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

How to organize the production of rubber tiles - a sought-after durable building material? For Russian market This is a fairly new line of business that promises to recoup the invested capital within six months. What equipment will be required, how many employees will work in production, and what makes rubber tiles successful in the market are discussed below.

It's pretty the new kind building material, widely used for finishing a variety of surfaces. The raw material for such tiles is crumb rubber, which is usually obtained by processing used car tires.

This type of material is distinguished by several useful and even unique properties:

1. Environmental friendliness. The basis of rubber tiles is rubber waste, most often recycled car tires. The law requires that they be taken to special recycling centers and pay for disposal. But in practice, motorists refuse to act legally. Unnecessary tires end up in landfills, where they pollute the environment for decades. Considering the complexity of disposal similar types waste for mass consumers and unwillingness to pay for it, organizing the acceptance of tires for recycling for a small fee will arouse significant interest.
2. Lifetime rubber coating reaches 15-20 years. It can withstand frosts down to -40 degrees and heat over +40 degrees without deformation. Does not fade in the sun and is not affected by any other natural factors. Moisture quickly evaporates from the low-porosity surface of the tile. An ice crust does not form on it, snow does not stick and is easy to clean off.
3. Products made from crumb rubber and coatings made from it are safe from the point of view of injuries, as they have a non-slip rough surface (especially textured varieties) even when wet. Therefore, they can be widely used at sports facilities or playgrounds.
4. Rubber tiles are easy to install yourself, and can be used immediately after installation (unlike, for example, concrete, which will take several days to dry).
5. Sound absorption - a coating of rubber particles absorbs sounds and noise, which is why it is often used for finishing industrial premises.
6. Modern tiles come not only in gray and black, but also in any color and size, which allows them to be used in landscape design and for design solutions.

As for the disadvantages of rubber tiles, they include poor fire resistance and higher cost compared to other types of coatings. The advantages clearly outweigh the disadvantages, so rubber coating is quickly gaining a leading position in the finishing materials market.

Smooth types of tiles should not be used for finishing outdoor areas and places where constant humidity is expected (near swimming pools) - it is better to prefer options with a pronounced texture.

In workshops and warehouses where there is a high risk of fire, it is also advisable to completely abandon crumb rubber coating in favor of ceramic tiles.

Where are rubber tiles used?

A whole range of different positive properties made rubber tiles popular in the most different areas. Among the areas of use of this material are:

• decoration of street alleys, adjacent areas, pedestrian and bicycle paths;
• covering of running tracks in stadiums;
• finishing paths to swimming pools, floors in gyms;
• flooring in workshops, garages;
• finishing of children's playgrounds and outdoor play areas.

Potential customers for such coatings include private retail clients planning to improve yards or summer cottages, as well as sports organizations, management companies, state and municipal institutions (through the public procurement system).

The high price of rubber tiles is justified by its multiple positive characteristics and a multi-stage manufacturing process.

How much does rubber particle coating cost?

The high price of rubber tiles is justified by its multiple positive characteristics and multi-stage manufacturing process. To make colored versions, various dyes are also used, which increase its cost.

On average the price for gray-black tiles is 1500 rubles per square meter. The cost increases depending on the shade and texture of the coating. In addition to color, the price of rubber tiles is influenced by its shape and texture (smooth - cheaper, embossed - more expensive), as well as thickness (the thicker, the higher the cost).

What stages does the coating production process include?

The production of rubber tiles includes several stages:

1. Procurement of raw materials, for example, processing old car tires into crumb rubber. The particle diameter should not exceed 4 millimeters.
2. Preparation of the mixture for future coating. It is obtained by mixing rubber particles, binders and dyes (optional) in a certain proportion.
3. Putting the mixture into molds and pressing.
4. Heat treatment and drying for 6 hours. After pressing, the rubber tiles are placed in the so-called “drying chamber”, where the temperature is maintained at about 60 degrees and high humidity. Under such conditions, all components (particles and binding materials) are tightly bonded to each other as a result of chemical reactions.
5. Unloading finished tiles from molds, cutting and drilling if necessary. Sometimes, at the customer’s request, special holes are drilled into finished mats to simplify their installation.
6. Quality control, delivery of products to customers or retail outlets.

Equipment for the production of rubber tiles

Now let’s look at what equipment for the production of rubber tiles on an industrial scale needs to be purchased by a startup enterprise. The list will be quite extensive, and its total cost is approaching two million rubles.

1. Equipment for processing tires (other raw materials) into crumb rubber. Mixers or mixers mounted on special tables are usually used. The price depends on the power and loading volume.
2. An apparatus for making a rubber mixture that mixes crumbs with binders and dyes.
3. Molds (from 20 pieces) and a molding table - here the mixture is loaded into the molds and assembled. It is advisable to purchase several types of molds: the simplest smooth, textured, “sports mats”. For a small enterprise, 3-4 mold options are enough, for larger ones - about 10.
4. Hydraulic Press.
5. Thermal chamber - for drying prepared rubber plates OK. Purchasing such a chamber is preferable to organizing drying in a separate room, since the chamber stably maintains the required temperature and humidity.
6. Scales.
7. Associated equipment - carts, installation tools, temperature sensor (if necessary), storage containers.
8. Equipment for cutting and drilling finished rugs.
9. Packaging technology (optional).

The most profitable option purchasing equipment for making coatings from crumb rubber will involve purchasing a ready-made kit. Currently, many companies offer different sets of everything necessary equipment at a price of 480 thousand rubles (the minimum set), and also deliver to the workshop and even install the entire set.

In addition to saving on equipment and delivery, this option guarantees:

1. reference and training information (from good companies must be included in the kit);
2. saving time on searching and installing equipment yourself;
3. 1 year warranty;
4. opportunity quick repair or replacing faulty equipment.

Currently, there are two main methods for producing rubber tiles, divided depending on the stroke technological process into “hot” and “cold”.

Hot and cold pressing: what to choose

Currently, there are two main methods for producing rubber tiles, divided depending on the progress of the technological process into “hot” and “cold”. As their names suggest, they differ in the temperature at which the molds are pressed. Each has advantages and disadvantages. Which one is preferable in modern conditions?

With the more common “hot” pressing, the rubber mixture in the mold is exposed to ultra-high temperatures, which melts all the components and binds them together. The only advantage of this method is a higher production speed, because after a hot press the tiles dry much faster. But practice shows that “hot” tiles are less strong, less durable and, moreover, forever retain a persistent smell of burnt rubber.

Cold pressing takes longer than hot pressing. But tiles produced in this way are stronger, can be used much longer without wear and tear, and do not have an unpleasant odor. The point is that with more low temperatures and prolonged pressure (about 5 tons), all components of the rubber mixture bond with each other much more strongly. In modern conditions, “cold” technology is more promising and therefore preferable for beginning manufacturers.

What should a workshop for the production of rubber tiles look like?

If an entrepreneur purchases a ready-made set and installation of equipment, there is no need to think through the layout of the premises on their own. Otherwise, explore shop floor layout options online. The main recommendations are as follows:

1. The total area of ​​the workshop should not be less than 100 square meters, and the ceiling height is less than 3 meters.
2. All communications must be connected to the workshop, especially a stable power supply (all equipment runs on electricity and, importantly, the drying chamber). The room must be equipped with exhaust ventilation.
3. Good access roads for trucks, comfortable area unloading and loading of products.
4. The room should be divided into working areas: a storage area for raw materials (not only crumbs, but also, for example, used tires, binding components and dyes), a mixture preparation area (crushing and mixing); area for working with molds, drying chamber, warehouse for finished tiles.
5. To begin work, the workshop must undergo sanitary and fire safety. Production should not begin without the appropriate permits.

The basis of rubber tiles is crumbs, usually obtained from recycled car tires.

Raw materials for rubber tiles: where to buy and how to save

The basis of rubber tiles is crumbs, usually obtained from recycled car tires. A good option there will be a reception point unnecessary tires for a nominal fee next to the production workshop. However, this option alone will not provide the entrepreneur with sufficient quantity raw materials.

Therefore, crumbs, like all other components (glue, dyes), should be purchased from wholesale suppliers. Nowadays it is more convenient to order all raw materials via the Internet. The price of a ton of crumbs starts from 15 thousand rubles, glue - from 150 to 200 rubles per 1 kilogram, and various dyes - on average 150 rubles per kilogram.

Employees of the rubber tile workshop

To service the production line, 3 employees are needed at the same time:

• worker preparing the mixture;
• an employee working with molds and controlling the drying chamber console;
• loader.

There is no need for special education for such production; specialized training in working with equipment and following the technological process is sufficient. The workers are led either by a shift supervisor or by a technologist who controls production and product quality.

Costs and payback: how much finance is required to start production and when will it pay off?

Starting the production of rubber tiles, including renting a workshop, purchasing raw materials and equipment, requires up to 2 million rubles. You can reduce costs by ordering a ready-made set of equipment from one manufacturer or by finding alternative options obtaining raw materials (for example, accepting old tires).

In a standard 8-hour working day, an average capacity workshop produces about 50 square meters of rubber coating, that is, in 20 working days (per month) - 1000 square meters. One meter finished material costs from 1,500 rubles, that is, in a month you can earn at least 1.5 million rubles. At similar rates of production and sales, it is possible to recoup the entire invested capital in 4-6 months.

The profitability of a business directly depends not only on the smoothness of the technological process, but also on sales channels. The more there are, the better. Such an enterprise should:

• accept orders from private clients and commercial firms;
• produce products for construction stores or organizations (preferably several);
• participate in competitions in the public procurement system.

If the volume of the drying chamber and storage space allows, work can be organized in 2-3 shifts to increase productivity. Such a pace will allow you to recoup your investments and reach a net profit much faster.

Conclusion

The production of rubber tiles promises entrepreneurs good profit, work in a niche with stable demand and trends towards production growth. Creating such a business will require about 2 million rubles, but proper organization They will return to sales within six months.

Fractional crumb rubber is the basic raw material for the manufacture of tiles and rubber coatings. This raw material is actually taken from waste; more precisely, it is extracted by recycling old worn-out car tires. 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, by its structure, is distinguished by its high strength and durability. Such rubber easily withstands acidic and alkaline solutions on its surface, is very elastic, does not stretch, does not bend and can withstand temperatures from -45 to + 60 degrees.

raw materials:
Automotive crumbs (or crushed rubber - RD) - are obtained by processing worn-out tires of other rubber goods. Its price depends on such indicators as: quality, manufacturing method, dimensions, place of manufacture and sale. In Russia, the retail price for crumbs ranges from 6-15 rubles per kilogram.

Places where crumb rubber is produced:
- factories that process car tires into crumbs, as the main raw material;
- for by-product production at rubber goods factories
- factories that retread tires by roughening them (tread treatment), as a production waste.

Crumb rubber fractions used:
Fractions of crumb rubber vary from 0.1 mm to 10 mm and directly depend on their purpose. Thus, small fractions (0.1 - 4 mm) are mainly used in the production of colorless (black) or colored single-layer products. In the manufacture of lower colored layers, mainly larger fractions (2-10 mm) are used. Most often, they are cheaper in comparison with smaller fractions, so they may contain textile or metal inclusions. The production of tiles with two layers (an upper thin colored layer, a lower dark layer with larger fractions of crumbs) 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 of crumbs into the cheap coarse fraction. Such crumbs may contain textile or other inclusions.
. Save on paint - the bottom layer remains black.
. Larger crumb fractions require a smaller amount of binder for crosslinking, which is carried out by enveloping the surface of the crumb particle
. The absence of a dye allows you to use less binder to crosslink the particles, since the mixture dries out in the colored crumbs.

Equipment and raw materials (prices)

The line that produces rubber coatings has the following set of equipment:

Volcanic press with a capacity of up to 100 m² per day. Price - approximately 350 thousand rubles;

Pressing forms. Cost - 30 thousand rubles apiece;

Drying chamber (for a mini business, it is possible to make it yourself), price from 100,000 rubles.

Raw materials:

Crumb rubber - black (17 thousand rubles per ton), colored (from 23 to 35 thousand);
. polyurethane glue - 140 rub/kg;
. dyes - 7 rubles per kg;

Electricity consumption by the line is 15 15 kW/h.

Coatings can be made:
- both soft and hard in density;
- waterproof, or with water passage (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 soft base(soil) or solid;
- with or without connections (sleeve, lock).

Rubber paving slabs are often laid parallel to regular paving slabs. It is for this combination that rubber coverings of similar sizes and shapes are created as regular paving slabs.

Premises for a mini tile production workshop.
The criteria by which rubber coatings are produced (provided that the equipment is optimal and has an average level of productivity):

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 out 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 glue consumption for manufacturing various coatings from 4 to 12% depending on the presence/absence of dye, density of materials, quality of glue, and size of tire chips used.

For example, to make a colored coating Mat 500*500*16mm (from fine crumbs) you need 6% dye and 5% glue from the amount of rubber crumbs.
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 fraction of rubber crumb 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 crumbs, the stronger the coating, but the thickness of the coating must be maintained.
6. Thick coatings (2 cm or more) are best made in two layers. For the upper part, use fine-fraction crumbs; for the lower part, use cheaper coarse-fraction crumbs (5-12 mm) with possible foreign inclusions. Each layer has its own proportions of glue. Each layer is mixed in different containers.
7. It is recommended to produce products of the same thickness on one pressing mechanism, regardless of the configuration, since thickness affects the operating time of the press (the thinner the product, the faster its formation).

Additional accessories for production.

Trolley for transporting raw materials (crumbs, dye).
- A trolley with a special tripod to transport containers with glue.
- Scales to weigh components (50 kg electronic scales are best).
- Trowels for uniform laying of coatings.
- Special mugs and scoops for measuring, depending on the standard of the product.
- Mixing glue and dye drill with attachments.

Price for selling rubber plates:

One pack
100 tiles - 57 thousand rubles.

Cost of 1 m² - 1,584 rubles.
Price of 1 slab - 570 rub.
The minimum quantity is 100 slabs (25 m²).

Sales of products.

For coating on production lines, in warehouses, or as a rubber coating for garages;
- used in areas near skating rinks, locker rooms, playgrounds;
- in combination with paving slabs;
- as a coating for various sports complexes or children's playgrounds;
- on farms, livestock production facilities;
- on roofs, terraces
- in baths and other places.

As we can see, the production of such products is part of the ecosystem, producing high-quality safety products - rubber tiles or crumb coating.

Production of tiles from rubber crumbs: