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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 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.
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 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 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 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.
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);
2. A shift of workers, which consists of 4-5 employees (1 senior per shift);
3. Power consumption:
- normative - 52 kW;
- average - 13 kW/h (due to the cyclical operation of the equipment);
4. The average level of productivity (taking into account possible stops and marriage). Equipment and materials are placed by sectors:
§ Raw material warehouse for storage of crumb rubber, its dyes and glue;
§ Preparation sector, where the material is used for dosing, mixing, weighing processes
§ Molding sector, with installed equipment for pressing and tables;
§ Warehouse with finished products, where manufactured products from tire crumb are stored.
The presses start to operate prematurely, 30-50 minutes before start-up, in order to warm up the press mechanisms.
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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. Selling price 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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The production of rubber tiles is the most effective method recycling of 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.
In the composition of the mixture for the manufacture of rubber paving slabs includes:
- crumb rubber fractions;
- glue;
- pigments;
- modifying fillers.
This 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 when high temperatures Oh.
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 activity will take a lot of your time and Money, so it is better to purchase finished products or order their manufacture 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 to install 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:
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 regime in 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. Into the mixer desired proportion rubber crumb, glue, pigments and modifying fillers are loaded.
- 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. cold way implies 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 connecting links do not dry, but are baked, which adversely 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 quality material with excellent performance. Production volumes can be increased by purchasing additional equipment.
The practice of using rubber coating shows its excellent properties. Rubber tile in many respects outperforms paving slabs and other coatings. It is enough to note its strength, extending the period of use up to two decades.
Choice of premises for production
Tile production needs a special room. It should preferably match the following requirements:
- the total area of the premises is not less than 80 square meters;
- ceiling height - not less than 3 meters;
- the internal temperature of the room is not lower than +15°;
- connection to an industrial power grid - from 20 kilowatts;
- floors with a flat surface;
- distance from the residential sector at least 300 meters.
Raw materials for the production of rubber coating
To forge manufacturing process, you will need to purchase the following materials:
- rubber crumb (color and black);
- dyes;
- polyurethane adhesive.
The main raw material rubber crumb. Basically, it is a waste tire. The key to the strength and durability of rubber crumb is the high quality of both natural and artificial rubber, as well as emollient oils and fillers that are used in the manufacture of tires.
Rubber crumb is produced as follows. First, waste rubber products are collected at a specially designated site. Then, from the place of storage of crumb rubber, it is delivered by a forklift to the workshop.
There it is loaded into a special plant that processes rubber products. The process of manufacturing crumb rubber of a certain fraction is started. Finished products are unpacked into bags and transported by forklift to warehouses.
Equipment for the production of rubber tiles
When buying this type of equipment, each entrepreneur primarily focuses on the amount of start-up capital. The market today offers a wide range of equipment of this profile.
So, what equipment will you need to open your rubber crumb tile business? The standard technological complex includes the following units:
- Mixers (six pieces). They are needed for the process of mixing various ingredients.
- Heating cabinets (or drying chamber). Here the raw material will be subjected to heat treatment.
- Six fixing stands for tiles.
- Forming tables (you will need three to six pieces).
- Mixer platforms.
- Press (hydraulic model) for the production of rubber tiles. This machine will provide the molding process of products.
- Molds They will serve for the manufacture necessary products.
- Conductor. It is necessary for the formation of technological holes.
This is the minimum set of components for the production line, which will allow you to start the process of manufacturing rubber tiles. This equipment will allow to produce products of different thickness and density.
Video: equipment for the production of rubber tiles.
Production technologies
In the production of two-layer tiles, for a softer and cleaner top layer, you will need colored fine rubber. For a dense lower base layer, you will need a black coarse crumb (0.2-1 cm).
The creation of each layer of rubber crumb involves a separate production process. It is assumed that the composition of the lower layer may include textile inclusions, metal elements and other impurities.
On initial stage production, a mixture is made with the addition of glue and pigment. All ingredients are mixed as thoroughly as possible. Then the resulting raw material is poured into molds having the desired parameters and a given shape.
Formation of products is achieved by pressing. After that, you need to carefully remove the tile from the molds. If the work is done flawlessly, then quality tiles packed and sent to the warehouse or transported directly to the customer.
Rubber crumb tile production methods:
- hot pressing;
- cold pressing.
The first - high-temperature - method is characterized by high productivity, but the tiles obtained by hot pressing lose their durability and acquire the smell of burnt rubber.
With cold pressing, both process productivity and product quality can be achieved. The main thing is to comply with all technological requirements.
Video: comparison of hot and cold pressed rubber tiles.
Stages of production of rubber tiles by cold pressing
- Mixture preparation. A line with six mixers will allow you to thoroughly mix all the components.
- Filling the mixture into molds.
- Pressing process. Molds are loaded into trolleys in ten levels, which are subjected to pressing - squeezing under pressure up to 5 tons.
- Drying. Carts are placed for 4-6 hours in a drying chamber, where the temperature is set to 60 °.
- Unloading carts and removing products from molds.
- Quality control of finished rubber tiles.
Advantages of the cold pressing method
- there is a thorough mixing of all ingredients, which affects the improvement of product quality;
- under pressure, the tile acquires a high density;
- a sauna effect is created in the drying chamber, which contributes to the good absorption of dyes and glue into rubber crumb - this will subsequently affect the strength and flexibility of the tile;
- cold pressed rubber tiles do not have a specific smell and do not suffer from the effects of the external environment.
Profitability of the rubber tile manufacturing process
A mini-factory, where this equipment will be located, can cost a novice entrepreneur in the amount of 2 to 3 million rubles, including VAT and a set of all work to launch the line.
You should not be afraid of the costs of acquiring equipment for the production of rubber tiles and organizing a business as a whole. They redeem themselves pretty quickly. The main advantage of such a line is that it will save on the labor of workers. Three or four operators will be able to serve it.
The profitability of the production of rubber tiles on such equipment will be 40%. With a 22-day work schedule, production output can be increased to 3,000 m2 of tiles per month.
The main thing is the competent operation of the equipment and a thoughtful approach to the production process. With a growing demand for rubber tiles and little market competition, there is every reason to expect the company to be successful.
- When purchasing equipment for the production of rubber paving slabs, you should responsibly approach the issue of choosing a supplier.
- A conscientious supplier will provide information on the location of sales markets and help create schemes for its sales.
- It would not be bad for a novice entrepreneur to acquire a list of documents for obtaining a certificate.
- The supplier can also provide assistance in acquiring the necessary raw materials for the production of rubber coatings.
- You should buy equipment for the production of rubber tiles from a supplier who will not only install it and help with the launch, but also give a guarantee for the implementation repair work in case of force majeure.
As additional equipment for rubber tiles, you will need to purchase a heating cabinet, a platform for a mixer, a molding table, stands for fixing tiles.
Before starting your own business, you should collect all Required documents and get a certificate for the products. It is also recommended to find a proven supplier of equipment and raw materials in advance. In this case, you can hope for warranty service for equipment, which will avoid long downtime. In advance, it is necessary to identify possible markets for the finished material. You should also rent a territory of sufficient area for the production and storage of products. After that, you can proceed to the purchase of equipment and raw materials, the search for personnel and the start of work.
