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 huge loads 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 tolerates acid 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 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 a soft base (ground) or hard;
- 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.
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 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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Rubber tiles have recently become quite common in landscaping; you can make them yourself, which will save you 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
Despite the fact that rubber tiles appeared on the Russian building materials market relatively recently, they have managed to gain worthy positions, 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 car tires. The starting 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 products in finished form, it will be cheaper even than the option in which the installations are rented.
To carry out production work rubber tiles 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 of the finished product, then both of these methods are equivalent, and 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 stores offer affordable prices rubber tiles, 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. It is being refuted today manufacturing companies using 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 a layer of sand. 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 it with a rubber hammer. 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 to improve your garden 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.
The practice of using rubber coating shows its excellent properties. In many respects, rubber tiles outperform paving slabs and other coatings. It is enough to note its strength, which extends its service life to two decades.
Selection of premises for production
Tile production requires a special room. It should preferably meet the following requirements:
- the total area of the premises is at least 80 square meters;
- ceiling height – not lower than 3 meters;
- internal room temperature – not lower than +15°;
- connection to an industrial power grid – from 20 kilowatts;
- floors with a flat surface;
- distance from the residential sector at least 300 meters.
Raw materials for the production of rubber coating
To establish manufacturing process, you will need to purchase following materials:
- crumb rubber (colored and black);
- dyes;
- polyurethane glue.
Main raw materials – rubber crumb. Mainly, it consists of used tires. The key to the strength and durability of crumb rubber is the high quality of both natural and artificial rubber, as well as softening oils and fillers that are used in the manufacture of tires.
Crumb rubber is produced as follows. First, waste rubber products are collected at a specially designated site. Then, from the place where the crumb rubber is stored, it is delivered by forklift to the workshop.
There it is loaded into a special installation that processes rubber products. The process of producing crumb rubber of a certain fraction starts. Finished products are packed into bags and a forklift transports them to warehouses.
Equipment for the production of rubber tiles
When purchasing this type of equipment, each entrepreneur primarily focuses on the amount of start-up capital. The market today offers a wide range of equipment of this profile.
So, what equipment will you need to open your own enterprise for the production of tiles from crumb rubber? B standard technological complex includes the following nodes:
- Mixers (six pieces). They are needed for the process of mixing various ingredients.
- Thermal cabinets (or drying chamber). Here the raw materials will be subjected to heat treatment.
- Six fixing stands for tiles.
- Forming tables (three to six pieces will be needed).
- Mixer platforms.
- Press (hydraulic model) for the production of rubber tiles. This machine will provide the process of molding products.
- Molds They will be used for manufacturing necessary products.
- Conductor. It is necessary for the formation of technological holes.
This is the minimum set of components for the production line, which will allow you to start the process of manufacturing rubber tiles. This equipment will allow us to produce products of varying thickness and density.
Video: equipment for the production of rubber tiles.
Production technologies
When producing two-layer tiles, for a softer and cleaner top layer you will need fine colored rubber. For a dense bottom base layer, you will need black coarse crumbs (0.2-1 cm).
The creation of each layer of crumb rubber involves a separate production process. It is assumed that the composition of the lower layer may include textile inclusions, metal elements and other impurities.
On initial stage production, a mixture is prepared with the addition of glue and pigment. All ingredients are mixed as thoroughly as possible. Then the resulting raw materials are poured into molds with required parameters and a given shape.
The formation of products is achieved by pressing. After this, you need to carefully remove the tiles from the molds. If the work is done without flaw, then quality tiles packaged and sent to a warehouse or transported directly to the customer.
Methods for producing tiles from crumb rubber:
- hot pressing;
- cold pressing.
The first - high temperature - method is different high performance, but the tiles obtained by hot pressing lose their durability and acquire the smell of burnt rubber.
With cold pressing, both process productivity and product quality can be achieved. The main thing is to comply with all technological requirements.
Video: comparison of hot and cold pressed rubber tiles.
Stages of production of rubber tiles using cold pressing method
- Preparing the batch. A line with six mixers will allow you to thoroughly mix all components.
- Putting the mixture into the mold.
- Pressing process. Molds are loaded in ten levels into carts that are subjected to pressing - compression under pressure of up to 5 tons.
- Drying. Carts are placed for 4-6 hours in drying chamber, where the temperature is set to 60°.
- Unloading carts and removing products from molds.
- Control over the quality of finished rubber tiles.
Advantages of the cold pressing method
- all ingredients are thoroughly mixed, which improves the quality of the product;
- under the press the tile acquires high density;
- a sauna effect is created in the drying chamber, which promotes good absorption of dyes and glue into the rubber crumbs - this will subsequently affect the strength and flexibility of the tiles;
- Rubber tiles obtained by cold pressing do not have a specific odor and do not suffer from exposure to the external environment.
Cost-effectiveness of the rubber tile manufacturing process
A mini-factory where this equipment will be located can cost a beginning entrepreneur from 2 to 3 million rubles, including VAT and the complex of all work to launch the line.
There is no need to be afraid of the costs of purchasing equipment for the production of rubber tiles and organizing a business in general. They will justify themselves quickly enough. The main advantage of such a line is that it will save on worker labor. Three or four operators will be able to service it.
The profitability of rubber tile production using such equipment will be 40%. With a 22-day work schedule, production can be increased to 3 thousand m2 of tiles per month.
Main - competent operation equipment and a thoughtful approach to the production process. With the growing demand for rubber tiles and insignificant market competition, there is every reason to count on the success of the enterprise.
- When purchasing equipment for the production of rubber paving slabs, you should take a responsible approach to choosing a supplier.
- A conscientious supplier will provide information on the location of sales markets and help create sales plans.
- It would be a good idea for a novice entrepreneur to acquire a list of documents to obtain a certificate.
- The supplier can also provide assistance in purchasing the necessary raw materials for the production of rubber coating.
- You should buy equipment for the production of rubber tiles from a supplier who will not only install it and help launch it, but also give a guarantee for the production. repair work in case of force majeure.
One of the types of materials actively used in landscaping today is rubber tiles - a fairly durable and easy-to-use paving surface. Having appeared in stores, it almost immediately gained a good position among other types of paving coverings.
Such tiles have many advantages, among which there is also an anti-slip feature; it is thanks to this unique advantage that this type of tile can be used all year round. And even if a crust of ice appears on such a coating during icy conditions, it can be easily removed using a regular crowbar.
A profitable and long-lasting material is all rubber tiles
The service life of rubber paving slabs is several years; the material is highly durable; even in the presence of frequent mechanical stress, this coating does not deteriorate or wear off. Another great advantage of this coating is the absence of puddles on it; even after heavy rainfall, there will be no even small accumulations of water on the surface of the rubber tile. The disappearance of puddles occurs due to the fact that all tiles have high porosity, which is why they have a drainage effect.
In addition to the fact that such material will almost always be dry, despite the abundance of rainfall, it can be used as a coating on any type of base. It doesn’t matter what this type of tile is laid on, gravel or asphalt, this tile will hold up perfectly for a long time, and even after years it will not lose its advantages. It is precisely because of such serious advantages that this type of tile is only increasing in popularity. Of course, the cost of such material does not always make it possible for those who wish to purchase it, but this does not mean that one can only dream of a good paving surface near their home.
You don’t have to buy it, you can make it yourself
In fact, rubber tiles can be made with your own hands, and the manufactured material will have no worse appearance and quality than those sold on the market similar materials, manufactured in production. For self-made This durable tile uses crumb rubber and is made from recycled car tires. Since natural or artificial rubber is present in the manufacture of tires, due to their processing, the manufactured crumb rubber, like the original products, is wear-resistant to various mechanical influences.
The ability to process the original product into a secondary one allows not only the production of new durable material, but also the safe disposal of deteriorated material, such as tires, at the same time. And although it is indeed possible to make rubber tiles with your own hands, it is still worth knowing that in order to achieve what you want, you need special equipment, the cost of which is too high, therefore, purchase it for production small quantity tiles doesn't make sense.
To make the material you will have to prepare well.
Easier to purchase required quantity such material on the market, but if you plan to open your own business producing such high-quality coating, then you can rent the necessary equipment for the first time. To produce such material, it is necessary to prepare such elements as a heating oven, mixer, hydraulic press, molds, tables. The process of manufacturing rubber tiles begins with the removal of steel elements present in rubber tires. Then the rubber products are crushed, maximum size one particle should not exceed 4 mm.
A polyurethane mixture and pigment are added to the crushed rubber, after which all these components are thoroughly mixed. Ready mix poured into molds and subjected to vulcanizing pressure. Tile production can take place in two pressing methods. During the hot pressing method, processing takes only 15 minutes at a temperature of 140 degrees. Cold pressing lasts as long as 4 hours at a temperature of 80 degrees. But, despite the existing differences in temperatures and processing times, the end result is no different and has the same characteristics.
But it’s worth considering a small nuance: making rubber tiles with your own hands will be much cheaper when using the hot pressing method, but if production has already started and an increase in productivity is needed, then in this case it is better to use the second cold pressing method.
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 covering it with asphalt or concrete;
- rubber tiles are pleasant to the touch, it is useful to walk on them barefoot, so they are ideal for covering children's and sports grounds;
- This material is convenient to transport and lay, the tiles do not crack or deform.
Rubber tiles are increasingly used. Today they lay out sidewalks and paths with it. adjacent areas, sports and children's playgrounds, summer cottages, stairs and much 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 are appearing on the market. Entrance fees to the business start at $150,000. The main costs go to the acquisition of the line, commissioning works 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 not so many manufacturers to the market. quality equipment.
How much can you earn?
Rubber tiles are 3-4 times more expensive than their concrete counterpart - paving slabs. 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 80 mm thick). Average productivity modern lines ranges from 1000 to 3000 sq.m. per month. It is not difficult to calculate the potential turnover of even a mini-enterprise. It ranges from 1.0 to 4.0 million rubles per month.
Rubber tile production technology
There are two common technologies for producing rubber tiles:
- hot pressing method;
- cold pressing method.
Each method has both its advantages and disadvantages. Moreover, the first option has much more significant disadvantages.
The hot pressing method is used by those manufacturers who decide to save on the purchase of expensive equipment. Today, Chinese production lines are actively offered to our entrepreneurs. Although the lines do have high productivity and are much cheaper than their analogues, the rubber tiles produced using such equipment are of very low quality.
The point is that under the influence high temperatures tile gets persistent odor burnt rubber. As a result, it emits not only bad smell, but substances harmful to humans. In addition, the product obtained in this way will be short-lived, hard and fragile. As a result of operation, such tiles quickly collapse under the influence of environment.
Despite the low quality of the resulting products and questionable safety, many continue to use the hot pressing method. This is explained by two main reasons:
- low cost of equipment, which means a lower entrance ticket to the business;
- lower costs for raw materials, since the process of melting rubber reduces the consumption of polyurethane.
As a result of this, products are obtained at a low cost and a competitive price in the market. But there are no prospects for a business built on this technology. Having purchased tiles once, the client, convinced of the low quality of the products, will no longer place a repeat order.
The cold pressing method allows you to obtain rubber tiles of a completely different quality. Products using this technology are more elastic, flexible and durable. The price for quality is higher costs for the purchase of equipment and reduced line productivity. The price difference compared to hot presses can be hundreds of thousands of dollars.
The production process using the cold pressing method is as follows: at the first stage, the components of the future product are mixed using mixers. Next, the raw materials are placed 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 the molds is moved to the drying chamber, where the products are kept for 4-6 hours at a temperature of 60 degrees. After drying is complete, ready tiles 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). Crumb rubber is purchased from suppliers. The average price is 19,000 rubles/ton. Polyurethane glue for hot pressing costs from 140 to 170 rubles per kilogram, for cold pressing - from 170 to 200 rubles / kg. You should approach the purchase of this component very carefully, because the strength of the finished product depends on the quality of the connecting 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. Almost 90% of line suppliers are Chinese manufacturers. The capacity of the hot pressing line ranges 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 molding technology starts from 3.5 million rubles. The production line consists of hydraulic press, mixers, heating cabinet, mold, stands for fixing tiles, molding tables, electric heater and auxiliary equipment (scales, carts, work equipment).
No matter what configuration the line is supplied in, an area of 80 sq. m. is required to accommodate it. m. The room must be heated, well ventilated and with sufficient electrical power (machines consume 15 kW/hour).
Production of rubber tiles - video
