The use of rubber crumb for the production of goods: the main types of products. Production of rubber coatings from crumbs
A promising business in 2015 is the manufacture of coatings from crumb rubber. The competition here is low and there are no monopolies. And the demand for coatings made from crumb rubber is growing every year, because new areas for its application are emerging.
What is so attractive about this business idea?
What is rubber crumb coating
rubber coating as modern material has a lot of winning features:
a) quality appearance;
b) different color, thickness and size;
c) not susceptible to damage from impacts;
d) non-slippery surface;
e) does not fade;
e) does not retain moisture;
g) heat resistant.
Service life of at least 40 years.
A rubber coating is made from crumb rubber by mixing it with glue and dyes and by exposure to certain temperatures.
Markets and technology for the production of crumb rubber coating
Before deciding to start any business related to production, it is necessary to determine the distribution channels finished products.
Purpose rubber coating: for playgrounds, areas near houses, blind areas, areas near swimming pools and skating rinks, floor coverings on farms, in baths, in industrial premises of various enterprises to reduce injuries.
The production technology does not require special knowledge. Rubber crumb for the manufacture of coatings is obtained by processing worn-out car tires and tires.
The production of rubber crumb and rubber plates are different directions, but they are interconnected. If you opt for the production of crumb rubber, then considerable investments will be required. However, investments in both these areas are almost identical.
Rubber crumb makes up 85% of the composition of a rubber tile or rubber coating.
Other components of the rubber crumb coating are polyurethane adhesive (10%), dyes in powder form (5%). If desired, to expand the range of products, you can use colored rubber granules to apply a variety of patterns on the surface of the tile.
The technology for manufacturing rubber crumb plates consists in mixing raw materials in a bunker and its subsequent vulcanization. ready mix molded into tiles various forms, size and thickness with molds. Depending on the size of the tile, a certain vulcanization temperature is set on the equipment. This method of production is called pressing.
Another way is vibrocasting. The finished mixture is poured into molds and kept on a vibrating table for two days.
How to start implementing a working business idea
If it is possible to invest about 1.7 million rubles already at the first stage, then it will be enough to choose a suitable warehouse and purchase the simplest equipment.
One production set allows to produce up to 2400 kg of rubber crumbs per day. The cost of one kilogram of crumbs in Russia is on average 12 rubles. But even if you have good start-up capital, you won’t be able to work “maybe”.
It is necessary to meticulously work out a business plan and provide for the development of production for the next 3 years. In addition, it is important to analyze the demand and market.
The payback period for a business, depending on production volumes and financial capabilities, ranges from six months to two years.
To organize a workshop for the production of rubber crumb coatings, the following basic equipment will be required:
- press - 300 thousand rubles;
— molds for the press — 30,000 rubles per item;
– mixers for raw materials up to 200 thousand rubles;
- a chamber for drying products (self-production is possible).
Need to buy and expendable materials- crumbs, dyes, glue. The smaller the crumb fraction, the more glue will be required. In the black coating, the share of glue will be from 4 to 6%, and in the color coating - from 7 to 9%.
For increase operational qualities rubber tiles use the technology of two-layer production. Wherein upper layer tiles are made from a small fraction of rubber crumbs, and the bottom layer is made from a cheaper large fraction. The cost of 1 sq. meters of finished tiles - up to 1500 rubles.
Free Raw Material Rubber Coating
Crumb rubber is produced from old car tires. Therefore, finding raw materials for processing is not difficult.
In fact, this is waste that can be purchased for nothing or taken at all for free.
The advantage of the business is that in Russia, for the time being, the disposal of tires for the population is free, and most car owners throw them away like trash. In Europe, tires that have become unusable must be taken to special points for recycling, paying for this service.
However, in Russia, most motorists are ready to give away used tires, but on the condition that someone takes them from them. This means that in order to organize tire recycling production, it is necessary to provide for additional transportation costs for collecting tires from the population or to conclude contracts with large transport enterprises, which will ensure an uninterrupted supply of raw materials.
The raw material is crushed mechanically or using advanced shock wave technology. However, she has more high cost. Its advantages include lower energy consumption and there is no need for large production areas.
But shock-ox new technology require the installation of a special refrigeration equipment. At a temperature of -90 degrees, the tire breaks into pieces, as it becomes brittle.
For the workshop, it will be necessary to rent or purchase a production facility with an area of 60 square meters and an electrical network with a voltage of 380 kW (the amount of electricity consumed by one installation is 15 kW per hour), hire two operators for one shift. You will also need two storage facilities: one for raw materials, the other for finished products. At the same time, the raw material warehouse should be four times larger.
For good profitability of production, it is optimal to operate the workshop around the clock in three shifts, 7 days a week. In this case, you need a minimum of 8 staff members. 
With a line capacity of 100 kg per hour, the production costs are as follows:
- equipment - about 30 thousand dollars (depending on modification);
- registration of certificates and other - 2 thousand dollars;
- rent of premises (cost per month - about 3 thousand dollars);
— wage production staff and sales department - from 5 thousand dollars.
But with the right marketing most of costs will be covered already in the first month by the sale of finished products. The operation of one plant for the production of crumb rubber with a capacity of 100 kg per hour will make it possible to produce 72 tons of finished products per month.
A ton of crumbs costs an average of $500. Thus, the income will be 36 thousand dollars.
A by-product in the recycling of old tires and tires is metal, the share of which is 25% of the total volume of raw materials. The sale of metal will bring additional profit.
Income from the sale of rubber tiles is disproportionately greater than the cost of producing raw materials for its manufacture. If we combine the production of crumb rubber and rubber coatings and place them on the same territory, then the cost of transporting raw materials can be excluded from the calculations.
The industrial production of rubber crumb and coatings from it is not only a profitable working business idea, but also an excellent modern production which makes it possible to make the environment cleaner.
In addition, technologies for the production of mixtures for the manufacture of pavement containing crumb rubber. As a result, construction costs can be reduced. highways. Road construction is another market for crumb rubber.
By the way, in order to start producing rubber crumb coatings, it is possible to take advantage of a franchise. Good luck to you in the implementation of the ideas of small production!
Today, one of the important industries in our country is the production of crumb rubber from tires.
It is the main material for the production various items.
Recently, a number of laws have been adopted in Russia, which significantly improves the conditions for the manufacture of raw materials, and in general changes the climate in this type of business.
In the article we will tell you what can be made from crumb rubber and in what areas it is used.
When converting tires into crumb rubber, there is an integral and associated type of entrepreneurship - this is the production and sale of finished products.
To acquire sustainable profits with this type of business take into account the inevitable risks.
Let us consider in more detail the use of these products in the national economy.
Rubber seamless
Manufacturers in the field of tire crumb processing have created unique seamless coatings, which are a filler floor with specific properties.
The technique for making it is to use special composition from crumb rubber with mixing of polyurethane and coloring elements.
This coating is environmentally friendly, it odorless and harmful substances.
The spheres of use of rubber sheets are very wide: they cover playgrounds for sports and children's activities, the area near the swimming pool, and for ennobling parks.
And, undoubtedly, it has a number of advantages over other coatings:
- Long service life from 25 to 45 years.
- Safety for people and animals.
- Providing a secure grip. This greatly reduces the risk of falling while driving.
- Waterproof flooring, which ensures quick drying after precipitation.
- Product attractiveness. A wide range of colors allows you to make its decoration limitless.
- Flat and smooth surface.
Such qualities of the material make it invaluable in the arrangement of stadiums and various playgrounds. It has found wide application at the entrance to houses, in the foyer, on stairs and ramps.
Treadmills
The flooring of such a product belongs to professional sports surfaces, in this regard, it must comply with international standards.
Although single requirement this element is not, however, there are a number of recommendations for their manufacture:
- material damping. This quality of the track is necessary for the comfortable training of athletes.
- Reliability and stability of the adhesion of shoes and the surface of the flooring.
- The guaranteed preservation of a form of a covering at temperature difference.
- Immune to wear and mechanical damage.
The composition of polyurethane with rubber crumb makes the running surface waterproof, which significantly affects safety. foundation track (it is not deformed during operation).
Use cases
The production of products from tire raw materials is multifaceted. It is used to make many items for various purposes.
Listed below are just a few of them.
Tile
Most suitable option in the manufacture of rubber crumb tiles, its two-layer production is considered: Bottom part the product is made of tire crumb, and the upper half is made of colored EPDM (ethylene propylene rubber).
The connection of such modular plates is made by locks, which simplifies the process and is accessible even to a beginner in this business.
In addition, she has a very reasonable price - from 1300 rubles per 1m 2. 
Tiles at the same time has the following advantages:
- An increased degree of injury safety of the product due to depreciation properties.
- Anti-slip properties.
- Resistance to abrasion, mechanical stress.
- Ease of installation.
- Various range of colors, which makes it attractive.
Tiles made from this material are used in the design of all kinds of sites, sidewalks, for laying out paths in squares and parks, when equipping runways at airfields, on piers, warehouses, farms and garages.
borders
Excellent material for the design and delimitation of public areas rubber crumb curbs are presented.
They have an excellent configuration, a different range of colors, they are unpretentious in maintenance and installation.
In this regard, borders have found wide use in fencing territories, as well as for marking roads, squares, courtyards, private gardens, play areas etc.
The main advantage of the products is their safety in case of contact with them.
Curbs made from tire rubber do not require painting or other additional maintenance.
They are resistant to minus and plus temperatures and do not crack during operation, they are perfectly cushioned in the event of a collision with them.
columns
The parking "landmark" made of tire rubber is a successful alternative to metal and concrete protection.
There are iron bars inside the product, allowing it to bend, but at the same time, the column does not break.
The installation of such elements occurs due to the anchor with a threaded connection.
These devices are used to delimit sidewalks from roads, fence off a parking area and separate moving traffic.
Figures for playgrounds
Tire rubber 3D elements are a small architectural form made of ethylene-propylene rubber. They are great for playgrounds and intended for children from 4 to 10 years old.
Rubber toys in the form of horses, mushrooms and other figures add variety to the play atmosphere and attract with a truly new approach to the playground.
These toys are safe for children, they are environmentally friendly, attractive to look at and create an exciting environment for play.
Manufacturing of fillers
Bag chair
This piece of furniture is the most common type of chair without a frame. The product has achieved such popularity due to the versatility of its configuration, and, accordingly, large range possible poses.
And all this is achieved thanks to the filler of rubber crumb with a small fraction (2-6 mm).
Such rubber granulate ensures the constancy of the volume and the pronounced result of the “flow around” the person in the bean bag.
tombstones
When arranging graves, it is traditionally customary to decorate them with marble tiles, and fill the passages with gravel or sand. But it helps to short term. Today there is an acceptable option for making tombstones - this is modern coating from tiles based on crumb rubber.
It is significant surpasses concrete surface by service life, since it is not affected by precipitation, it has a much larger range of colors and, in addition to this, it is quite budget cost.
Boxing bags
Such a sports equipment, like a boxing bag or a pear, is filled with a homogeneous material: sand and other loose mixtures.
However, crumb rubber creates the desired effect when practicing strokes.
In addition, she has all the necessary qualities.
Tire crumb for such products should be from 2-3 to 4-6 mm in size.
road construction
Road construction is another area where rubber tire crumbs are used. asphalt pavement using tire crumb has a number of advantages:
- Performance improvement roadbed. This is due to the acquired depreciation properties of the coating.
- Such a road provides more reliable engagement between the surface and the wheels, which significantly reduces the accident rate.
- Reduction of tire wear.
- Extended time between repairs.
- Reduces the likelihood of a rut due to the elasticity of the roadway.
For modified coating reflective qualities are noticeably reduced. Concerning increased travel safety.
Bituminous mastics
Rubber-bitumen resin is used for waterproofing in various fields of human activity.
It is distinguished by two types:
- Mastic used at normal room temperature.
- Resin with heating to the desired degrees.
Towards roll materials this rubber-bitumen coating has several advantages:
- the possibility of application in hard-to-reach places;
- possessing excellent astringent qualities (sticking to different surfaces);
- reliable protection against corrosion of underground pipelines;
- homogeneity of the mixture and resistance to deformation.
Surfaces treated with rubber-bitumen mastic are not exposed to fungus, mold and other aggressive influences.
Heaters
Another popular area of use of tire crumbs is various heaters and seals.
The most popular is modified rubber insulation (EPDM, SBR or NBR), which is considered the basis of porous rubber.
The total volume of pores in such a heater can vary from 25 to 75%, and the size of each cell is about 0.4 microns.
This rubber is called microporous, and its properties directly depend on the qualities of the polymer base.
In relation to monolithic, this rubber stands out for its properties, such as:
- softness;
- noise and vibration isolation;
- elasticity.
Cellular mats
To protect the room from dirt and debris, cellular rugs are best considered.
These products are embossed coatings with holes inside.
Wherein they are made from polymer material with the addition of crumb rubber and are designed for long term operation.
Thanks to the cells, the earth does not remain on the surface, but crumbles inside the holes - on the floor. When cleaning, it is enough to move the mat and easily sweep away the debris with a broom.
Business Outlook
Related videos
This video tells about the main areas of application of tire crumbs, in particular, about all types of rubber coating production and business for the sale of tiles for playgrounds, sidewalks and other products:
Conclusion
After reading the article, you learned what can be made from tire crumbs and where it is used.
Tire recycling is a complex and requires a lot of investment for the purchase of equipment, rent of premises and other expenses.
But if you decide to open your own business for the manufacture of any products from tire crumb, then the result will not be long in coming. I wish you success!
In contact with
The production of crumb rubber is a very promising, and more importantly, environmentally sound industry. This is a relatively new word in industrial technologies, not all post-Soviet republics have enterprises for the production of crumb rubber. The production of crumb rubber coatings can become a monopoly enterprise, and the big plus is that the demand for crumb rubber products is steadily growing, and the range of areas in which products are used is constantly expanding.
Rubber crumb products are not only in great demand, the lack of a large number competitors allows you to quickly sell products in the right amount. The enterprise for the production of products from rubber crumbs is not particularly science-intensive, the production technology does not require the development of very complex technologies. Therefore, it is not only useful, but also a very profitable technology.
Before proceeding with the manufacture of crumb rubber tiles, it is necessary to take into account two main factors that determine the success of the intended business - these are financial opportunities and the sales market
How is crumb rubber made?
Finance is the factor that you should build on, you need to know your financial potential, which includes both personal savings and the possibility of obtaining funds from credit institutions and investors. If it is not possible to immediately create a large enterprise for the production of crumb rubber, you can limit yourself to a medium-sized workshop that requires a minimum of financial investment. Of course, if there are no restrictions on funds, it is possible to build a factory for the production of crumb rubber products, with large area and worth several tens of thousands of million dollars.
The sales market is the main factor that determines how much money is worth investing in a business. If $ 100,000 is invested in the business and a simple crumb production line is installed. It will be able to produce about 2000 kg of products. Then you can limit yourself to local buyers, but if a large enterprise, you will have to look for a buyer also outside your region.
How best to make crumb rubber
For the production of crumb rubber, the most common tires from any technique are used. Raw materials are very cheap, as tires have served their time and are, in fact, garbage. In some cases, they are offered for free, and only pickup is included in the expense items.
On the this moment there are two methods for obtaining crumbs: a method in which mechanical grinding and more modern method shock wave. Since not every enterprise can make rubber crumb using the shock wave method, the new technology requires new investments, the mechanical method of processing is more common.
Sales
Rubber crumb and products from rubber crumb photos, which are presented on the site, are used in a wide variety of areas:
- road surfaces with the addition of rubber;
- coatings for sports and playgrounds;
- paving slabs and paths;
- construction industry;
- waterproofing materials;
- sorbents for purification of natural reservoirs from oil products.
Photo of the entire line of products and products from crumb rubber
Making tiles from crumb rubber can allow a business to flourish much faster. Since the demand for rubber crumb products is much higher than for raw materials, Production Line for the manufacture of coatings from rubber crumb or other product, will bring great profit to the common cause.
The manufacture of rubber crumb products, photographs of which are published on the site, is the last link in the production chain, starting from recycling rubber tires, before the creation of modern rubber coatings.
| Name | Up to 20 tons, rub/t | 20 t - 200 t, rub/t | more than 200 tons, rub/t |
| Tire crumb | |||
| KRSh 0.5 | 20001 | 19600 | 18900 |
| KRSh 0.63 | 20001 | 16900 | 18900 |
| RD 1.0-2.0 | 14000 | 13500 | 13000 |
| RD 1.0-3.0 | 13000 | 12500 | 12000 |
| RD 2.0-4.0 | 12000 | 11500 | 11000 |
| RD 25 | 8000 | 7500 | 7000 |
In this article:
The production of crumb rubber is quite a promising industry. In the CIS, there are relatively few competitors in this market, they do not even have a relative monopoly, and in some regions they are also very dispersed. In addition, the demand for crumb is steadily growing, and the scope of its application is constantly expanding.
Not to mention sales. In the crumb rubber industry, as in any industry, distribution channels are of central importance. Demand this species product grows, and the market is not oversaturated with competition, which means that when right approach to a sales organization, to sell a similar product in required volumes is quite real.
Such an enterprise is not science-intensive and does not require development sophisticated technology production.
Depending on the volume of investments, the payback period is 6-24 months. All these factors reduce the potential risks of this type of business, and increase its attractiveness from the investor's point of view.
Crumb rubber production volume
What is the optimal production volume? There is no single answer to this question, because the scale of the business depends on many conditions. However, there are two key factors that often determine the choice:
Factor #1: Finance
It is always worth starting from your own financial potential (personal savings + the possibility of obtaining the necessary borrowed funds or attracting investors). The fact is that the production of rubber crumb allows you to choose almost any desired production volume:
- You can start with small-scale production, which will require a minimum investment;
- Build a rubber crumb factory with total area several thousand sq. meters and a total cost of 15-50 million dollars;
- Choose any intermediate option.
At the same time, of course, not only your own financial potential is taken into account, because the market in your region can also dictate its conditions (see Factor No. 2).
Factor #2: Market
Of course, if you are able to invest $100,000 in production, then you have no choice. All that is required is to rent a warehouse space of 60 sq. m, several storage facilities, buy the simplest rubber crumb production line and start with the production of 800-2400 kg of products per day.
If you are thinking about a larger business, without assessing the market conditions in your area, it is unlikely that you will be able to succeed.
What is the demand for this product and availability of distribution channels? Who are the competitors in the market, and what market share do they occupy?
All these factors must be taken into account, and, of course, take into account your own expansion plans for the next 1-3 years. Naturally, the numbers will be quite approximate, but you will have a certain benchmark, and this is always better than working on a whim.
Rubber crumb production technology
The crumb is made from rubber tires and tires that have completely exhausted their resource. There is no need to talk about the difficulties of finding raw materials for the production of crumbs or about its high cost. On the contrary, waste tires and tire production waste are in abundance. They can be bought for next to nothing, and in some cases they are generally free (you only have to pay shipping costs).
Almost any tires (car, truck, bus, etc.) are suitable for such production. share the following types raw materials:
- Spent pneumatic chambers and tires;
- Waste tires (including those with metal and fabric cords).
Today (December 2012) there are two main technologies for obtaining crumbs from tire production waste:
- Mechanical grinding;
- Shock wave grinding.
Shock wave grinding technology has appeared relatively recently, therefore it is precisely mechanical way processing is the most widespread in the world.
Installation of equipment for the production of crumb rubber by shock wave grinding requires special re-equipment of the production facility and installation of expensive refrigeration units. Nevertheless, the placement of such equipment is possible on a much smaller production area, and its energy consumption is significantly lower than analogues.
Such equipment is ideal for large and medium-sized industries, however, the application mechanical method obtaining crumbs may also be economically viable.
Expenses
It is really possible to start the production of crumbs with small volumes and with relatively small investments. The simplest crumb rubber production lines require only 60 m 2 of production space, a 380 V power supply, and two operators per shift.
Of course, working in 3 shifts (non-stop) 7 days a week is the most profitable, so the staff of production workers should consist of 8 people.
Consideration should also be given to the need for at least two storage facilities, one for raw materials (tyres) and the other for finished products. The warehouse for raw materials should be 4-5 times larger than the warehouse for finished products, for example, 400 sq. m and 100 sq. m, respectively.
Fixed costs:
- The cost of equipment is $70,000-$150,000.
- It is also worth laying down small sums for certification and examination (up to $2,000).
Total fixed costs:$72.000-$152.000
Variable line maintenance costs:
- Monthly rental of warehouse space $3,000-$6,000;
- Monthly salary for production staff $3,000-$7,000;
- Monthly salary for non-production personnel (sales department) $1,500-$2,500.
Total variable costs:$8.000-$16.000.
Total:
The total cost for the first month of production will be $80,000 - $170,000.
After the first month, variable costs should ideally be fully covered by sales revenue.
If a line with a higher productivity is installed, for example, 500 kg/h, the equipment costs can be up to $1.000.000-$1.500.000. Variable costs will increase in proportion to the volume of production. If it is planned to install two or more lines, then the costs increase in proportion to the increased output.
Revenue
Given the productivity of 100 kg of rubber crumb per hour in three shifts, the monthly output will be:
- 100 kg/hour *24 hours *30 days = 72.000 kg or 72 tons of crumb per month.
- At average price$500 per ton revenue from the sale of crumb rubber will be $36,000.
In addition, do not forget that the share of metal in tire production waste is 15-25%, or:
- 25 kg of metal cord per hour * 24 hours * 30 days = 18.000 kg or 18 tons of metal per month.
- At an average price of $200 per ton the proceeds from the sale of scrap metal will be $3,600.
total revenues :
- $36.000+$3.600 ~ $40.000
- — possible downtime (10%),
Total: $36.000.
This amount is significantly higher variable costs for doing business.
Sales
The main areas of use of crumb rubber are:
- Rubber-asphalt and road concrete barriers with the addition of rubber;
- Coverings for football fields, tennis courts and other sports and playgrounds;
- Production of waterproofing materials.
- Products for the construction industry (pallets, anti-slip coatings etc.).
- Rubber paving slabs;
- Production of sorbents, waterproofing and thermal insulation materials etc.
Already at the stage of business planning, it is necessary to identify manufacturers of similar products in your area and begin to establish contacts with them.
Production of crumb rubber tiles
Business risks can be diversified by setting up the production of coatings from crumb rubber or, for example, tiles. The fact is that the demand for tiles or coatings does not directly depend on the demand for raw materials (crumb), which means that these are essentially two different directions activities under one roof.
In addition, such a business will provide a steady demand for your rubber crumb plant. Do not forget that finished crumb products have a larger margin than the raw materials used in their production. This will increase profits.
The costs of such diversification will amount to approximately equal to the sum necessary to start the production of crumb rubber. The ideal option will locate both enterprises on the same territory, so as not to spend money on the transportation of raw materials.
Over time, if the business turns out to be successful, it is worth thinking about expanding production capacities and the range of output.
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 components. High Quality (various oils, synthetic rubber, fillers), since these products must withstand enormous loads for a very long period of time.
Of all existing species 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 in 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 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), the price is 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 inclusions different color;
- 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 the usual paving slabs. It is for this combination that rubber coatings of similar sizes and shapes are created, as regular tile for the sidewalk.
A room for a mini tile production workshop.
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. Occupied technical line area - 70-100 m² (excluding 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. Average consumption of glue for manufacturing various coatings 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 baby, the stronger coating, but compliance with 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. On the same pressing mechanism, it is recommended to produce products of the same thickness, 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 coating for various sports complexes or 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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