Production of crumb rubber boards. Do-it-yourself rubber crumb tile. Crumb rubber tile production as a market

Mixing system (mixer with geared motor, filling platform, forming table, plastic surface inside the tank, electrical cabinet)

Recently, a popular material for the landscape among the owners of private houses, summer cottages, is positioning paving slabs from tires or plastic bottles, often created with your own hands.

Although, despite the "home-made" nature, tiles are increasingly being used specifically for arranging various public facilities, for example, squares, sports grounds, parks, and pedestrian crossings. The owners of private objects themselves, with no less success, make original tiles for laying the floor in the garage, gazebo.

If you have a huge land plot on which a tennis court is located, or a basketball court, you should immediately develop a plan for laying this surface with your own hands with an original, unlike anything material.

Advantages and specifics of the material used

The main advantages that distinguish the tile material, created by hand from improvised materials (tires, plastic bottles), include the following:

Production of coating from used car tires

New pavement from old tires

The production of material and laying it with your own hands provides for the following:

Production and installation of plastic structures, bottles

Paving slabs from plastic waste

The main advantages of plastic products

Plastic bottles are distinguished by their compliance with all environmental requirements and standards, positioning them as a clean product. During operation, carcinogenic substances do not affect the human body, thereby becoming a completely safe product in all respects.

The eventually created coating is able to withstand many hours of stress, as well as environmental influences, such as freezing, while properties are not lost over time. In addition, the surface is non-slip, guaranteeing an excellent combination with shoes.

And finally, it is impossible not to answer the maintainability of the structure, because a damaged element can be easily replaced with a new one, without spending too much time and effort. As with rubber plastic bottles affordable and beneficial for the owner, and has all the relevant strength characteristics.

Video: Rubber crumb coatings

With the rapid growth in demand for rubber tiles, there is a low number of manufacturers on the market. This means that your rubber tile business will develop with little competition, and therefore has a chance of early success.

Where is rubber tiles used?

Initially, the production of rubber tiles was organized in order to cover playgrounds with a non-traumatic coating. Then it began to be used on other sports grounds, halls and even in swimming pools. Today, the use of tiles has expanded significantly.

The main advantages of this coverage are:

• non-slip surface;
• demonstrates high orthopedic and soundproof properties;
• resistant to temperature extremes, frost-resistant;
• does not lose aesthetic properties during prolonged use;
• easy to install, easy care;
• does not break, does not crumble, durable;
• service life - at least 10 years;
• variety in color and shape.

Production room

To start the production of crumb rubber tiles, you need to find a suitable room. The main requirements for it are as follows:

• ceiling height - from 3 m;
• heating, so that the temperature inside the room is from 15 ° C;
• industrial power grid (from 20 kW);
• flat floor for equipment installation;
• total area - from 80 sq. m.
• the workshop is located at least 300 meters from residential buildings.

Raw materials for production

The production of rubber tiles will require the purchase of such materials:

• dyes (7 rubles/kg);
• polyurethane glue (140 rubles / kg);
• rubber crumb: colored - 23-35 thousand rubles / ton, black - 17 thousand rubles / ton.

The main raw material is crumb rubber. Today, the production of crumb rubber uses mostly used tires. Other used rubber products are sometimes used. The production of crumb rubber is as follows. On a special site near the place where the production of crumb rubber takes place, all used rubber products are stored. From there, they are delivered by forklift to the workshop and loaded into special equipment for the processing of rubber products. There, the production of rubber crumb of the established fraction takes place, which is packed in bags and transported to warehouses by the same forklift. At this stage, the press is not needed.

The production of crumb rubber can be organized independently. This will greatly reduce the cost of your business, focused on the production of rubber coatings. But at first, contractors can be found for the production of crumb rubber.

Technology for the production of rubber tiles

Depending on what coatings are planned to be produced, crumbs of a certain fraction are used. For example, if a two-layer tile is produced, then the top layer is prepared from fine colored rubber. Lower, main and dense - from black large (2-10 mm). For each of the layers, a separate production of rubber crumb is provided. At the same time, the top layer is softer and cleaner. The composition of the bottom may include metal elements, textile inclusions, and so on.

The first stage of production involves the preparation of the mixture. Glue and pigment are added to the raw materials, and all this is well mixed. To do desired tiles, raw materials must be poured into molds. They have the appropriate shape and size. Then a special press produces the formation of products. After this, the product must be removed from the molds and inspect how well the work has been done. Quality tiles packed and sent to the warehouse.

Equipment for the production of rubber tiles

If your business plan involves the production of raw materials, you will need equipment for the production of rubber crumb. It can be made in two ways: classical mechanical or new, shock wave. For mechanical equipment for the production of crumb rubber will be cheaper. It can be installed in any workshop. Under the second method, it is necessary to convert the room, but the equipment will require less area, and performance will be better.

Be sure your spending plan should include the purchase of equipment for the production of rubber tiles. It includes the following components:

• drying chamber (from 100 thousand rubles);
• two mixers for raw materials (100-200 thousand rubles);
• molds (30 thousand rubles / piece);
• volcanic press, which produces up to 100 m² of tiles per day (350 thousand rubles).

This should be your equipment procurement plan. But today, companies offer ready-made production lines that can be operated in one or two shifts. Their productivity can be a minimum of a thousand or a maximum of 3 thousand m² per month. The cost of such a line is from 2 million rubles. It consists of:

• fixing stand;
• Press forms;
• molding table;
• heating cabinet;
• Hydraulic Press;
• vibrating table;
• screw conveyor;
• cutting machine;
• cyclone;
• wheel bead cutter;
• chip-producing machine;
• belt conveyor;
• shredding machine.

The main advantage of the line is saving on the labor of workers. 3-4 operators can serve it.

Also, the cost plan should include the purchase of additional equipment:

• trolley for transportation of raw materials;
• trolley for transporting glue;
• electronic balance;
• trowels, scoops, mugs;
• drill with nozzles.

Staff

Separately, the business plan provides for the formation of staff. It directly depends on the number of shifts for which production is designed. With continuous work, you can work in three shifts all week. Then 8 workers should be involved in the production.

Financial plan

The expenditure plan includes:

• rent of premises - 3-6 thousand rubles;
• delivery and installation of equipment - from 2 thousand rubles;
• equipment - 70-150 thousand dollars;
• salary - 5 thousand dollars (including accounting and sales department);
• purchase of crumbs (black - 17 thousand rubles / ton, non-ferrous - 23-25 ​​thousand rubles).

The income plan consists of selling tiles for about $500 per ton. It is possible to produce 72 tons of products per month in three shifts. In addition, the income plan can include the sale of metal, which is collected during the processing of tires. This is another 3.6 thousand dollars (about 18 tons per month). In total, the revenue part will be about 36 thousand dollars.

As statistics show, investments can pay off in six months, and on average - in a year.

Production of rubber tiles in Russia: a 4-step business plan with all calculations, a list of equipment and examples from retail.

Good business- this is the one that allows you to earn good money and bring benefits to society.

In this sense, one of the best options, according to many, this production of crumb rubber tiles.

After all, this baby in her "past life" was car tires, all kinds of hoses and other similar waste that is toxic to the environment. Having established the production of rubber tiles, in fact, from garbage, you will not only be able to help in the recycling of waste, but also ennoble the city or village.

Indeed, rubber tiles for the street or large premises have recently become very popular, because they allow you to fold almost any floor pattern, are not afraid of moisture and temperature changes, and are not hard and slippery even on the hardest ice. Agree, some pluses.

This market in Russia is not yet filled, therefore it is quite possible to occupy your niche and get a good share in this extremely promising field.

Rubber tiles: production, product features and market overview

Before proceeding directly to development, it is necessary to understand the products themselves: what is rubber tiles and who needs them. By answering these questions, we will understand whether it is worth doing this at all.

What is "rubber tile"?

As it is easy to guess rubber tiles are rubber tiles. Yes, it sounds very simple and banal, but it really is. The manufacturer takes two types of rubber crumb - colored (for the surface) and black (for the base), mixes with special glue, presses, and gets the finished product.

Many also produce crumbs themselves - they collect old tires, grind them on special equipment, and thus get “reclaimed rubber”. In other words - . True, such rubber still needs to be “devulcanized” so that it is more suitable for reprocessing. Although everything, in fact, depends on the production technology of a particular product.

Rubber tiles: production by 5 types of use

1. Street paving slabs (gray or black);
2. Tiles for garden plot(most often green, the color of the grass);
3. For playgrounds (colorful, bright);
4. For sports fields (with appropriate different types sports markings);
5. Anti-slip coatings and overlays on the steps.

*Examples of using rubber tiles.

Also, the tile can have a different thickness, which will indicate its durability and protective functions, and hence the price. The thickness is usually from 10 to 80 mm, although another can be made to order.

Actually, you can produce all this at your enterprise. The production of crumb rubber tiles, in fact, is not very diverse - the composition is almost the same everywhere (rubber crumb + glue). The difference is only in the color, thickness and shape of the plate.

Crumb rubber tile production as a market

Let's say right away: they are buying, and every year more and more actively. Since this is mainly how it often happens in domestic realities, no one keeps accurate calculations. However, we are confident that the market is growing in indirect terms.

First, demand is growing. Recently, playgrounds and sports facilities in Russia have become much more meticulous than before. This is connected both with the elections and with the World Cup. The fact is that, according to the standards adopted in developed countries, playgrounds should not be finished with concrete or asphalt, but with such rubber tiles, which (in theory) should reduce the risk of child injuries.

As for the cladding of stadiums and running tracks, there is a direct indication from international sports organizations how exactly they should be designed. And the rubber tile here is the most, as they say, "must-have" - ​​that is, a mandatory attribute.

PS. Of course, small producers are unlikely to be able to become the main supplier of rubber tiles to a large stadium (public procurements of this scale have their own “kitchen”), but an order for lining a playground or a sports complex of a school is quite within the power of small and medium-sized businesses.

There is one point - every year there are more and more sellers of rubber tiles. If it is being sold more and more, then it means that they are buying more actively (after all, no one will work at a loss). And since they buy more actively, they produce more and more, because the common economic truth says: "Demand creates supply".

Production of crumb rubber tiles from the point of view of Rosstat

In particular, the following table can be found in the archival bins of the chief state accountant:

*Production of the main types of rubber and plastic products on years.

There we are interested in the last line, which describes the materials. This includes the production of rubber tiles as a branch of the national economy.

As you can see, the production of such coatings increased from 2010 to 2014 from 250,000,000 sq. m. to 371,000,000 sq. m. At the same time, we see some decline in production in 2013 compared to 2012, but then growth resumed, although not in the same volumes as before.

But that was three years ago, what now? The same Rosstat gives us more relevant food for thought - data on the production of rubber coatings for January 2017 compared to the same indicator in 2016.

In the table, we see that in January 2017, 1,400,000 sq. m of reclaimed rubber plates. Here we immediately note that this is a narrower segment, which just includes our products. That is, this is good, it allows us to better assess the volumes and growth rates of this market.

So, in January, 130.2% of these rubber plates and coatings were produced in Russia, compared to 2016. Translated into simple language, this means that an indicator of 1,400,000 square meters. m of rubber plates is 30.2% more than in January last year.

Here we, in fact, got the growth rate of this market at the beginning of 2017: + 30% compared to last year's figures.

The table also contains a comparison of January 2017 to December 2016, but here you need to take into account the seasonal factor: in January, almost a week falls on new year holidays, and production this month is always lower than the previous one. Therefore, it is necessary to compare data from January to January, December to December, etc.

Production of rubber tiles: determining the cost

One of the main criteria is the ratio of the price of the final product to the cost of its production.

We will talk about the cost in the corresponding section, after describing the equipment and calculating labor costs, and now we will indicate the approximate prices of tiles with different characteristics.

As we wrote earlier, the tile differs little in its structure. The main difference is the size and thickness. This directly affects its weight, and hence the amount of rubber raw materials that we need to produce it.

*Approximate prices in Russia as of the end of 2016.

Prices for 1 sq. m on the open market for rubber tiles Russian production will fluctuate within 1,000-2,000 rubles, depending on the thickness of the canvas. You can also find Chinese crafts for 700-800 rubles per 1 sq. m., but experts recommend that such products be treated very carefully, because poorly glued crumb rubber can crumble the next day.

At the same time, Chinese, as well as, by the way, European manufacturers do not include the conditions of the Russian winter in the operating standards. And it is harsh, and can literally destroy unprepared material. Therefore, it is recommended to buy high-quality domestic rubber crumb tiles.

The cost of production of rubber tiles starts from 650 rubles per m2 and can reach up to 1,250-1,500 rubles for especially thick slabs.

In fact, a lot depends on factors such as office rent, utility costs, logistics, etc. Therefore, the price for production in the Moscow region and somewhere beyond the Urals will be different. The selling price, however, will also be different (this time in favor of Moscow).

Technology for the production of rubber tiles

To begin with, not one, but two technologies for the production of rubber tiles are currently being used:

1. hot pressing technique.
2. Cold pressing technique.

1) Hot pressing.

This technology for the production of rubber tiles was especially popular in the first time after the appearance of the material on the Russian market. The method is cheap, fast and relatively simple. But at the same time, it is toxic, and the product after its use comes out of poor quality, quickly falls apart. This technology is often used by Chinese manufacturers when working on the cheapest product.

Its essence is that the rubber crumb is not so much glued together with a special compound, but baked on a special machine-press. At first glance, the resulting tile is not much different from better samples, although, of course, it stinks of burnt gum much stronger. But who on the street learns this? So the state of affairs suits many.

Rather, it suited them until the Russian buyer figured out this scheme.

The fact is that such a purchased and installed tile “falls off” along with the first snow. Or maybe it won’t reach it, because the compressed and heated gum, unlike the glued one, immediately breaks its structure under the influence of temperature changes.

If you live in a country with a temperate stable climate, then it will last quite a long time, but we are talking about the Russian sharply continental climate. Here, concrete slabs do not always withstand the load, what can we say about pressed rubber?

The massive use of this technology, by the way, was one of the reasons for the decline in production in 2013. By this time, the first buyers of rubber tiles had time to be disappointed in it, because. following the results of 1-2 winters, such a product decayed back to a state of crumbs. The result was a wave of bankruptcies of such enterprises that tried to sell a low-quality product at high prices.

2) Cold pressing.

Since 2014, the Russians have become better versed in rubber tiles, which gave this market a second wind, because now they have begun to produce tiles on more modern and high-quality equipment.

Cold pressing is long and not as profitable as hot pressing, but much more effective. Compressed rubber crumb with high-quality glue will withstand more than one winter.

Why didn't they switch to cold presses earlier? Equipment for the production of crumb tiles is much more expensive than that needed for the hot process. For large enterprises, the difference can be hundreds of thousands of euros or dollars. This makes the business less attractive in terms of investment.

Cold pressing technology goes through the following stages:

1. Mixing glue and rubber crumbs in special industrial mixers (preparation of raw materials).
2. The resulting mass is placed in prepared molds.
3. The press forms plates with a pressure of more than 5 tons.
4. The resulting boards are placed in drying chambers where, at a temperature of about 60 degrees Celsius, the products are dried for 5-6 hours (depending on the thickness of the tiles).
5. The final stage is drying at room temperature and quality control on a special table.

For comparison, the hot pressing method assumes that the mold is heated directly under the press. At the same time, the amount of adhesive in this form is much less, therefore it does not need to dry out under special conditions later. So, you won't have to buy dryers. However, the quality will be much worse.

Raw materials for the production of crumb tiles

Frankly, in the very subheading lies the answer to this question - yes, tiles are made from crumb rubber mixed with glue. Everything seems to be simple. But, as is often the case, the complexity lies in the details.

1. Rubber crumb.

In general, it is not difficult to find a supplier of crumb rubber. This recyclable material is available in abundance today, because it is made from car tires that have served their time.

A ton of such regenerated rubber crumb will cost 19-20,000 rubles (multi-colored is a little more expensive). A special polyurethane composition adapted for cold pressing can be found on the market at a price of 170-210 rubles per kilogram. A similar option for a hot tile release technique is 140-180 rubles for the same weight.

2. Glue.

Note that in this case, it is not so much rubber that is important as glue.

The characteristics of recycled tires are approximately the same. But the glue, which will bear the entire load in the future with changes in temperature and humidity, may be different.

Therefore, it is worth choosing glue with great attention in accordance with the price / quality ratio. If you have just started your business, then it is better to buy polyurethane from several manufacturers to check which one you can trust.

3. Other consumables.

Incidentally, the list Supplies It is worth including dyes. Of course, you can buy multi-colored crumb rubber in advance.

But, firstly, it is more expensive, and secondly, you never know in advance what color the buyer will like this season. A suitable dye costs 80 - 200 rubles per kilogram.

Equipment, workshop premises and other components of the industrial production of rubber tiles

We have already understood from reading the previous sections that in the production of tiles it is not so much the raw materials that are important as the equipment - it is this that accounts for the largest share of the costs.

According to market players, for one small workshop for 3-5 workers, it is necessary to purchase equipment for 1,500,000 - 4,000,000 rubles.

Everything here is also very ambiguous. Hot pressing equipment is cheaper, and cold pressing equipment is more expensive. The most expensive is the installation of an entire assembly line for cold pressing. At the same time, these lines are also very different in price, because some are more automated, while others are less.

On average, you need to focus on 2-2,500,000 rubles of initial investment:

Equipment for the production of rubber tiles (tape assembly)

If you need a more serious production, then you cannot do without an assembly line. Here is what is included in this equipment:

TO necessary equipment the presence of a car should also be attributed, otherwise how are you going to deliver tons of tiles to the assembly site?

The cost of the assembly line is about 3,500,000 - 4,000,000 rubles, although incomplete lines can be found on the market for 2,000,000 rubles.

Note that almost all assembly lines presented in Russia are made in China. The exception is only the most expensive units. To work on such a line, 3-5 people are needed, depending on the level of automation of production and its volume.

Speaking of volumes - the average assembly line produces from 1000 to 3000 square meters. m of rubber tiles per month. To produce the same volume of products in the usual way, at least 7-8 people will be required. That is, already serious savings on salaries.

Another important point: to place automated line for the production of rubber crumb tiles, a minimum of 80 square meters will be required. m. free space, as well as access to voltage lines with a power of 15 kW per hour (this is how much the machines consume). This is not to mention the ventilation system - the pairs of heated rubber and glue are quite toxic, although with the proper level of respiratory and eye protection they will not cause much harm.

Staff

A minimum of three operators is required to operate one automated tape. When working in three shifts, it turns out that the staff should be 9 people. If the scale of production is larger, then 4-5 people will be needed in one shift.

However, you should not immediately set yourself up for emergency work in such an intensive mode. Immediately after starting a business main problem will not produce tiles, but sell them.

Thus, you will not need three shifts of workers. But over time, when you acquire contacts, form your well-established sales scheme and start scaling your business, then you will need to recruit staff.

We present to your attention a detailed video

about the production of rubber tiles

We consider the income and expenses of the business for the production of rubber tiles

Finally, we have reached the culmination of any business plan - the calculation of profits. To determine how much we have earned from the company of our rubber dream, we must first accurately calculate the cost of consumables and the salaries of employees.

Let's assume that we will work in one shift. The salary fund for three people is about 75,000 rubles. They must work in a room of 80 sq. m - which means that its rent will cost 10 - 15,000 rubles.

For the production of 1 sq. m rubber tiles of medium thickness (40 mm) we need the following consumables: