Production technology of rubber tiles. We open the production of rubber tiles: equipment price, manufacturing technology and business plan Rubber paving slab production technology

Outdoor and indoor tiles are in great demand, especially when it comes to rubber tiles. This unique, durable, non-slip material is used for paving playgrounds, playgrounds, swimming pools and recreation areas. It is used in shopping, entertainment and sports centers, administrative offices and private homes. Production rubber tiles became an opportunity for many people to start their own business. The manufacturing technology of this coating is relatively simple and does not require significant costs, and the resulting product is characterized by low cost and excellent quality.

Raw materials for tiles

Making rubber tiles at home is quite possible, because crumb rubber is used as a raw material. It is obtained from ordinary car tires. They are crushed in special crushers.

The composition of the mixture for the production of rubber coatings includes the following components:

fine rubber crumb;
special dyes;
polymer glue;
modifying fillers.

During the manufacturing process, the adhesive acts as a binding element. Thanks to him, the composition acquires the consistency that is needed for further molding.

Important! Synthetic or natural rubber is used as raw material. Recycling tires from cars allows you to get a high-quality coating and dispose of unnecessary material.

Necessary equipment

The production of rubber tiles is impossible without the use of special equipment. The manufacturing process at home is difficult to imagine without arranging a mini-line. It includes several settings:

To make rubberized tiles, you need a volcanic press. Depending on the processing method used and the temperature produced, cold and hot pressing are distinguished.
The manufacture of rubber tiles is impossible without the use of molds into which the prepared composition is poured. For home production, 3-4 molds are usually enough.
Also, you can't make quality tiles without mixer with centrifuge. It will ensure thorough mixing of all components.
Production of soft paving material cold pressing method necessarily implies the passage of a stage with heat treatment. To do this, you need a heating cabinet.

The following are used as auxiliary equipment in the production of crumb rubber tiles:

platforms for mixers;
molding tables;
stands for fixing workpieces.

But on early stages production without auxiliary equipment can be dispensed with. To purchase a complete set of equipment, you will spend from $26,500 to $39,500.

Advice! If you are planning to make tiles for own needs, then all necessary equipment can be rented.

Manufacturing technology

The technology for the production of rubber tiles provides for two ways to process recycled materials:

Shock wave crushing. With such processing, car tires are placed in special chambers. There they are crushed due to shock-wave action. The equipment is fully automated, so only one worker is required for operation.
If do-it-yourself rubber tile production is carried out, then it is more suitable mechanical crushing. In this case, recyclables are crushed using cutters. This crushing technique is used more often, since it does not require additional costs for the purchase of equipment. Mechanical crushing takes place in several stages:
- a landing ring made of metal is removed from the tires;
- then the tires are cut into strips 40-50 mm wide;
- after that, the landing rings that are in the material are again removed;
- now the resulting rubber bands are ground to a state of crumbs with a diameter of not more than 4 mm, but not less than 1 mm;
- at the end, the raw materials are sorted into fractions.

The production of rubber tiles from rubber fractions is carried out by one of two methods:

Hot working method requires the use of raw material vulcanization in a special press. The vulcanization temperature is 130-140°C. The following advantages speak in favor of choosing this technology:
- acceptable cost (this technology is cheap, which has a beneficial effect on the retail price);
- the speed of the process (it takes literally half an hour to manufacture);
- the low price of molds allows you to purchase several pieces at once, which will increase production volumes.

Making tiles from crumb rubber cold pressing method. In this case, the vulcanization of raw materials is carried out when heated to a maximum of 80 degrees. The technology requires the use of special ovens in which the chips are sintered. Peculiarities cold technology are as follows:
- high quality of the received product;
- the cost of production will be higher than with hot pressing (this is due to the cost of electricity to power the cabinets);
- the process takes a lot of time (it takes an hour and a half to process raw materials).

Process steps

The production of crumb rubber tiles involves several stages of work:

On preparatory stage the production process consists in the processing and preparation of recyclable materials. Automobile tires are crushed to crumbs of the required fraction manually or using special equipment.
Mixture preparation. Construction mixers are loaded with components necessary for the manufacture of rubber coatings: rubber crumb, polyurethane adhesive, coloring pigments, modifying aggregates.
Product molding. The prepared and thoroughly mixed mixture is poured into molds.
Then the method cold or hot pressing prepared raw materials in molds are pressed to the required density and thickness. In hot pressing, materials are baked at a high temperature.
Baking. This stage will be only in the production of tiles by cold pressing. Its essence lies in the fact that the prepared molds are installed in heating cabinets. In them, the products are processed at low temperatures.

In order for the resulting products to have the required operational and technical characteristics, it is important to correctly select the size of rubber crumbs and strictly observe the material manufacturing technology.

The resulting tiles are durable, strong and highly resistant to wear. Due to the porous structure, puddles do not form on the surface of such a coating, since after rain, water quickly seeps through the material and goes into the ground. Laying tiles is made on any flat base.

Rubber tiles - the know-how of the last few years. It is just beginning to conquer the construction market, but it already claims to become the number one coating in the near future for the improvement of suburban areas. But what benefits can an entrepreneur take from this trend?

The manufacture of this building material is a new, low-competitive, but promising area of production. The guarantee of business success is the advantages of manufactured products over other types of coatings. Rubber crumb tiles:

safety;
durable (its service life is at least 20 years);
has anti-slip properties.

In addition, it does not crumble and does not crack at low temperatures, and, due to the elasticity of the material, frost is very easily chipped from it. The tile is able to pass water through itself, and therefore, when correct installation there are no puddles on its surface. The range of rubber tiles is wide: it is made in different colors, sizes, can vary in thickness, shape and even the pattern that decorates the surface.

All this allows you to use the coating:

on playgrounds;
in kindergartens;
on sports grounds;
when making country paths;
for arrangement of sites near ponds, fountains, pools;
in garages;
in car services;
in areas where animals are kept.

Potential buyers of products are:

private persons;
building stores;
construction companies;
organizations involved in the improvement of the city.

Stages of production of rubber tiles

Preparation of a mixture, including crushed rubber crumb, coloring pigment and glue in mixers.
Putting the finished mixture into molds.
Pressing and molding in a hydraulic press.
Heat treatment, which gives products the necessary specifications.
Unloading molds.
Quality control and packaging.
Shipment to the warehouse.

Minimum equipment package to start a business

The best option to start a business for the production of crumb rubber tiles - the purchase of the entire line of equipment from one supplier, for example, from EcoStep, which is the largest supplier of crumb rubber in Russia, which offers several modifications of mini-factories that differ in productivity and the number of types of products.

To launch a full-fledged business, the company recommends purchasing an EcoStep mini-factory as standard. It includes the following types of equipment:

The total cost of the equipment set, including VAT and commissioning, is 1,970,000 rubles.

Calculation of the cost price of rubber tiles at EcoStep mini-factory

Although the set of equipment provides for the possibility of manufacturing 14 types of products, the most popular products are EcoStep rubber tiles 500 mm x 500 mm, 40 mm thick.

In the total volume of orders, it occupies 70%, and therefore the calculation of the cost, and in the future, the profitability of production, is best done based on the cost of producing tiles of the specified format.

Product Feature

Name: safety rubber tiles EcoStep 500*500*40 mm.

Material characteristics:

size 500*500*40mm
tile weight - 7 kg.
weight 1m 2 - 28 kg.
number of pieces in one m2 - 4 tiles

Parameters of the mini-factory

Work is carried out in 2 shifts.
The duration of the shift is 8 hours.
Productivity of 1 change - 45 m 2 .
During the day, the plant produces - 90 m 2 of finished products.
The average monthly productivity of the plant when working in 1 shift is 990 m 2 of finished products (with 22 working days).
The average monthly productivity of the plant when working in 2 shifts is 2,500 m 2 of finished products (with 22 working days).

payroll fund

The site will require 4 people: three workers and a shift supervisor. Their salary will be 17,000 rubles and 20,000 rubles, respectively. Thus, the wage fund when working in 1 shift is 71,000 rubles per month, in 2 shifts - 142,000 rubles per month.

Labor costs per 1 m 2 of products is 71000/990 = 71.71 rubles

UST (Unified Social Tax) - 34%, which is 24.38 rubles. in the cost of 1m 2 of finished products.

Requirements for production and storage space

To accommodate the EcoStep mini-factory, a heated room with an area of at least 100 m 2 with a ceiling height of at least 3 meters is required. To accommodate a warehouse, a room with an area of 100 m 2, possibly unheated, is required.

At a rental rate of 150 rubles/m 2, the cost of renting premises per month will be 30,000 rubles, which is 15.15 rubles. per 1 m 2 of finished products.

Consumables costs

Crumb rubber - 16 rubles / kg
Polyurethane binder - 149 rubles / kg
Coloring pigment - 80 rubles / kg.

Cost calculation

Calculation of the cost of materials for the production of 1 m 2 of EcoStep 500 x 500 rubber tiles 40 mm thick.

Material name	price, rub.	Consumption, kg	Cost, rub.
Rubber crumb

Taking into account other costs for the implementation of activities, it is possible to determine the cost of 1 m2 of rubber tiles.

cost of 1 m2 of rubber tiles EcoStep 500 x 500 40 mm thick.

Business profitability for the production of rubber tiles at the EcoStep mini-factory on the example of the production of EcoStep 500 x 500 tiles with a thickness of 40 mm *

* Please note that all calculations presented in the table are conditional and are given as an example of the potential profitability of this type of activity. The moneymaker factory recommends that you independently calculate the payback of the project before starting any activity.

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 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 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.
The criteria for the production of rubber coatings (provided that the equipment is optimal and has an average level of performance):

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.

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 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:

Many people dream of starting their own business, but they decide to invest in the production of a unit. It is much easier and more reliable to engage in the resale of Chinese goods, and if this type of activity is to your liking, then it is better to master it than to try to figure out how to set up the production of rubber tiles and paving stones with your own hands. For people who are fond of manufacturing paving slabs, on the contrary, it will arouse genuine interest and desire to create, that is, to create real masterpieces from simple monophonic rubber raw materials. This article will detail how to make this type of business the most profitable.

Rubber paving slabs: properties and applications

To produce competitive products, it is necessary to study not only the basic technical specifications product, but also to understand how to improve the properties of the product. A businessman must become an expert in the production of rubber paving slabs, and it is necessary to start from the basics. This type of product has the following properties:

These qualities distinguish this type of building materials from similar products. Rubber paving slabs can be used for:

Arrangement of children's playgrounds.
Covering platforms and steps in front of the house.
Erection of elements of landscape design.
Laying sites near car washes, swimming pools, showers.
Floor coverings for industrial enterprises.
Arrangement of a site with anti-slip properties near the entrance to shopping centers and shops.

Products made under high pressure can also be used for laying in a garage or car park. Such rubber plates they have increased strength and density up to 1000 kg/m3, which makes it possible to withstand the weight of a truck without changing the geometry.

Considering the great demand for rubber tiles, it can be said with confidence that with a properly developed business plan and a competent marketing policy, an entrepreneur will return the invested money in the shortest possible time and will receive high profits for many years.

Raw materials for rubber tiles

In order to open a mini-factory for the production of rubber tiles, it is necessary to develop a plan for the supply of raw materials in advance. This kind building material consists of 90% rubber, so the development of a business plan should begin with finding out all options supply of crumb rubber. You can get enough of this material as follows:

Purchase ready-made crumb rubber.
Make your own raw materials.

In the first case, raw materials are purchased from suppliers who are currently present on the domestic market in sufficient quantities so that it is possible to choose the material at the most suitable price and delivery method.

The second option involves the purchase of equipment for the production of crumb rubber. Despite the apparent complexity of the event, even for small tile factories, this method of obtaining raw materials will significantly increase the profitability of the business. Crumb rubber is obtained by recycling old car tires. It will not be difficult to acquire enough material for processing even in a relatively small settlement. It is enough to organize the reception of recyclable materials from the population, as well as to agree with the owners of tire shops on the acceptance of tires, the technical indicators of which do not allow the product to be used for its intended purpose.

Rubber crumb is the main, but not the only component of paving slabs. In order to form a homogeneous mass from rubber crumb with reliable fastening of each particle of the raw material to each other, a polyurethane binder is used. Such glue will allow you to securely fix the rubber crumb in the product, but only on condition that a high-quality one-component substance was purchased. Good quality products are famous European production, therefore, to purchase a binder, it is necessary to conclude an agreement with reliable foreign suppliers.

To give products greater aesthetics, a pigment dye is added to the rubber mass. For the manufacture of multi-colored rubber tiles, as a rule, powder dye is used, the main component of which is iron oxide.

Properly selected raw materials will make it possible to produce high-quality rubber tiles, therefore, if you have a desire to engage in this type of business for a long time, it is recommended that you spare no time for careful selection of product suppliers. At self-manufacturing crumbs also need to take into account some nuances. In this case, only car tires, while preventing such inclusions as metal cord elements from entering the finished rubber raw material.

Equipment for the production of rubber tiles

Making rubber crumb tiles with your own hands is possible only if machines are purchased that will automate the tile production process as much as possible. For this purpose, special equipment is used, with the help of which raw materials are kneaded, compacted and molded into rubber mass. A novice businessman who has decided to invest in the production of crumb rubber tiles cannot do without purchasing the following equipment:

Mixer.
Press.
Thermal cabinet.
Forming table.
Tile stand.
Press form.
Mixer platform.
Conductor.

Each machine or device is designed to perform a specific function, so before you buy equipment for the production of rubber tiles, you need to study the basic principles of such devices. A correct understanding of the functioning of the equipment will allow not only to select high-quality products in order to organize a mini-production of rubber tiles and paving stones, but also to optimize the initial financial investment as much as possible.

Crumb rubber tile production line

The mixer is necessary for mixing crumb rubber, polyurethane adhesive and dye. An entrepreneur needs not only to choose a high-quality mechanism that does not require too burdensome maintenance during operation, but also to choose a device that is suitable in terms of volume. For a small mini-workshop, focused only on the production of rubber paving slabs, a mixer with a working volume of 40 liters is enough. If you plan to open a large plant for the production of rubber building materials, then you will need to purchase several devices with a volume of more than 100 liters.

The standard design of the mixer is an open barrel, inside which, with the help of a special rotating knife, the raw materials are mixed. For easy movement around the workshop, such products have 4 wheels at the bottom of the structure. You can buy a rubber crumb mixer both domestic and imported. Products Russian production, as a rule, is not inferior in quality to the best European samples, while the price of products will be much lower, due to the absence of the need for customs clearance of goods.

The press is one of the most expensive elements of the rubber tile production line, but without this device it is impossible to produce a quality product of the required density. The average productivity of this type of machine is 100 m2 per day, which is a good indicator for a small production. If you want to expand your business, it will be enough to purchase a few more machines and properly install the equipment in the workshop. You can buy a press both from domestic equipment manufacturers and from reliable foreign suppliers.

Such elements of the production line as: oven, forming table, tile stand, mold, mixer platform and jig must also be optimally matched. Typically, companies involved in the sale of equipment for the production of rubber tiles have in their assortment everything you need to install a turnkey mini-factory. By purchasing a ready-made line, an entrepreneur often manages to significantly save money and time. In addition, with the "wholesale" purchase of equipment, the intermediary can provide services for the installation of the production line, as well as for its maintenance.

Technology for the production of rubber tiles

The production technology of rubber tiles is not difficult. Currently, cold and hot methods of manufacturing this type of material are used.

Cold way.

This option for the production of tiles is the most labor-intensive, but the quality of the products is at a high level, and by reducing the cost of paying for electricity and purchasing more expensive equipment, the profitability of the business will be very high.

The process of manufacturing rubber products by this method is carried out in several stages:

Prepare the mixture. To do this, mix polyurethane glue, rubber crumb and dye in a mixer.
Expose the mixture high pressure on a cold press.
Send the "semi-finished product" to the drying cabinet.
Lay out the tiles on a special table to complete the drying process at room temperature.

If technological process has not been violated, then the output will be a high-quality rubber product of the required color.

Hot way.

The initial stage of production of rubber tiles using heat treatment is identical to the above-described technology for manufacturing such products in a cold way, but then the process is greatly simplified. For the production of material it is necessary:

Mix raw materials in a mixer.
The material is put into molds and pressed on a special machine under high pressure and temperature.

After the end of the pressing cycle, such products do not require further processing and are completely ready for use. The method of hot pressing can significantly speed up the production process, but the product loses its frost-resistant properties as a result of such processing. This option is most suitable for the manufacture of rubber tiles for laying indoors, as well as for arranging outdoor areas in southern regions countries.

Calculation of production profitability

The rubber tile business is a very profitable business, but before you purchase equipment, rent or build a room to house a work shop, you need to draw up a detailed business plan. As a rule, such a document is a description of possible expenditure transactions in the organization production process, as well as the calculation of the estimated amount of funds received from the sale of the finished product. The price of equipment is not low, therefore, before starting your business, you need to acquire initial capital.

For the purchase of equipment, an entrepreneur needs to spend:

Mixer - 90,000 rubles.
Press for rubber tiles - 300,000 rubles.
Form for tiles - 3,000 rubles. (need to purchase at least 30 pieces)
Drying chamber - 100,000 rubles.
Auxiliary equipment - 70,000 rubles.

The last category includes: scales, carts, spatulas and tables. You can do without a drying chamber if you produce rubber tiles only in a hot way. The price of the mixer, in this calculation, is given subject to the simultaneous mixing of no more than 40 liters of the working mixture. For large production volumes, you will need to purchase a more powerful device.

The total cost of equipment for mini-production will be 650,000 rubles. Unfortunately, this amount alone is not enough to open your own business. To accommodate the equipment, it is necessary to rent a room that is suitable in terms of area and availability of communications. If the premises are rented outside the city limits, then the monthly expenses will be about 50,000 rubles.

In addition, you will need to hire workers:

Manager.
Accountant.
2 - 3 workers.

About 200,000 rubles will be required to pay wages every month.

The acquisition of raw materials will also require significant cash outlays before the company receives the first income. The average cost of materials is:

Rubber crumb - 25,000 rubles / t.
Glue - 250 rubles / kg.
Dye - 15 rubles / kg.

In addition to the listed expenditure items, the entrepreneur will need to pay utility bills, and before starting work, register an individual entrepreneur or LLC.

In total: in order for a rubber tile plant to start functioning, an initial capital of at least 1 million rubles is required.

The income of the enterprise is formed by the sale of finished products. At present, the wholesale of rubber tiles is about 1000 rubles/m2. Even with the minimum performance of the equipment, the revenue will be at least 100,000 rubles per day. If the production of paving slabs from crumb rubber is carried out seven days a week, then the monthly revenue will be 3 million rubles.

The total monthly expenses will be about 1.5 million rubles. Thus, the entrepreneur will return all the money spent within the first month. cash and make a profit.

In practice, it is not always possible to recoup the production of paving slabs from crumb rubber in such a short time. Usually, at least 3 months are needed for this purpose. This is due to marketing problems and the presence of competition. In order to speed up the process of bringing new products to the market, it is recommended to spend money on advertising in various media. Usually, small expenses aimed at conveying information to a potential client are more than paid off, due to the possibility of selling more goods on the market.

From year to year, rubber coatings are becoming more and more popular. There are several reasons for this:

covering a sidewalk with rubber tiles is much cheaper than asphalt or concrete;
rubber tile is pleasant to the touch, it is useful to walk on it barefoot, so it is ideal for covering children's and sports grounds;
such material is convenient to transport, lay, the tile does not crack and does not deform.

The rubber tile finds more and more wide application. Today it lays sidewalks, paths adjoining territories, sports and playgrounds, summer cottages, stairs and more.

The production of rubber tiles is a business for the future. This suggests that the material cannot but be in demand. Therefore, more and more enterprises producing rubber coatings appear on the market. Entry ticket to the business starts at $150,000. The main costs go to the acquisition of the line, commissioning and development of technology. The main difficulty in organizing a business is finding suppliers of reliable equipment. The high demand for rubber coatings created an increased demand for the purchase of machines for their production, which, in turn, attracted manufacturers of not very high-quality equipment to the market.

How much can you earn?

Rubber tiles are 3-4 times more expensive than their concrete counterpart - paving slabs. The cost of one square meter, depending on the thickness of the product, starts from 1050 rubles (for a tile 10 mm thick) and reaches 1800 rubles (for a tile of 80 mm). The average productivity of modern lines is from 1000 to 3000 sq.m. per month. The potential turnover of even a mini-enterprise is easy to calculate. It ranges from 1.0 to 4.0 million rubles per month.

Technology for the production of rubber tiles

There are two common technologies for the production of rubber tiles:

hot pressing method;
cold pressing method.

Each method has both its advantages and disadvantages. Moreover, the first option disadvantages are much more significant.

The hot pressing method is used by those manufacturers who decide to save on the purchase of expensive equipment. Today, Chinese-made lines are actively offered to our entrepreneurs. Although the lines really have high productivity and are much cheaper than analogues, rubber tiles on such equipment are of very low quality.

The point is that under the influence high temperatures the tile gets a persistent smell of burnt rubber. As a result, it radiates not only bad smell but substances harmful to humans. In addition, the product obtained in this way will be short-lived, hard and brittle. As a result of operation, such a tile quickly collapses under the influence of the environment.

Despite the poor quality of the resulting products and questionable safety, many continue to use the hot pressing method. This is due to two main reasons:

low cost of equipment, and hence a lower entry ticket to the business;
lower raw material costs, since the consumption of polyurethane is reduced in the process of melting rubber.

As a result, products are obtained with low cost and competitive price in the market. But there are no prospects for a business built on this technology. Having bought a tile once, the client, convinced of the low quality of the products, will no longer make a second order.

The cold pressing method allows you to get rubber tiles of a completely different quality. Products using this technology are more elastic, flexible and durable. The price for quality is higher equipment costs and reduced line productivity. The difference in price compared to hot presses can be hundreds of thousands of dollars.

The production process by cold pressing is as follows: at the first stage, the components of the future product are mixed using mixers. Next, the raw material is put into molds. Then the molds are loaded under the press, where the molds are compressed with a load of 5 tons. At the next stage, the trolley with molds moves to the drying chamber, where the products are kept for 4-6 hours at a temperature of 60 degrees. After drying, the finished tiles are unloaded onto a special table for quality control.

Raw materials for the production of rubber tiles

The main raw materials for the production of rubber tiles are crumb rubber and polyurethane binder (glue). Rubber crumb is purchased from suppliers. The average price is 19,000 rubles/ton. Polyurethane adhesive for hot pressing costs from 140 to 170 rubles per kilogram, for cold pressing - from 170 to 200 rubles / kg. The purchase of this component should be approached very carefully, because the strength of the finished product depends on the quality of the binder component.

To give products an aesthetic appearance, dyes are actively used in the production of tiles. Depending on the type of color, the cost of the dye varies from 80 to 190 rubles/kg.

Premises and equipment

The price of a set of equipment depends on the production technology. A mini-factory for the production of rubber tiles by hot pressing will cost from 1.5 to 2.5 million rubles. Practically, 90% of line suppliers are Chinese manufacturers. The capacity of the hot pressing line is from 50 to 100 sq.m. per shift and can be serviced by 4-5 workers.

The cost of a set of equipment using cold forming technology starts from 3.5 million rubles. The production line consists of a hydraulic press, mixers, a heating cabinet, a mold, stands for fixing tiles, molding tables, an electric heater and auxiliary equipment (scales, trolleys, working equipment).

Whatever configuration the line is supplied with, it will require an area of 80 sq. m. The room must be heated, well ventilated and with sufficient electrical power (machines consume 15 kW / h).