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 high-quality components (various oils, synthetic rubber, fillers), since these products must withstand enormous loads for a very long period of time.
Of all existing types of rubber, tire rubber, by its structure, stands out for 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.
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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 of production crumb rubber:
- 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):
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1. The area occupied by the technical line is 70-100 m² (not counting the warehouse); Equipment and materials are located by sectors: |
General axioms:
1. Glue consumption.
§ The amount of binder is inversely related to the crumb fraction. The smaller the crumb, the more binder is needed for crosslinking. The larger, the smaller.
§ Dyes dry 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.
Selling price 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 covering 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:
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Order
We offer equipment for production rubber tiles and rubber floor coverings based on crumb rubber. All equipment is produced by our company and is fully adapted to the wishes of customers. You can buy the set of equipment you are interested in for the production of rubber tiles and other floor coverings from our company at an affordable price.
On modified lines for the production of rubber tiles offered by our company, you can produce: seamless floor coverings, curbs, Treadmills, paving slabs, paving stones, step pads, sports mats, entrance mats based on crumb rubber and much more.
Equipment for the production of rubber tiles (rubber coverings) is a popular and highly profitable production, the products of which are used in great demand. Rubber tiles are produced using the cold pressing method, which allows us to obtain high quality products.
We suggest studying the characteristics of high-quality equipment for the production of rubber tiles, as well as additional equipment and components necessary for the production of rubber floor coverings.
A set of equipment for the production of rubber tiles "ARFC OPTIMAL" allows you to significantly expand the range of products. This kit can produce up to 7 types of high-quality rubber coatings.
Equipment for the production of rubber tiles
Our company offers equipment for the production of rubber tiles of various capacities. You can buy equipment for the production of crumb rubber products from us at an affordable price. Starting a rubber tile business is easier than you think. Contact our company and our specialists will offer you the necessary set of equipment for the production of rubber tiles, paving stones, borders and seamless coatings based on crumb rubber for children's and sports grounds according to your budget.
Making rubber tiles is the most efficient way to recycle old used tires. The final product is characterized by high strength and wear resistance. The production of such material allows us to solve two important problems - to produce products with excellent performance qualities and to safely dispose of them. unnecessary tires. This is a great idea for those who want to start a business at home.
Raw materials for the production of rubber tiles
If you are planning to get into production 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 processing old car tires, so there will be no problems with the purchase of raw materials.
You can make crumbs from tires with your own hands, but in this case you cannot do without special equipment.
Used tires can be purchased for next to nothing or received for free, incurring only transportation costs.
The composition of the mixture for the production of rubber paving slabs includes:
- crumb rubber fractions;
- glue;
- pigments;
- modifying fillers.
This is a recycled material from old car tires, which is obtained by mechanical crushing and then separating unnecessary impurities such as textile fibers and metal cords. The crumb composition includes synthetic rubber, various oils and fillers, so the raw materials are initially strong and wear-resistant. Tires are not afraid of acids and alkalis.
Automotive rubber is highly elastic and perfectly retains its given shape. It is difficult to deform even with 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 make it possible to obtain finished products of different colors. The dyes are in a dry powdery phase. They can be organic and inorganic. Externally, the pigments look like multi-colored flour. Coloring of the mixture for making tiles from crumb rubber occurs when the dye interacts with polyurethane glue. The coloring substance envelops the crumb rubber and gives it the desired color.
Inorganic dyes can be based on:
- titanium dioxide – white;
- iron oxide – red;
- iron oxide hydroxide – yellow;
- cobalt – blue.
Mixing primary colors allows you to get different shades.
Polymer glue
The binder that is added to the mixture to produce tiles is a non-toxic polyurethane-based mass. It could be:
- one-component;
- two-component.
The second option differs in composition. It comes with a hardener. When choosing glue, pay attention to its quality. It bears the entire load, so it is worth purchasing binders in small quantities from several manufacturers and empirically choosing the appropriate option.
Modifying fillers
This component makes it possible to increase the strength and wear resistance of secondary raw materials, and also imparts elasticity to the finished product. At low concentrations, modifying fillers do not improve mechanical properties, but at high concentrations, the material becomes brittle, and therefore the mechanism of its destruction changes.
Tile molds
You can make molds for rubber tiles yourself. But this activity will take a lot of your time and Money, so it is better to purchase ready-made products or order their production 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. Non-metallic molds, after removing the finished rubber, are treated with an acid solution to eliminate dust.
Equipment for the production of
Components for the production of tiles using cold pressing will cost more than for hot pressing. The most expensive option is to install an automated line. Such equipment is suitable for industrial production, so you will 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;
- transport trolleys;
- molding tables;
- drying chamber.
The components of the working mixture are loaded into a mixer with low-speed blades, which mix them thoroughly. 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 this, the molds are placed on carts and placed under the 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.
To produce raw materials (crumb rubber) 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 shock wave crushing method is used. Such equipment is fully automated.
Manufacturing technology
To produce tiles, 2 pressing methods are used:
- hot;
- cold.
The first option is cheaper and faster. But at the end you will get a toxic product of low quality. Domestic manufacturers prefer cold pressing. This method allows you to obtain durable tiles, but it is not very productive.
The energy costs for both methods are the same. Only the nature of electricity consumption differs. With the hot method, electrical energy is consumed cyclically, only during operation of the press. When cold pressing, it is necessary to constantly consume electricity to maintain the desired temperature regime in drying chambers.
Let's consider the main stages of production:
- Preparatory. At this stage, the main raw materials are prepared. Old for this car tires freed from metal rings and textile threads, after which they are crushed in a crusher to the desired fraction.
- Preparation of the mixture. Into the mixer the required proportion Rubber crumbs, glue, pigments and modifying fillers are loaded.
- Molding. Ready mixture fill special forms and send them to the press.
- Pressing. The raw material is compressed to a specified density and thickness.
- Baking. In the hot production method, the material is baked under pressure at +130°C. Cold way involves the installation of forms with raw materials in heating cabinets for processing more low 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.
- Availability of lubricant in the molds before loading the mixture.
- Maintain proportions when preparing the mixture.
- To increase the water resistance of the tiles, you need to use a smaller fraction of crumbs and increase the press pressure.
- The larger the fraction of crumb rubber, the faster the color of the material is lost during operation.
- It is better to make tiles more than 2 cm thick in two layers. Upper layer- from small crumbs, the bottom one - from large ones. If you want to make a two-layer rubber tile, you will need an additional mixer to prepare different layers.
- One pressing machine must produce tiles of the same thickness, regardless of its configuration. The thinner the coating, the faster its formation occurs.
Many manufacturers produce two-layer rubber tiles. This approach allows them to significantly reduce the cost of the finished product, since the mixture includes a cheap large fraction of the feedstock.
Proportions
To prepare a mixture of crumb rubber, all the necessary components are taken in the following proportions:
- crumb rubber – 80%;
- polymer glue – 10%;
- pigment – 3.5%;
- modified fillers – 0.5%.
The smaller the crumb fraction, the more glue will be needed. Pigment substances dry out the binder, so there may be less of it in black tiles. Before pouring ingredients into the mixer, they must be accurately dosed using a scale. Failure to comply with the technology may negatively affect the quality characteristics of the finished product.
Hot way
For the hot method of producing tiles, you will need a vulcanization press, under which the vulcanization process occurs at a temperature of +130°C. The molds with the mixture are kept under pressure for 30 minutes. After this, you can remove the finished tiles.
Hot pressing significantly increases volumes because 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. These tiles have a stronger burnt rubber smell. In addition, it quickly deteriorates under the influence of various environmental factors.
The glue should be well absorbed into the structure of the mixture components. With the hot method, it 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 bake, which negatively 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, the carts with the molds are loaded into special chambers for drying. They are kept for 4-6 hours at +60°C. After this time, the carts can be removed from the chamber.
The productivity of the cold method depends on the volume of the drying chamber. The larger the chamber, the more carts it will fit. Thanks to this, you can regulate the quantity of products produced.
At first glance, it may seem that making tiles this way is less productive. Cold pressed chemical reactions slow down, the glue has time to reliably bind all components and as a result you get a durable quality material with excellent performance characteristics. Production volumes can be increased by purchasing additional equipment.
Quite common in Lately When arranging territories with rubber tiles, you can make them yourself, which will save money. As a result, it will be possible to obtain products that have a bright appearance and are easy to install.
Features of rubber tiles
Even though rubber tiles have appeared on the market building materials In Russia relatively recently, it has managed to gain a worthy position, because the products have excellent qualities, including anti-slip features that allow the tiles to be used at any time of the year. If a crust of ice forms on the surface of the coating, you can get rid of it by using a crowbar.
Rubber paving slabs made from crumbs have a long lifespan, the material is quite durable and does not wear out under significant mechanical stress. You will not encounter the problem of puddles forming on the surface of paths made of this tile, since it has a drainage effect due to its porous structure. The products allow moisture to pass through quite well. After the products are ready, they can be laid on any type of base, this could be, for example, gravel, soil, concrete, sand, and asphalt.
Raw materials for making tiles
Do-it-yourself rubber tiles are made using crumb rubber, which acts as a recycled product from car tires. Source material is rubber, which can be natural or artificial. This determines the strength qualities of the final coating, as well as its extremely high resistance to mechanical wear. Thus, the production of the described products allows us to perform two functions, one of them is the production of material with excellent performance qualities, while the second is expressed in the safe disposal of unnecessary goods.
Technical equipment
Do-it-yourself rubber tiles can only be made if you have the appropriate equipment, which has a very impressive cost. If you intend to engage in manufacturing for running a business, then purchasing it is advisable, whereas if you are faced with the task of laying a path on a personal plot, then it is preferable to purchase the products ready-made; it will be cheaper even than the option in which the installations are rented.
To carry out work on the production of rubber tiles you should buy:
- heating cabinet;
- mixer;
- hole jig;
- Hydraulic Press;
- set of forms;
- platform, tables and stands for the mixer.
If you plan to purchase such equipment, then you will have to pay approximately 1,590,000-2,370,000 rubles. In the minimum price option you will receive the most modest set of equipment, while the highest price includes a mini-factory.
Technological production process
Do-it-yourself production of rubber tiles is carried out by the method of initially removing steel elements from tires. Afterwards, the prepared rubber products are crushed to particle sizes ranging from 1 to 4 mm. Then the crumbs are combined with a binder polyurethane mixture, pigment and brought to a homogeneous state. The mixture must be poured into molds, subjecting future products to vulcanizing pressure.
Making rubber tiles with your own hands can be done by hot or cold pressing, but both of these processes are carried out when exposed to elevated temperatures. In the first case, the temperature is maintained at 140 °C for a quarter of an hour, while in cold processing the products undergo a four-hour treatment at 80 °C. If we consider the final quality characteristics finished product, then both of these methods are equivalent; in terms of energy consumption, the methods are also equivalent. But if you set up a production line yourself, the “hot” method will be much cheaper, but if you want to increase productivity, then you should choose the “cold” finishing technology.
Production Features
If your business is based on rubber tiles, you can produce them yourself by investing approximately 2 million rubles. This includes startup costs and equipment. Any beginning businessman is interested in the question of when the business will begin to pay off. In the described case, this will happen in about 6 months. Rubber tiles can be supplied to stores, from where they will be purchased for arranging children's and sports grounds, private garages, garden paths, gazebos, and terraces.
The myth about the production of rubber tiles
Despite the fact that rubber tiles are available in stores at affordable prices, home craftsmen continue to produce them with their own hands. But there are still myths about the quality or production process. One of them is expressed in the fact that products produced by hot pressing have less high quality compared to analogues obtained using cold process technology. This statement absolutely cannot be considered correct. This is now being refuted by production companies that use both methods.
Carrying out installation
Laying rubber tiles with your own hands begins with arranging beacons. Afterwards the area is prepared. Initially, crushed stone is laid out on the ground; it will act as a drainage layer. Laying must be done on a base with some slope, this will allow wastewater flow to the sewer. A curb should be placed along the edges of the path, otherwise the sidewalk will creep at the first spring melting of the snow. Before you begin installing the tiles, you should lay sand layer. For this purpose, it is recommended to use exclusively clean sand, which does not have additional impurities. The thickness of this layer should be approximately 5 cm.
Laying of products should be carried out along a pre-stretched cord, which is located along the perimeter of the marked area; it can be stretched along pre-installed pegs. After every 3 laid rows, it is necessary to carefully analyze the evenness of each tile individually. You can allow some error, which is limited to 0.5-1 cm. Once one element is in its place, you can correct its position by gently tapping rubber mallet. If the area allocated for the path remains free at the edges, it can be filled with slab elements, which are recommended to be cut using discs with diamond chips.
Final installation work
Having completed laying the tiles, its surface must be compacted using a vibrating plate and covered with clean sand, after which it must be swept out, which will allow the seams to be clogged. Tiles made from rubber crumbs can be used for beautification personal plot. Do-it-yourself rubber paving slabs can be made in a short time, and then they will fit into any exterior and last for quite a long period of time.
Not so long ago, such a phenomenon as rubber tiles appeared on the domestic building materials market, the sale of which is rapidly gaining momentum and is already a fairly promising type of business activity.
This type of coating, such as tiles made from waste rubber, is universal and is also highly safe to use. This makes it possible to use the material for laying children's and sports grounds, sidewalks and other places.
Rubber paving slabs have a long service life and beautiful appearance, which makes them attractive to most buyers. Today, the niche for the production of this building material is practically unoccupied, therefore it is low-competitive and can bring considerable, and most importantly, stable income.
Production of rubber tiles - advantages and disadvantages
Regardless of whether development is planned or in a crowded metropolis, aspiring entrepreneurs should remember that the enterprise will develop successfully only if, in addition to profit, it will benefit people.
A small workshop for the production of tiles from crumb rubber is an example of this: the absence of a large number of competitors makes it possible to consistently earn a lot of money. In addition, old car tires, rubber objects and waste are used to produce this building material, so the company will provide assistance locality in their disposal.
The raw materials for the production of paving paving are durable and strong materials, and the finished products are easy to install and distinguished increased wear resistance. Rubber tiles have a number of undeniable advantages in comparison with similar products made from cement-concrete mixtures. These include:
- durability;
- high consumer demand;
- high degree of security;
- ease of care;
- ease of installation of the coating;
- beautiful view of the tiled areas.
Rubber tiles are characterized by excellent resistance to precipitation, as well as low and high temperatures. The material does not crumble over time and retains its original shape. In addition, the tile is not subject to deformation under mechanical stress, which is why it is preferred by a large number of buyers.
As for the service life, rubber plates can last at least 25 years. Special attention the high degree of safety of this building material deserves, since if a person falls on such a coating, the risk of injury is minimal. In addition, the surface of the slabs has an anti-slip effect, which is why they are widely used in arranging playgrounds for children.
The material is easy to maintain, so it will be enough to clean the surface of accumulated dirt. Please note that rubber plates are readily purchased by car repair shops and service stations. Unlike concrete surfaces rubber is highly resistant to impact chemical substances and oils.
Water quickly passes between the seams of the facing products, so puddles never form on the tiles (after rain, on sinks). There is also no need to prepare areas for laying rubber slabs, since they are easily installed on sand, soil, wood and other bases. If you need to replace a damaged element, this can be done without dismantling the entire coating masonry. Rubber plates retain an attractive appearance for a long time appearance, its shape and color saturation.
In addition to the above advantages, rubber coating is in demand for laying warehouse and basements, gyms, car parks, courtyards, sidewalk parts of streets, parks and adjacent areas of public institutions.
Due to its characteristics, the material is becoming more and more popular every year and is in demand among buyers. But, despite such a wide range of positive qualities of rubber plates, their production still has some disadvantages. First of all, it is worth noting the flammability of finished products, therefore, when arranging various objects, the proper level of fire safety should be ensured. Another disadvantage of tiles made from crumb rubber is the rather high price. However, despite these points, investments in the development of an enterprise (as opposed to such areas as, for example,) for the production of products from crumb rubber pay off quite quickly.
Crumb rubber tiles - options for starting a business
Beginning businessmen who decide to open their own enterprise for the production of rubber paving slabs should know what production options exist. Their scale depends on the amount of initial investment in business development, as well as on the expected volume of finished products:
- Making rubber tiles at home. This type developing your own enterprise does not require large financial investments from the entrepreneur; moreover, a person can work independently at the initial stages, which will allow him to save on wage costs for hired employees. If you make the tiles yourself, you won’t need to buy expensive ones, and the finished product will be of fairly high quality. A significant disadvantage of making tiles is the large time investment, however, you can quickly earn money to scale the enterprise and purchase production equipment. At the same time, it wouldn’t hurt to open a small one at home, which will significantly expand the range of building materials. In most cases, entrepreneurs with this business model take work to order and, by agreement, produce a certain amount of tiles from ready-made rubber crumb compositions with their own hands.
- Mini-factory. The best option To run your own business is to open a mini-factory for the production of rubber tiles. To equip it, you can easily purchase the necessary equipment, which will make your business profitable and quickly pay for itself. Such an enterprise can be located on an area of 100 m², which will be enough to store raw materials and finished products. At the mini-factory, only a few people work in one shift, who fully ensure a continuous work cycle. The equipment of a small manufacturing enterprise consumes about 13-15 kW of electricity per 1 hour of operation. In addition, it can be used to produce rubber tiles of any complexity and fulfill fairly large volumes of orders.
- Franchise cooperation. With a certain amount of investment, entrepreneurs can start operating a franchise. On average, starting a business using this model will require about 2 million rubles, so the franchisee must carefully assess their capabilities. The franchisor company provides assistance to aspiring entrepreneurs in organizing the marketing of the enterprise, creating their own website and promoting it (social networks, targeted and other channels for attracting traffic). Also, a technologist from the franchisor can work at the franchisee’s plant for some time, who will tell you about all the intricacies of tile production and train the staff. Moreover, companies offering work to businessmen under this scheme post information about the enterprises with which they begin work under the relevant agreement on their own information resources and present them as partners. This allows potential buyers to directly contact the franchisee and place an order. Entrepreneurs are provided with significant assistance in equipping the enterprise, the established client base is transferred, and training is also provided, during which novice businessmen learn how to always be in good plus. The patron company ensures uninterrupted supply of high-quality raw materials and provides experienced specialists for repair and adjustment of technological equipment. Working according to this scheme is guaranteed to bring businessmen to a stable, large income, which does not depend on the economic situation in the country. The largest Russian franchisors that offer cooperation in this area on favorable terms are the companies Master Fiber, Ecostep and Art-Prime.
- Industrial production. From the name of the option it becomes clear that it is suitable exclusively for entrepreneurs who own substantial capital, since without large investments it is almost impossible to organize large-scale production. To create this model, a detailed business plan is developed, a product line is thought out, and sales channels are looked for in advance. It is assumed that at full manufacturing plant There will be a large number of employees working.
Manufacturing technology of rubber paving slabs
Since the emergence of small-scale production in Russia, almost all enterprises have used the method of producing rubber tiles by hot pressing. Thanks to it, you can quickly obtain finished products with minimum costs, besides, it is quite easy to learn. However, hot pressing is highly toxic, which certainly affects the health of the company’s personnel; moreover, the technology is not capable of ensuring high quality of the finished product. The products have a short shelf life and fall apart quite quickly, losing their attractiveness and physical properties.
Important: Due to the low quality of the resulting products, it is not recommended to use hot pressing technology for the production of tiles. The coating obtained in this way is unlikely to last longer than 1 winter season. For this reason, since 2013, most of the Russian enterprises specializing in the production of rubber tiles have closed.
According to the “hot” technology, rubber crumbs are placed in a special tank of a press machine, where they are baked, while the gluing of particles with a special composition is minimal. If “hot” tiles are used in regions with a temperate climate, they can last quite a long time. However, such products are not able to withstand heavy loads.
But today “cold” production technology is popular paving slabs made of rubber. The cost of manufacturing products in this case is significantly higher compared to the previous method, and it also takes much more time. But pressing crumb rubber impregnated with a special adhesive composition guarantees high quality products and a long service life. Cold pressing technology is divided into several main stages, which include:
- preparation of raw materials for the production process;
- mixing crumb rubber with adhesive;
- evacuation of the finished mass from the mixer into the mold;
- formation of slabs by pressing;
- drying products;
- checking the quality of rubber plates.
First, rubber crumbs are unloaded into the tank of an industrial mixer, after which glue is added to the raw material. Then the components are thoroughly mixed together until a homogeneous mass is formed.
After this, molds are prepared into which the finished raw material is loaded. Under high pressure, rubber and glue are pressed, resulting in a durable coating that can withstand heavy loads. Raw slabs are sent to special drying chambers, where they are dried for 4-6 hours at a temperature of 60°C. At the end production process The finished tiles are placed in a warehouse, where they are stored until they are sent to customers.
How to start the production of tiles from rubber crumbs?
Let's look at the main stages of starting a business.
Business registration
To open a business producing rubber tiles, an entrepreneur is recommended to contact the tax service, register as an individual entrepreneur and choose a simplified taxation system. If you plan to cooperate with legal entities, it is advisable to register an LLC.
The entrepreneur also needs to select the OKVED codes that will be required for reporting. Suitable for tile production:
- "Production of other rubber products» − 25.13;
- “Production of rubber products not included in other groups; production of ebonite and products made from it" - 25.13.2.
After registering the legal form of the enterprise, you should begin obtaining the necessary permits from Rospozhnadzor and the Sanitary and Epidemiological Station. This can be done after premises for production activities have been selected, which need to be put in order in accordance with the requirements of regulatory organizations, and then their representatives can be invited to receive permitting documents. You will also need to issue a certificate confirming the finished product’s compliance with GOST standards.
Important: It will take the entrepreneur about 2 weeks to complete the documentation. The cost of registration and obtaining permits ranges around 15 thousand rubles.
Search for premises
To produce rubber paving slabs, an entrepreneur needs to find suitable premises. It is not very profitable to rent space within the city limits, since the fees for them are very high. It is better to find them in suburban areas or industrial areas.
It is also important to consider the availability of high-quality transport links when searching for production space. This point is one of the key ones when organizing a business, since it is directly related to the speed of delivery of raw materials and finished products to customers.
If you plan to open a mini-factory, you should select premises with a total area of about 100 m² and a ceiling height of at least 3.5 m. Mandatory premises in the enterprise should include a production workshop, a place for storing and preparing raw materials, an area for storing finished products, a bathroom and a room personnel. It is also necessary to check the serviceability of:
- water supply and sewerage;
- electrical network (380 V for the ability to connect equipment);
- lighting;
- exhaust and ventilation systems;
- heating.
If industrial premises are to be repaired, it is imperative to comply with all the requirements of the SES and fire protection, otherwise it will be quite problematic to obtain permits to conduct business activities.
Purchase of raw materials
As a rule, there are no difficulties in finding suppliers of raw materials, since they are available on the market sufficient quantity. Most tiles are made from old tires.
The cost of 1 ton of shredded tires fluctuates around 20 thousand rubles. It would be good if you can find suppliers who use . This way you can save on purchasing them. The same can be achieved if you purchase black chips and various dyes for rubber, since finished colored raw materials are somewhat more expensive. The purchase of polyurethane crumbs for cold pressing will cost 17-21 thousand rubles. If you use the hot method of making tiles, the raw materials will cost slightly less - 14-18 thousand rubles for the same volume.
Important: Most entrepreneurs, in order to save money, prefer dyes instead of ready-made colored chips to create beautiful tiles(its price can reach 35 thousand rubles per 1 ton). The cost of the dye varies between 90-200 rubles per 1 kg.
It is important to pay attention to the quality of the glue that will be used in production. The quality of paving slabs and their strength directly depend on this. You can buy it at a price of 200 rubles per 1 kg.
Equipment purchase
Beginning entrepreneurs should be aware that prices for equipment necessary for working using cold pressing technology are higher than equipment for working using the hot method. If an entrepreneur wants to install an automatic line for the production of rubber tiles, he will have to pay significantly more. So, to equip production you will need:
- industrial mixer – 150 thousand rubles;
- volcanic press (with a capacity of up to 100 m² of tiles per day) – 400 thousand rubles;
- heating cabinet (drying chamber) – 120 thousand rubles;
- mold – 300 thousand rubles (for 10 pieces);
- auxiliary equipment – 60 thousand rubles.
As a result, you will have to spend 1,030,000 rubles on the purchase of equipment for the production of rubber tiles. Costs can be reduced slightly by purchasing fewer molds, but this will affect production volumes.
If an entrepreneur wants to buy a ready-made tile production line, he will need to pay about 4 million rubles (incomplete lines for 2 million rubles). Almost all equipment that is available on the domestic market is made in China. Higher quality equipment can be purchased for much more.
Purchase automatic line is a profitable investment that will pay for itself very quickly. For example, the equipment allows you to produce up to 3 thousand m² of finished products in 1 month. If you use conventional equipment, 8 workers will be required to produce the same amount of products (you can save money on their maintenance).
Recruiting staff
The company must employ personnel under the supervision of a technologist who knows all the secrets of producing high-quality paving slabs. Finding a qualified specialist is quite difficult. To attract his attention, his salary must be at least 40 thousand rubles.
There should be 1 production master and 3 workers per shift who will produce the tiles. In the summer, the number of customers increases significantly, so it is possible to organize round-the-clock operation of the enterprise. The finished goods warehouse needs 1 storekeeper. As for the sales manager, this person must be hired from the first days of work, since the search for sales channels must be carried out constantly.
Where to sell finished products?
The issue of marketing finished products is extremely important for the stable operation of the enterprise. It can be offered a large number of people. For example, you need to notify residents of cottage villages about a product, and applications will not take long to arrive.
It also wouldn’t hurt to advertise on television and other media channels. Should be created Commercial offer for wholesale buyers and personally visit them. To do this, you need to go to markets and supermarkets for building materials, landscaping companies and landscape design, as well as construction companies.
Important: Please note that shops prefer to work with tiles universal sizes and standard shapes, while design companies purchase exclusive products.
It is beneficial for the manufacturer to have a team of professionals who will lay tiles for customers. Thus, the company undertakes comprehensive provision of services, increasing its income.
Production of rubber tiles - financial plan
Let's consider a sample business plan for the production of rubber tiles.
Expenses
Imagine that a company operates on a day shift and has a staff of 4 people. Their salary is 100 thousand rubles monthly. In addition, the monthly rent of the premises will be about 15 thousand rubles, communal payments- 10 thousand rubles.
To make 1 m² of rubber tiles (40 mm thick) you will need the necessary materials in the amount of 865 rubles. If 1 thousand m² of tiles are produced, the company will spend 865 thousand rubles on this. But it is also important to take into account single expenses for purchasing equipment, registering a business, obtaining permits and other expenses.
Income
A 40 mm thick tile costs about 1,600 rubles per “square”. This means that buyers will pay 1.6 million rubles for 1000 m². Of these, about 600 thousand rubles will be net profit companies. Let's assume that the equipment was purchased at a price of 2 million rubles. This means that the payback of the enterprise will occur in 3-4 months.
Questions from new businessmen
Let's look at frequently asked questions on the topic.
What else can be made from crumb rubber?
Rubber is considered universal material, which is widely used to make various products. On its basis, high-quality roofing material. Mannequins, as well as punching bags and bags, are also stuffed with polyurethane or crumb rubber. In addition, the material is widely used for:
- manufacturing of ladders;
- road surfaces;
- bridge cladding.
In addition, crumb rubber is used in the production of fiber-reinforced concrete. It is popular in regions with cold climates.
Do-it-yourself rubber crumbs - is it possible?
Yes, it's possible. To do this, you need to purchase special equipment that allows you to grind car tires. But they are first put in freezer, in which the temperature reaches minus 80°C. Under such conditions, the rubber begins to deteriorate and is easy to crumble. The crumb is possible without special effort cook at home, for which you need to arm yourself with a hatchet and a sharp knife. First, the tire is cut lengthwise, and then chopped crosswise with an ax.
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As you can see, the business of producing rubber tiles is a promising type of entrepreneurial activity; it can bring considerable profit and pays off fairly quickly. Production technology is not difficult to master. In addition, the absence of a large number of competitors will allow many entrepreneurs to stay afloat for a long time.
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