Rubber crumb coating is the trend of this year. Moreover, the production of this coating is a very popular area that can bring serious profits. There is practically no competition in this niche, and there are no large monopolies either. In addition, there are more and more new directions where this coating is applied.
What are the benefits of crumb rubber coating? This modern material has mass positive qualities that attract consumers:
- The coating looks expensive, of high quality;
- Wide range of colors;
- Large size range;
- Various thickness;
- Impact resistant surface;
- Does not slip;
- Moisture does not accumulate on it;
- Does not lose the brightness of colors under the influence of solar radiation;
- Thermal stability;
- Long service life - more than 40 years.
The manufacturing technology is quite simple - a mixture of glue with crumb rubber and the desired color dye is heated to a certain temperature.
Sales market and features of coating production
Before starting to implement the idea, you need to analyze the demand and identify a potential market. Since the use of rubber crumb coating is quite versatile, sales can be found in different directions. So, the rubber coating will be in demand for:
- Creation of a covering on children's playgrounds;
- Landscaping of the local area in the private sector;
- Equipment of production sites with a non-slip surface, which reduces injuries;
- Floor coverings in washing and dressing rooms in saunas and baths;
- Covering blind areas and areas near ice rinks or pools;
- Farm floor coverings.
The production technology is so simple that special skills are not required. This direction can even be done as an extension of the service sector.
For example, owners of a tire shop can use old and unnecessary tires to optimize their workspace and earn additional income from used parts. They are the basis for creating such a convenient product in the future.
The composition of the rubber coating is as follows:
- rubber crumb;
- polyurethane adhesive;
- powder dye.
Automobile tires and tires are crushed to obtain a homogeneous mass. This raw material makes up 85% of the total mass of the finished coating. It should be noted that there is another direction - the production of rubber tiles, but it is somewhat different from what is being considered now. Directly for the production of crumb rubber, you will need quite expensive equipment, but it quickly pays for itself.
To expand the range, as an option, rubber granules of different colors can be added in the form of patterns.
The production process is called pressing, and it looks like this:
- rubber crumb, polyurethane glue and dye of the desired color in the ratio of 85:10:5 are loaded into the bunker, everything is mixed;
- molds are filled with the mixture;
- the desired vulcanization temperature is set depending on the parameters of the tile;
- finished tiles are removed from the molds after cooling.
There is a second option for making a rubber coating from crumbs, vibrocasting: instead of molds, molds are poured in a vibrating table for two days.
Where to begin?
If you have 1.7 million rubles for the initial start, you can immediately rent a room for workshop equipment, buy molds or a vibrating table, equipment for crushing rubber, and start producing crumb coatings.
If you buy a grinder, it will be able to produce almost 2.5 tons of crumbs per day. average price the same kilogram on sale fluctuates around 12 rubles.
Of course, attractive figures do not guarantee a successful development of events. Each step should be worked out, expressed in a business plan with a time period of at least 3 years. You will also have to rely on a certain sales market, that is, simply starting production without sales is an absolutely unsuccessful undertaking.
Costs and payback
When it comes to payback time launched production, here everything is individual and depends on the scale of the enterprise itself and on the success of sales finished products. On average, this figure ranges from one and a half to two years.
The calculation of costs (for the purchase of basic equipment for the organization of the workshop) will be approximately as follows:
- molds for the press - 30 thousand rubles. for one piece;
- press - about 300 thousand rubles;
- mixing hopper - approx. 200 thousand rubles;
- a chamber for drying the finished coating - it will require the cost of improvised materials, and so - you can do it yourself.
Where to get money to start own business? This is the problem faced by 95% of new entrepreneurs! In the article, we have revealed the most relevant ways to obtain start-up capital for an entrepreneur. We also recommend that you carefully study the results of our experiment in exchange earnings:
Except minimal necessary equipment you will need to spend a certain amount of money on the purchase of raw materials: glue, the crumb itself, powder dyes.
The possibility of production using a two-layer technology should also be considered, which will increase the quality of the finished rubber crumb coating. The point is that the bottom layer of the coating will be made from large and cheaper crumbs, and the top layer will be made from a fine fraction of rubber crumbs.
The retail price per square meter of finished products reaches 1,500 rubles.
Coating production from free raw materials
Since obsolete rubber products are used for the production of crumb rubber, mainly wheel tires, it is not difficult to find raw materials for production - any tire shop will give away a bunch of tires and other rubber waste for free.
In general, the raw materials for production are free auto junk.
It should be emphasized the advantages of opening such a business in Russia. The free disposal of broken rubber products for cars determines the behavior of people - everything unnecessary is simply thrown away. Compared to European countries, the owner of the car must pay a commission for recycling unnecessary tires, and also deliver them to a special recycling center himself.
In our country, the car owner will be happy to give away tires for free, just not to waste his time on it. If the tires themselves are free, then to collect them you need to go around the city and nearby settlements. Depreciation on fuel and lubricants and payment to the driver are added to the expenses. Alternatively, you can enter into an agreement with large transport companies about the supply of tires - the flow of rubber for production will be stable.
Rubber tire grinding technology is one of two options:
- mechanical impact;
- shock wave effect.
The second option is more compact (in terms of installation dimensions) and economical in terms of electricity consumption, but the installation itself will require serious investments to buy it. In addition, it will be necessary to supplement the shock-wave installation with refrigeration equipment. The tire will break into small pieces under the influence of a temperature of 90 degrees.
In order to locate production, it is necessary to find and rent a room provided with electricity with a voltage of 380 kW versus the usual 220, this is due to the fact that the characteristics of the installation require an energy flow of 15 kW/h. The area sufficient for production is 60 square meters. m.
From the workforce, you can limit yourself to hiring a minimum number of employees, based on round-the-clock work without days off in three shifts - two operators per shift, and in general, a staff of 8 employees. Two storage rooms should be equipped - one large for raw materials, the second - 4 times smaller for finished products.
As already mentioned, a working seven-day round-the-clock week will be the most profitable and cost-effective. You should be prepared for fairly large expenses. For example, if the productivity of the workshop is 100 kg / hour, you will have to spend:
- $30,000 for the purchase of equipment (depending on the model and equipment of the instruments);
- 2,000 dollars for the execution of various documents, certificates;
- $3,000 monthly to pay rent for the premises;
- Approximately $5,000 should be payroll for staff, monthly.
At the indicated productivity, 72 tons of coating will be produced at the end of the month, with the implementation of which most of the costs will already be covered. And this is - if you sell crumbs, $ 500 per 1 ton of crumb rubber ($ 36,000 for the first month of work).
There will still be a small additional income to support the enterprise - 25% of total weight the raw material is the metal released from the tires, plus tires are often given away with broken metal parts of the wheel. The sale of metal will bring a small income, compensating for part of the costs.
If you organize the production of rubber tiles on your own, combining the processing and production of rubber coating, the cost of delivering raw materials will be equal to zero, increasing all economic indicators firms.
A working idea for the recycling of tires and the production of rubber crumb and coating from it can not only bring good income organizer, but also to make the environment cleaner without harming nature.
It must be said that such an idea has already been put into practice in the production of pavement, to which the mentioned material is added - crumb rubber. Thus, the constructed roads become less expensive, and for crumb producers it is a fairly stable consumer, providing stable work orders for even a large enterprise.
At the moment, already operating enterprises offer to open their own franchise business. Don't be afraid to take action, grow and market your business the right way.
The production of rubber crumb (or rubber granulate) on an industrial scale is a promising line of business. This material is used in the construction industry, and construction volumes in Russia have returned to growth. In the 3rd quarter of 2018, 72.5% more private houses were put into operation compared to the same period in 2017. Accordingly, crumb consumption is growing.
In this article, we will tell you how to properly organize a business and what is important to consider. Also in the text is the calculation of profits and expenses, the payback period of the business.
What is crumb rubber and where is it used?
Rubber crumb is a product of secondary processing of rubber raw materials. It is necessary for the production of tiles and paving stones, rubber coatings.
Fractionated rubber granulate withstands heavy loads for a long time. It is mainly made from car tires, which include high-tech components.
The material is used to create such coatings:
- roads, sidewalks, playgrounds, house adjoining territory;
- industrial and sports grounds (reduces injury risk);
- blind areas, approaches by pools, skating rinks, in dressing rooms in saunas, baths.
Also, the crumb is used in landscape design as a finishing and roofing material - for thermal insulation. There are technologies for using crumb rubber in automotive production.
Material Advantages
The key to the popularity of rubber granulate is its remarkable performance characteristics. The crumb is elastic, but does not stretch or bend. The covering differs in durability and firmness - does not react to acid or alkali.
The crumb has other advantages:
- Attractive appearance. It is possible to create black and colored coatings with different fraction sizes. The crumb does not react to sunlight, the paint does not lose brightness over time.
- The coating can be made suitable in size and desired thickness.
- The crumb does not slip, is shockproof.
- Moisture does not accumulate on the surface of the material.
- The material is heat-resistant, can withstand temperatures ranging from -45 to 60°C.
Brief Market Analysis
On the Russian market there are large manufacturers of crumb rubber and coatings, tiles based on it. About 60% of tire recycling in the country falls on 4 plants: in Moscow, Vladimir, Volgograd and Smolensk regions.
Prior to the events associated with the entry of Crimea into Russia, this area of activity in the country was actively developing. For example, in 2013 almost 14 thousand tons of rubber granulate were produced, which is 15% more than in 2012.
However, due to international pressure and crisis phenomena in the Russian Federation, the production of the material fell sharply - by mid-2014 it had decreased by 71% (by 2013). The share of importers offering a higher quality product began to grow.
Now, against the background of the revival of the economy, interest in this area is also recovering. Moreover, the niche in the regions is actually free.
Rubber crumb production technology
The raw material for the production of granulate is used car tires and tires. The process consists of several stages:
- Tire preparation, cleaning, cord removal (metal part).
- Cutting tires into strips of the desired length (depending on the capabilities of the equipment).
- Rubber crushing (depending on the processing technology used).
- Filtration of crumbs through special sieves, separation into fractions of the appropriate size. There are different fractions: from 0.1 mm to 10 mm.
There are two common rubber processing technologies: shock wave and mechanical.
In the first method, the rubber is cooled to ultra-low temperatures, then destroyed by a shock wave from an electrical device or a microexplosion.
The mechanical method is more popular. Rubber is crushed first at room temperature (up to 30°C), then at 100°C, then at low temperature. Finally, the crumb is crushed with the help of "ozone" (ozone knife).
How to open the production of rubber crumb and what is needed for this?
Will be required large investments. The table below shows the size of the initial investment - the amount is divided into several articles. The main expenses are for the purchase of equipment.
Table 1. The value of the initial costs for the crumb rubber business.
|
Expenditure item |
Cost, rub. |
|
Registration |
|
|
Obtaining a license |
|
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Premises for rent, 200 sq. m |
|
|
Equipment |
|
|
Additional expenses |
|
|
RUB 8.18 million |
Prices are relevant for a city with a population of up to 1 million people. Additional costs include the cost of electricity, advertising, cosmetic repairs.
The documents
First of all, you need to choose the form of activity: IP or LLC. It is easier to apply for an IP, you can choose a low tax rate. But LLC will allow to produce more product and cooperate with big companies. Large manufacturers are advised to choose the form of a legal entity.
When registering with the Federal Tax Service, the OKVED code 25.13 "Production of other rubber products" is entered.
To get started, you need to obtain a license (the cost is 300-500 thousand rubles). Need to lead working room in order, purchase equipment and receive a certificate from Rospotrebnadzor.
The quality of rubber crumb is regulated by GOST 8407-89 “Secondary rubber raw materials. Tires and tire chambers. Specifications".
room
The production premises should be located at a distance from the residential sector - no closer than 300 m. It is recommended to rent a suitable workshop on the outskirts or in the industrial area of the city. The rent here is cheaper, the location suits all requirements.
According to our business plan for equipment, a room with an area of 150 sq. m. It should be divided into the workshop itself with equipment, premises for storing raw materials and finished products, rooms for workers, a bathroom, and a director's office.
The circuit must have:
- flat floor;
- high ceilings (5 m);
- ventilation systems, air purification, fire safety, heating, electricity (380V);
- redecorating;
- stable air temperature of 15-18°C.
Raw material
This is the main item of monthly expenses - you will regularly need to purchase large volumes of used vehicle tires and tires. Finding them is easy. The number of cars in Russia is constantly increasing, as is the volume of consumption of rubber products. It is important to get them - Russia does not have a developed system for the collection and disposal of these wastes.
There are several ways to purchase raw materials - buy on an ad, organize a collection point yourself or pick up tire waste in places where they accumulate (at tire shops and trucking companies, at landfills and quarries, at unauthorized dumps).
In the presence of large-scale production it is better to start cooperation with companies that can offer the required amount of raw materials.
For production, worn tires, tires, air chambers, old fabric or reinforced rubber are suitable.
Equipment for the production of crumb rubber
We will choose a line for processing used and recyclable old tires LPSh-600 Russian production(mechanical grinding).
This equipment is designed for constant loading, has a compact size (150 sq. m), consumes little electricity (127-166 kW in total), differs high performance(up to 600 kg/h).
Comprises:
- bead cutter SOB-01;
- machine for processing bead rings SPBK-01;
- tape-cutting machine SLR-01;
- chips-cutting machine SChR-01;
- shredder for shredding tires ShR-01 with a straight conveyor 4.5 m long;
- rotary crusher SDR-01;
- vibrating separator VS-01 with exhaust, cyclone and filter;
- magnetic separator SEMAG SM-01 with 2 bucket conveyors 3.5 m long;
- vibropneumocomplex VPSK-01 with a bucket conveyor 3.5-4 m long;
- vibrating sieves SV-01 with bucket conveyor 3 m long;
- electrical equipment.
Staff
It is not necessary to hire expensive specialists with qualifications. You need to hire the following employees:
Table 2. Personnel for work at a mini rubber crumb plant.
|
Job title |
Main responsibilities |
|
Workers, 3 pers. |
Maintenance of equipment, control of its work |
|
Loaders, 2 pers. |
Loading and unloading, supply of raw materials, storage of finished products |
|
Technologist, 1 person |
Monitoring the operation of machinery and production technology, troubleshooting |
|
Sales manager, 1 person |
Work with suppliers, search for sales channels |
|
Driver, 1 person |
Logistics, delivery of goods to consumers |
|
Accountant, 1 person |
Maintaining accounting records |
|
Director, 1 person |
Management and control over the entire operation of the enterprise |
A businessman himself can be a director. A technologist and an accountant can be hired by outsourcing, a driver can be taken with his car.
Marketing
Develop a strategy to promote your product. Apply these methods:
- Creation of a business card site. The Internet is now the most convenient way to get information. Develop a website, fill it with useful information.
- Direct work with consumers. Explore the industries that use rubber granulate. Work directly with organizations. Send suggestions to e-mail, organize personal meetings with their representatives, conduct negotiations.
- Sales through trade and retail networks of building stores.
- Outdoor advertising on city billboards, publication of advertisements in newspapers.
Rubber crumb as a business: a plan with profitability and payback calculations
The size of the initial investment is 8.18 million rubles.
The capacity of the rubber processing line is 600 kg per hour. With 22 working days per month (8 hours each), up to 100 tons of material can be produced.
The cost of 1 ton of crumbs is from 13 thousand rubles. up to 18 thousand rubles depending on the faction (black color). The average value is 15.5 thousand rubles. This means that in a month it is possible to sell products worth 1.5 million rubles.
Monthly costs will be approximately 800 thousand rubles. (8 rubles per 1 kg). Net profit per month - 700 thousand rubles. But such a figure can be achieved if all the crumbs produced in a month are sold. The probability of this at first is small.
According to "dry" calculations, the business will pay for itself in 1 year. However, in reality, production pays for itself in 1.5 - 2 years, since the sale of all manufactured products at the first stages is a utopia.
Tables 3. The main values of the financial calculation of the business.
Making rubber crumb as a business has serious advantages and disadvantages. On the one hand, the niche is not filled - especially in the regions, which means that competitors will not crush. On the other hand, you need a lot of money to start a business. Spending 8 million to produce crumbs requires courage and faith in success.
The industrial business idea of launching a mini-factory for the production of crumb rubber by recycling tires attracts with an excellent ratio of large cash turnover and short payback periods. And most importantly, recycling is the production of money from garbage. Your attention is invited to a business plan for the production of crumb rubber with calculations and analysis of opportunities. For example, it is worth paying attention to the additional income from the extraction of metal from tire cords, in which it is already 7%. What other useful secrets this production keeps, we will consider in more detail.
Tire crumb mini-factory
How to correctly calculate the rate and volume of production of rubber crumb from recycled car tires? The answer to this question is not so simple. The production of rubber crumb depends on many nuances. There are two key factors that made this activity attractive from an investment point of view. They will help answer this question.
Factor #1: Industrial Small Business Entry Threshold
First of all, you should correctly assess your financial reserves that you own (own savings and possible loans). It is worth noting that this type of industry is possible with different investment volumes, which means that such a business scales well. With small investments in the initial phase, income can be minimal, taking into account regular expenses for electricity, transportation costs, salaries of employees, taxes, etc. It is worth noting here that this concept of a business idea underlies the recycling of waste (used car tires). And according to tradition, in order to get gold from garbage, you need to do a lot of work. Therefore, too little investment significantly increases the risks. It is possible to start production on a large scale by constructing a specialized enterprise with large areas, for example, several hundred square meters, which will be worth a large investment. Do optimal choice investment strategies in favor of the golden mean between these boundaries.
Factor #2: Small Business Manufacturing Capacity
In case you have about $17,000 of money, the choice should not be an issue. For this money, you can purchase a production line for processing tires into crumbs with a minimum configuration and a capacity of 100 kg / hour. In this case, the most important thing will be to find and rent a warehouse with an area of about 100 m 2 and a production room whose area should be an average of 40 m 2, plus a few more small storage facilities. In this case, the production of crumb rubber can start from a production volume of 800 kilograms of the finished product daily (100 kg / hour in 1 work shift).
What you need to process tires into crumb rubber
The minimum complete line for processing tires into crumb rubber includes the following equipment, which can be found on the Internet at prices:
- Bead cutting machine - $ 2,150
- Tape cutter - $ 2,700
- Shredder for shredding rubber - $ 7,650
- Circular sieve - $ 1,000
- Conveyor with magnetic separator - $1,000
- Bead ring processing machine - $2,500
TOTAL: $17,000
Technology for the production of crumb rubber by recycling tires
Video clip, which is shown schematically in the form of 3D animation technological process tire processing by crushing into crumb rubber:
As you can see in the video, the production process is extremely simple.
If you decide to conduct this activity on a more serious level, an analysis of the sales market in the region where you are going to launch your project will be necessary. Without this work, it is unlikely that the products will generate a profitable income. Will have to include in the business plan the costs of marketing research sales market for finished products in a particular region.
What is the need for this product and in what distribution channels can it be sold? Who else is interested in this industry and what is the competition in the market?
The answers to these questions need to be taken into account and, obviously, to calculate the development opportunities economic activity over the next few years. It is unlikely to accurately foresee the subsequent course of events, but approximate calculations will indicate at least the direction in which it is worth moving. Such determination is better than blind action.
Business plan for the production of crumb rubber with calculations
In the production of crumb rubber, used, old, defective car tires were used. For obvious reasons, one should not even talk about the search for raw materials and their price. Old tires can be found in large quantities. You can buy them for a minimal fee, and sometimes you can pay for shipping to your company.
The production of crumb rubber, as already mentioned, is quite affordable for small businesses. The $17,000 production line can quickly process a wide variety of tires: car, bus and other tires.
At the moment, there are two main methods by which crumb rubber is produced:
- mechanical crushing.
- crushing method shock wave.
Shock wave crushing of rubber into crumbs is a relatively young method of tire processing. The most popular mechanical crushing.
The production of rubber crumb using a shock wave requires a special approach. In particular, it is necessary to have equipment in which the products will be located, similar to refrigerated pantries, which are quite expensive. The advantageous possibility of installing equipment for the production of rubber crumb from tires using the shock wave method on smaller production areas is noticeable. You can save on monthly rent. At the same time, the cost of electrical energy will be less than with an analog installation. But all the same, such equipment is fully justified for large and medium production volumes, since it is very expensive.
The manufacture of crumb rubber can start with a small production volume and at a relatively low cost. Enough 40 square meters of production space with a ceiling height of 3m. A direct rubber crumb production line will be installed, a 380 volt power supply will be connected and 2 workers will control the operation of the semi-automatic equipment.
The best option during the period of reaching the payback point of the business is to work continuously for a whole week. To do this, three work shifts should be organized. As a result, the staff will consist of eight persons. In addition, you should take care of the places of storage of raw materials and finished products. In this case, the space for storing tires should take out four, and even five times more. In this regard, the surface of the room for raw materials (tires) may require up to 100m 2, and for the storage of finished rubber crumb - 20m 2.
On this basis, the cost of 100 kilograms of products per hour will change and change. In this business plan, we will determine the fixed costs for the month:
- Purchase of tires at a price of $40 per 1 ton - $960 (requires 24 tons of raw materials per month).
- The cost of renting a warehouse will be about $400-600 per month.
- The salaries of workers who maintain the production line are $300-$700 per month;
It's a good idea to give customers the opportunity to recycle tires for money. Having your own collection point will help not only to reduce transport costs for the delivery of raw materials, but also immediately receive preliminary additional income, which is described below.
If the production line produces 100 kilograms per hour, working without interruption, then in a month the amount of finished products will carry out 24 tons of crumb rubber (100 kg * 8 hours * 30 days = 24000).
Taking into account the average retail price of crumb rubber of $0.28 per kilogram, we get a gross monthly income of $6720 (0.28*24000).
It is also worth noting that during production, metal remains in the waste (wire in the tire courts). Its volume is about 7%.
Interesting fact! According to Goodyear Tire and Rubber, the average tire weight is about 22 pounds (up to 10 kg). At the same time, it contains 0.68 kg of steel cord (it serves as a reinforcing for the rubber structure in tires).
On the one hand, this is industrial waste, and on the other hand, positive side- this is a significant additional profit: 0.7 kg of metal wire and tire steel cord. And that 0.7 * 10 tires / hour * 8 hours * 30 days = 1680 kg of metal from 24 tons of tires - monthly!
The average price of scrap metal is about $200 per ton. As a result, we will receive an additional $336 profit from the sale of metal cord wire. It is worth considering how to organize your acceptance of car tires for recycling for money.
This amount of benefit is sometimes a more economically justified income received in the process of implementing this activity.
Tire recycling products
Where is rubber crumb from tire recycling used? This unique and durable building material is indispensable in the following industries:
- Production of paving slabs from crumb rubber.
- When covering roads, asphalt and concrete fences on roads with the addition of crumbs.
- In the production of safety coating for sports, playgrounds and gyms.
- in landscape design.
- Production of hydrophobic materials.
- The granules are used in construction industry production of rubber plates, palettes, roofing materials and the like.
- Rubber crumb granules are also used in the production rubber mats for pedestrians.
- Rubber crumb found use in filtration different kind liquids, creating thermal insulation of industrial premises.
In order to minimize the risk, it is possible to expand the scope of rubber crumb manufacturing. So, it is possible to produce rubber plates or other shells of this material. The need for these products does not depend on the need for crumbs. Therefore, in one enterprise you can create two completely different areas of activity.
One of the big expectations of the industry is the production of crumb rubber. We have this type of industry today is not particularly developed.
Do not forget about such an important component, which is the sale of finished products. The popularity of crumb rubber as a building material is growing. There are more and more new competitors on the market. As a result, if you have the right approach to selling this product, you can easily adjust the sales channels. This type of production does not require special skills, it is technologically simple.
Depending on the amount invested in the product, the payback period can stretch from six months to two years. Relatively short payback periods are the next plus in the interests of this type of activity. Consequently, the high demand for the product (like all building materials), minimization of risks and the mentioned thresholds for entering the production technology - makes it attractive from the point of view of investment.
Crumb rubber, even after its complete grinding, retains the same properties as solid rubber:
- has a noise-absorbing effect;
- it is resistant to damage;
- has a low weight;
- safety;
- environmentally friendly and non-toxic;
- has an anti-slip effect;
- waterproof;
- heat-resistant.
What is crumb rubber for?
- For the production of ecological floor coverings for various purposes;
- for sealing;
- For decoration of figures on children's playgrounds;
- for the manufacture of car parking posts and fencing curbs;
- Fill punching bags;
- during the construction of roads;
- production of heaters.
This range of applications for rubber granules can be continued, as they are an indispensable material in many areas of production and construction.
Types of crumb rubber
One of the types of crumbs produced by RBXGroup is shavings. The rubber is cut into oblong chips. Most often, this type of grinding is used to make the bottom layer of the floor covering.
Cuboid crumb - granules after cutting have a more regular shape. Due to the small number of voids when pressing this type of rubber, the product is more rigid and durable. Most often, the cuboid shape is used for the manufacture of seamless flooring.
Ragged shape - the surface area of the granules is larger compared to the previous types of crumbs, and the material products are softer.
Rubber crumb coating price per 1m 2
Rubber crumb for sports grounds is one of the most demanded products of our company. We produce granules that meet the requirements of the Ministry of Sports of the Russian Federation for laying on outdoor training and workout grounds. In RBX, you can buy a ready-made coating for playgrounds made of crumb rubber in the form of plates with a Dovetail lock and rubber granules of any fraction.
Fractionated crumb rubber is the basic raw material for rubber tiles and flooring. This raw material is actually taken from waste, or rather, it is obtained by processing old worn tires from cars. Car tires are made from fairly expensive components. High Quality(various oils, synthetic rubber, fillers), as these products must withstand enormous loads for a very long period of time.
Of all the existing types of rubber, tire rubber, in its structure, stands out for its high strength and durability. Such rubber easily tolerates the ingress of acid and alkaline solutions on its surface, is very elastic, does not stretch, does not bend and is able to withstand temperatures from -45 to + 60 degrees.
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raw material:
Automobile crumb (or crushed rubber - RD) - is mined as a result of the processing of worn tires of other rubber goods. Its price depends on such indicators as: quality, method of manufacture, dimensions, place of manufacture and sale. In Russia, the retail price per crumb fluctuates between 6-15 rubles per kilogram.
Places of rubber crumb production:
- factories that process car tires into crumbs as the main raw material;
- for side production at RTI factories
- factories that restore tires by roughening them (tread processing), as a waste product.
Used crumb rubber fractions:
Fractions of crumb rubber vary from 0.1 mm to 10 mm and directly depend on their purpose. Thus, fractions of a small type (0.1 - 4 mm) are mainly used in the production of colorless (black) or colored single-layer products. In the manufacture of the lower colored layers, mainly fractions of a larger nature (2-10 mm) are used. Most often, they are cheaper compared to smaller fractions, as they may contain textile or metal inclusions. The production of tiles with two layers (the upper thin colored layer, the lower dark layer with large crumb fractions) is acceptable and relevant when the initial thickness of the product exceeds 1.5 cm.
Layering allows you to reduce the cost of the product due to the following points:
. Inclusion in the composition of a cheap large fraction of crumbs. Such a crumb may contain textile or other inclusions.
. The housekeeper on the paint - the bottom layer remains black.
. Larger crumb fractions require a smaller amount of binder for their crosslinking, which is carried out by enveloping the surface of the crumb particle
. The absence of a dye allows the use of less binder for crosslinking the particles, since the mixture dries out in the colored crumb.
Equipment and raw materials (prices)
The line, which produces rubber coatings, has the following set of equipment:
Volcanic press with a capacity of up to 100 m² per day. Price - about 350 thousand rubles;
Press molds. Cost - 30 thousand rubles a piece;
Drying chamber (for a mini business, it is possible to make it yourself), price from 100,000 rubles.
Raw material:
Rubber crumb - black (17 thousand rubles per ton), colored (from 23 to 35 thousand);
. polyurethane glue - 140 rubles / kg;
. dyes - 7 rubles per kg;
Consumption of electricity by the line - 15 15 kW/h.
Coatings can be made:
- both soft and hard in density;
- waterproof, or with the passage of water (drainage);
- thin and thick;
- as colorless (black), colored, or black with patches of different colors;
- with good grip, and more slippery;
- with or without a pattern;
- single-layer or with several layers;
- for laying on a soft base (soil) or hard;
- with connections (sleeve, lock) or without them.
Paving rubber tiles are often laid in parallel with the usual paving slabs. It is for this combination that rubber coatings of similar sizes and shapes are created as ordinary pavement tiles.
A room for a mini tile production workshop.
Criteria for the production of rubber coatings (provided that the equipment is optimal and has an average level of performance):
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1. The area occupied by the technical line - 70-100 m² (not counting the warehouse); Equipment and materials are placed 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 the glue. Because of this, its amount in the black coating is smaller.
§ The higher the density of the product, the less glue is needed.
2. The average consumption of glue for the manufacture of various coatings is from 4 to 12%, depending on the presence / absence of dye, the density of materials, the quality of the adhesive, and the size of the tire crumb used.
For example, to make a color coating Mat 500 * 500 * 16mm (from crumbs of fine fraction), you need 6% dye and 5% glue from the amount of rubber crumb.
a) Black coating (crumb size - 4-10mm) - 4% glue.
b) Black coating (crumb size - 2-3 mm) - 5% glue.
c) Black coating (crumb size - 1.2-1.8 mm) - 6% glue.
d) Color coating (crumb size - 1.2-1.8 mm) - 7-9% glue.
3. Water resistance increases, the smaller the crumb rubber fraction and the higher the pressure.
4. The larger the crumb, the faster the color of the product will be lost due to abrasion.
5. The larger the crumb, the stronger the coating, but the thickness of the coating must be observed.
6. Thick coatings (2 cm or more) are best made in two layers. For the upper part, use a crumb of a fine fraction, for the lower part - a cheaper crumb of a large fraction (5-12 mm) with possible foreign inclusions. Each layer has its own proportions of glue. Each layer is kneaded in different containers.
7. On the same pressing mechanism, it is recommended to produce products of the same thickness, regardless of the configuration, since the thickness affects the time of the press (the thinner the product, the faster its formation).
Additional accessories for production.
Trolley to transport raw materials (crumbs, dye).
- Trolley with a special stand to transport containers with glue.
- Scales to weigh components (preferably 50 kg electronic).
- Trowels for uniform laying of coverings.
- Special mugs and scoops for measuring, depending on the standard of the product.
- Mixing glue and dye drill with nozzles.
Price for the implementation of rubber plates:
One pack
100 tiles - 57 thousand rubles.
The cost of 1 m² is 1,584 rubles.
The price of 1 plate is 570 rubles.
The minimum lot is 100 slabs (25 m²).
Sales of products.
For coating on production lines, in warehouses, or as a rubber coating for garages;
- use in areas near ice rinks, locker rooms, playgrounds;
- in combination with paving slabs;
- as a covering for various sports complexes or children's playgrounds;
- on farms, livestock facilities;
- on roofs, terraces
- in baths and other places.
As you can see, the release of such products is part of an ecosystem, dealing in high-quality safety products - rubber tiles or crumb coating.
Production of crumb rubber tiles:
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