sent to the drying chamber.
The performance of all electrical equipment depends on the size of the drying chamber. For production to be profitable, its area must be at least 200 m².
For the production of raw materials (rubber crumb) at home, a mechanical crushing method is used using special cutters. This inexpensive equipment is suitable for making tiles in the garage. In industrial production, the method of shock-wave crushing is used. Such equipment is fully automated.
Manufacturing technology
For the production of tiles, 2 pressing methods are used:
- hotter;
- cold.
The first option is cheaper and faster. But at the end you will get a toxic product of poor quality. Domestic manufacturers prefer cold pressing. This method allows you to get durable tiles, but it does not have high performance.
The energy costs for both methods are the same. The only difference is the nature of electricity consumption. With the hot method, electrical energy is consumed cyclically, only during the operation of the press. During cold pressing, it is necessary to constantly consume electricity in order to maintain the desired temperature in the drying chambers.
Consider the main stages of production:
- Preparatory. At this stage, the main raw material is prepared. To do this, old car tires are freed from metal rings and textile threads, after which they are crushed in a crusher to the desired fraction.
- Mixture preparation. Rubber crumb, glue, pigments and modifying fillers are loaded into the mixer in the required proportion.
- Molding. The finished mixture is filled into special forms and sent under the press.
- Pressing. The raw material is pressed to a predetermined density and thickness.
- Baking. With the hot method of production, the material is baked under pressure at +130°C. The cold method involves the installation of molds with raw materials in heating cabinets for processing at lower temperatures (+60 ° C).
It is necessary to strictly adhere to the production technology of rubber tiles. Pay special attention to the following important nuances:
- Rubber crumb size. The quality of the coating and its physical and mechanical characteristics depend on this parameter.
- The presence of lubricant in the molds before loading the mixture.
- Compliance with the proportions in the preparation of the mixture.
- To increase the water resistance of the tile, you need to use a smaller crumb fraction and increase the pressure of the press.
- The larger the fraction of rubber crumb, the faster the color of the material is lost during operation.
- Tiles with a thickness of more than 2 cm are best made in two layers. The top layer is made of fine crumbs, the bottom layer is made of large crumbs. If you want to make a rubber tile with two layers, you will need an additional mixer to prepare the different layers.
- On one pressing machine it is necessary to produce tiles of the same thickness, regardless of its configuration. The thinner the coating, the faster its formation.
Many manufacturers produce two-layer rubber tiles. This approach allows them to significantly reduce the cost of finished products, since the composition of the mixture includes a cheap large fraction of the feedstock.
Proportions
To prepare a mixture of rubber crumb, all the necessary components are taken in the following proportion:
- crumb rubber - 80%;
- polymer glue - 10%;
- pigment - 3.5%;
- modified fillers - 0.5%.
The smaller the crumb fraction, the more glue will be needed. Pigments dry out the binder, so there may be less of it in black tiles. Before pouring the ingredients into the mixer, they must be accurately dosed using a scale. Failure to comply with the technology may adversely affect the quality characteristics of the finished product.
hot way
For the hot tile production method, you will need a vulcanizing press, under which the vulcanization process takes place at a temperature of + 130 ° C. Forms with a mixture are under pressure for 30 minutes. After that, you can excavate the finished tile.
Hot pressing significantly increases the volume, as it speeds up the process of making tiles. However, fast is not always good.
When using the hot method, the characteristics of the product deteriorate, which negatively affects its quality. This tile has a more intense smell of burnt rubber. In addition, it quickly collapses under the influence of various environmental factors.
The glue should be well absorbed into the structure of the components of the mixture. With the hot method, he does not have time to firmly bind all the components, so the tile becomes fragile and not strong enough. Under the influence of high temperatures, the connecting links do not dry, but bake, which negatively affects the elasticity of the tile and its strength.
cold way
The finished rubber mixture is loaded into molds and placed under a press. After pressing, carts with molds are loaded into special drying chambers. They are kept for 4-6 hours at +60°C. After this time, you can remove the carts from the chamber.
The productivity of the cold method depends on the volume of the drying chamber. The larger the chamber, the more carts will fit in it. Thanks to this, you can control the amount of products produced.
At first glance, it may seem that making tiles in this way is less productive. With cold pressing, chemical reactions slow down, the glue has time to securely bind all the components, and as a result, you get a durable, high-quality material with excellent performance characteristics. Production volumes can be increased by purchasing additional equipment.
Tiles and pavers made of crumb rubber are low-cost and pretty good quality product.
The material does not require expensive raw materials and a large amount of labor.
For manufacturing, it is enough just to purchase several special machines and rent a small workshop.
Rubber paving slabs and paving stones are at the peak of popularity today. It is easy to sell not only at retail to individual companies and individuals, but also sell in large quantities to merchants.
In this article we will talk about the production technology of these products and give a description of the equipment.
This product has many benefits. The crushed rubber tires from which it is made are high quality material. For its manufacture good synthetic rubber is used, expensive fillers and oils.
Advantages rubber crumbs:
- It is durable, “does not bend” under heavy weight, it can be laid in workshops, garages and car washes.
- It serves for a long time and faithfully up to 35-40 years, and at the same time it does not wear out and does not “shed”.
- Resistant to moisture, remains intact and dries quickly even after tropical showers, so it is used in water parks and saunas.
- She is not afraid of sudden changes in temperature, she is not afraid of either severe frosts (up to -40) or debilitating heat (up to +50).
- Shoes do not slip on it - it is difficult to get injured on such a tile; “sports” surfaces are paved with it - tennis courts, playgrounds.
- The material is not spoiled by aggressive substances, it covers the floors of chemical laboratories.
- Tiles are easy and inexpensive to install and clean. Stairs, entrances to buildings, shopping centers and many other "public" spaces with a large human flow are paved with it.
Also, paving slabs made of rubber crumb can be given a wide variety of shapes, sizes and colors, fit beautifully into the interior of the premises and the landscape. It is placed in summer cottages and in elite cottage settlements, on balconies and terraces.
Technology for the manufacture of tiles and paving stones
Cold and hot pressing are the two most popular technologies used today to produce tiles and paving stones.
hot way
Using the hot process technology, tiles can be produced cheaply and quickly.
It should be borne in mind that such products are not durable, they are “afraid” of severe frosts.
Find a buyer for a similar product is real only in the temperate climate zone.
To make hot pressing you need:
- First, give the raw material the desired condition. To do this, in a special mixer, it is necessary to create a continuous mass of crumbs and a binder - polyurethane glue.
- Distribute the mixture over the molds and send it under a special volcanic hot press, which is heated by electricity or steam. He heats the mass and gives it the desired shape with the help of pressure exceeding 5 tons. After such pressing, the material is ready - nothing else needs to be done with it.
Process time and temperature depends on the thickness of the mixture:
- if this indicator is 8-15 mm, you need to press for 3-7 minutes at a temperature of + 120-130 degrees;
- if 15-25 mm - 5-10 min. at +140-150;
- if 25-40 mm - 15-18 min. At +150;
- if 40-50 mm - 20 min. also at +150.
cold way
"Cold" pressing is a more time-consuming and costly process. But it’s also much more realistic to make good money on it, since all of the above advantages are inherent in the “cold” tile.
To produce cold-pressed products, it is necessary:
- Prepare raw materials. To do this, you need to do the same as in the case of hot pressing: create a continuous mixture from a binder of polyurethane adhesive and rubber crumb. Plus add coloring matter. The important point is that glue will be required an order of magnitude more.
- Move this mixture into molds and send it to be pressed under 5-ton pressure in a volcanic cold unheated press.
- Further, the material is sent to a special chamber (heating cabinet) to dry at a temperature of + 50-60 degrees. How long it stays there depends on the thickness. The thicker the material, the longer the drying time. On average, this process takes 5-7 hours.
- After heat treatment in a special chamber, the material is “dryed out” at normal room temperature.
The thickness of the rubber crumb fractions depends on how much the raw material is crushed. The finer the rubber, the finer the fraction. This thickness can vary more than a hundred times– in the range from 0.1 mm to approximately 10-12 mm.
From thin fractions (up to 4 mm), a relatively expensive single-layer colored tile is produced, from thick fractions - a cheaper material from several layers of the original black color.
The quality of the "large" crumbs is lower, because it contains an undesirable admixture ("inclusions") from metal or fabrics.
But it is also cheaper to produce for two reasons:
- firstly, it is not painted;
- secondly, to create a single-layer "solid" product, it is necessary that the adhesive binder completely envelops each individual crumb.
Therefore, the larger the individual rubber particles, the less binder needed to connect them.
The tile can also be “combined”, when the top layer is “high-quality” thin, and the bottom one is cheap and thicker. Such material is usually about one and a half centimeters thick.
Components
For the manufacture you will need the following components:
- Direct rubber crumb. The tile consists of 80-90% of it.
- Polyurethane bonding adhesive. It accounts for about 10% of the total size of the material. Such glue not only binds the crumb into a solid tile, but is also used to connect it to any surface.
- Dye. In a tile it is 5%. Usually the coloring matter looks like a powder.
- Colored rubber granules. This substance is used to create patterns on the surface of the finished product and make it aesthetic in appearance. It is quite possible to do without this component.
rubber crumb can be purchased at:
- special processing plants;
- enterprises producing RTI (rubber products). On them it is a by-product of production;
- factories that retread damaged tire treads. One of the waste products of this process is crumb rubber.
Equipment
For small production you will need:
- volcanic press, which can produce up to 100 m 2 of products in 1 day. Its cost is in the region of 300 - 400 thousand rubles;
- drying chamber (heating cabinet). Its price is 100,000 - 150,000 rubles;
- molds for crumb rubber - 40,000 rubles. each. They will need at least 3-4;
- construction mixer (centrifuge type) - 120,000 - 220,000 rubles. They will need 2.
Also in the manufacture can not do without equipment such as:
- tables (for forming) and platforms for mixers;
- trolleys for moving barrels of glue;
- a spatula to trim the mixture in the molds when laying;
- scales (electronic);
- specialist. a drill equipped with a nozzle to mix the components;
The price of raw materials and materials for the production of rubber tiles:
- 1 ton of black rubber crumb costs an average of 20,000 rubles;
- a ton of non-ferrous - 25,000 - 40,000 rubles;
- 1 kg of polyurethane glue - 150 rubles;
- dyes - 8-10 rubles. for 1 kg.
The electricity consumption will be approximately 15 kW / h.
You can buy equipment from these manufacturers, as Alfa-SPK, ECO-TOP, Alfa-MSK LLC, intermediaries delivering it from other countries (Far East Trans and others) at an affordable price .
Tile molds
Rubber tile molds can be purchased from the equipment manufacturers listed above. Common Sizes: 550x550x55 (45) mm, 1100x1100x55 (45) mm.
Business plan
The production of rubber tiles from crumbs is not very expensive. To create a small plant, you will need approximately 1,200,000 rubles.
To ensure the production process, it is necessary:
- an area of approximately 120-130 m 2 for a workshop and warehouses for storing raw materials and finished products;
- 3-4 workers for one shift;
- accountant and manager.
1 m 2 of tiles can be sold for 1,700 rubles, and 100 tiles can be sold in bulk for 62,000 rubles.
The profitability of such production is quite high - in the region of 20-40%, and if up to 35 m 2 of products are produced per day, then the costs incurred will pay off in 4-6 months.
During this time you can get sales revenue of about 7.5 million rubles.(35 1700 21 days 6 months = 7,497 thousand rubles).
Monthly:
- Income 35 1700 21 days. = 1,249.5 thousand rubles.
- Consumption 920 thousand rubles.
- Profit 1249.5-920 = 329.5
Profitability will be:
329,51249,5∙100%= 26,4%
By gradually developing the business, increasing productivity, you can achieve a higher indicator.
Can you make tiles at home?
It is unrealistic to produce high-quality products that are made in a cold way "at home". Here is the "hot" cheap option is quite realistic.
For the manufacture of rubber paving slabs with your own hands, large areas, money and time are not required - it will be enough to buy equipment such as a hot press, molds, and, of course, raw materials in the form of crumb rubber and other components.
If you buy the cheapest used equipment, then the initial investment will not exceed 200,000 - 250,000 rubles.
Thus, do-it-yourself mini-production of crumb rubber slabs is possible even in the garage. Problems can start later - at the sales stage. "Hot" tile is a product with a not very good reputation, so finding customers can be a problem.
Related videos
The author of this video talks about how to implement a business idea for the production and sale of crumb rubber tiles and pavers, about choosing a machine and equipment for making it at home, as well as about the advantages of this material and its advantages over other types.
Conclusion
As you can see, making rubber crumb tiles is a very profitable business, especially with a competent business plan.
This business does not require large expenses and quickly pays off.
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