Selection of equipment for the production of rubber tiles. Making rubber crumb tiles at home Rubber crumb products

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

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

The rubber tile finds more and more wide application. Today, sidewalks, paths of adjacent territories, sports and playgrounds, summer cottages, stairs and much more are laid out with it.

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

How much can you earn?

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

Technology for the production of rubber tiles

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

1. hot pressing method;
2. cold pressing method.

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

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

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

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

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

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

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

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

Raw materials for the production of rubber tiles

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

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

Premises and equipment

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

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

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

Production of rubber tiles - video

Production of rubber tiles in Russia: a 4-step business plan with all calculations, a list of equipment and examples from retail.

A good business is one that allows you to earn good money and bring benefits to society.

In this sense, one of the best options, according to many, is production of crumb rubber tiles.

After all, this baby in its “past life” was car tires, all kinds of hoses and other similar waste, toxic to the environment. Having established the production of rubber tiles, in fact, from garbage, you will not only be able to help in the recycling of waste, but also ennoble the city or village.

Indeed, rubber tiles for the street or large premises have recently become very popular, because they allow you to fold almost any floor pattern, are not afraid of moisture and temperature changes, and are not hard and not slippery even on the hardest ice. Agree, some pluses.

This market in Russia is not yet filled, therefore it is quite possible to occupy your niche and get a good share in this extremely promising field.

Rubber tiles: production, product features and market overview

Before proceeding directly to development, it is necessary to understand the products themselves: what is rubber tiles and who needs them. By answering these questions, we will understand whether it is worth doing this at all.

What is "rubber tile"?

As it is easy to guess rubber tiles are rubber tiles. Yes, it sounds very simple and banal, but it really is. The manufacturer takes two types of rubber crumb - colored (for the surface) and black (for the base), mixes with special glue, presses, and gets the finished product.

Many also produce crumbs themselves - they collect old tires, grind them on special equipment, and thus get “reclaimed rubber”. In other words - . True, such rubber still needs to be “devulcanized” so that it is more suitable for reprocessing. Although everything, in fact, depends on the production technology of a particular product.

Rubber tiles: production by 5 types of use

1. Street paving slabs (gray or black);
2. Tiles for the garden plot (most often green, the same color as the grass);
3. For playgrounds (colorful, bright);
4. For sports grounds (with markings corresponding to different sports);
5. Anti-slip coatings and overlays on the steps.

*Examples of using rubber tiles.

Also, the tile can have a different thickness, which will indicate its durability and protective functions, and hence the price. The thickness is usually from 10 to 80 mm, although another can be made to order.

Actually, you can produce all this at your enterprise. The production of crumb rubber tiles, in fact, is not very diverse - the composition is almost the same everywhere (rubber crumb + glue). The difference is only in the color, thickness and shape of the plate.

Crumb rubber tile production as a market

Having dealt with the approximate description of the product itself, it's time to look at the rubber tile market in the Russian Federation - does anyone buy it?

Let's say right away: they are buying, and every year more and more actively. Since this is mainly how it often happens in domestic realities, no one keeps accurate calculations. However, we are confident that the market is growing in indirect terms.

First, demand is growing. Recently, playgrounds and sports facilities in Russia have become much more meticulous than before. This is connected both with the elections and with the World Cup. The fact is that, according to the standards adopted in developed countries, playgrounds should not be finished with concrete or asphalt, but with such rubber tiles, which (in theory) should reduce the risk of child injuries.

As for the cladding of stadiums and running tracks, there is a direct indication from international sports organizations how exactly they should be designed. And the rubber tile here is the most, as they say, "must-have" - ​​that is, a mandatory attribute.

PS. Of course, small manufacturers are unlikely to be able to become the main supplier of rubber tiles to a large stadium (government procurement of this scale has its own “kitchen”), but an order for lining a playground or a sports complex of a school is quite within the power of small and medium-sized businesses.

There is one point - every year there are more and more sellers of rubber tiles. If it is being sold more and more, then it means that they are buying more actively (after all, no one will work at a loss). And since they buy more actively, they produce more and more, because the common economic truth says: "Demand creates supply".

Production of crumb rubber tiles from the point of view of Rosstat

There are more weighty arguments in favor of this business - Rosstat. Yes, it does not take into account small-scale production and does not specifically single out rubber tiles in general indicators. However, he is quite capable of demonstrating the “average temperature in the ward”.

In particular, the following table can be found in the archival bins of the chief state accountant:

*Production of the main types of rubber and plastic products by years.

There we are interested in the last line, which describes the materials. This includes the production of rubber tiles as a branch of the national economy.

As you can see, the production of such coatings increased from 2010 to 2014 from 250,000,000 sq. m. to 371,000,000 sq. m. At the same time, we see some decline in production in 2013 compared to 2012, but then growth resumed, although not in the same volumes as before.

But that was three years ago, what now? The same Rosstat gives us more relevant food for thought - data on the production of rubber coatings for January 2017 compared to the same indicator in 2016.

In the table, we see that in January 2017, 1,400,000 sq. m of reclaimed rubber plates. Here we immediately note that this is a narrower segment, which just includes our products. That is, this is good, it allows us to better assess the volumes and growth rates of this market.

So, in January, 130.2% of these rubber plates and coatings were produced in Russia, compared to 2016. Translated into simple language, this means that an indicator of 1,400,000 square meters. m of rubber plates is 30.2% more than in January last year.

Here we, in fact, got the growth rate of this market at the beginning of 2017: + 30% compared to last year's figures.

The table also contains a comparison of January 2017 to December 2016, but here you need to take into account the seasonal factor: in January, almost a week falls on the New Year holidays, and production this month is always lower than in the previous one. Therefore, it is necessary to compare data from January to January, December to December, etc.

Production of rubber tiles: determining the cost

One of the main criteria is the ratio of the price of the final product to the cost of its production.

We will talk about the cost in the corresponding section, after describing the equipment and calculating labor costs, and now we will indicate the approximate prices of tiles with different characteristics.

As we wrote earlier, the tile differs little in its structure. The main difference is the size and thickness. This directly affects its weight, and hence the amount of rubber raw materials that we need to produce it.

*Approximate prices in Russia as of the end of 2016.

Prices for 1 sq. m on the open market for Russian-made rubber tiles will fluctuate between 1,000-2,000 rubles, depending on the thickness of the canvas. You can also find Chinese crafts for 700-800 rubles per 1 sq. m., but experts recommend that such products be treated very carefully, because poorly glued crumb rubber can crumble the next day.

At the same time, Chinese, as well as, by the way, European manufacturers do not include the conditions of the Russian winter in the operating standards. And it is harsh, and can literally destroy unprepared material. Therefore, it is recommended to buy high-quality domestic rubber crumb tiles.

The cost of production of rubber tiles starts from 650 rubles per m2 and can reach up to 1,250-1,500 rubles for especially thick slabs.

In fact, a lot depends on factors such as office rent, utility costs, logistics, etc. Therefore, the price for production in the Moscow region and somewhere beyond the Urals will be different. The selling price, however, will also be different (this time in favor of Moscow).

Technology for the production of rubber tiles

Having realized the needs of the market, it is worth moving on to the production part - to determine what equipment is needed for the production of rubber tiles, what technical processes will need to be established, how many employees you will need to ensure the production process, etc.

To begin with, not one, but two technologies for the production of rubber tiles are currently being used:

1. hot pressing technique.
2. Cold pressing technique.

1) Hot pressing.

This technology for the production of rubber tiles was especially popular for the first time after the appearance of the material on the Russian market. The method is cheap, fast and relatively simple. But at the same time, it is toxic, and the product after its use comes out of poor quality, quickly falls apart. This technology is often used by Chinese manufacturers when working on the cheapest product.

Its essence is that the rubber crumb is not so much glued together with a special compound, but baked on a special machine-press. At first glance, the resulting tile is not much different from better samples, although, of course, it stinks of burnt gum much more strongly. But who on the street learns this? So the state of affairs suits many.

Rather, it suited them until the Russian buyer figured out this scheme.

The fact is that such a purchased and installed tile “falls off” along with the first snow. Or maybe it doesn’t reach it, because the compressed and heated gum, unlike the glued one, immediately breaks its structure under the influence of temperature changes.

If you live in a country with a temperate stable climate, then it will last quite a long time, but we are talking about the Russian sharply continental climate. Here, concrete slabs do not always withstand the load, what can we say about pressed rubber?

The massive use of this technology, by the way, was one of the reasons for the decline in production in 2013. By this time, the first buyers of rubber tiles had time to be disappointed in it, because. following the results of 1-2 winters, such a product decayed back to a state of crumbs. The result was a wave of bankruptcies of such enterprises that tried to sell a low-quality product at high prices.

2) Cold pressing.

Since 2014, the Russians have become better versed in rubber tiles, which gave this market a second wind, because now they have begun to produce tiles using more modern and high-quality equipment.

Cold pressing is long and not as profitable as hot pressing, but much more effective. Compressed rubber crumb with high-quality glue will withstand more than one winter.

Why didn't they switch to cold presses earlier? Equipment for the production of crumb tiles is much more expensive than that needed for the hot process. For large enterprises, the difference can be hundreds of thousands of euros or dollars. This makes the business less attractive in terms of investment.

Cold pressing technology goes through the following stages:

1. Mixing glue and rubber crumbs in special industrial mixers (preparation of raw materials).
2. The resulting mass is placed in prepared molds.
3. The press forms plates with a pressure of more than 5 tons.
4. The resulting boards are placed in drying chambers where, at a temperature of about 60 degrees Celsius, the products are dried for 5-6 hours (depending on the thickness of the tiles).
5. The final stage is drying at room temperature and quality control on a special table.

For comparison, the hot pressing method assumes that the mold is heated directly under the press. At the same time, the amount of adhesive in this form is much less, therefore it does not need to dry out under special conditions later. So, you won't have to buy dryers. However, the quality will be much worse.

Raw materials for the production of crumb tiles

Frankly, in the very subheading lies the answer to this question - yes, tiles are made from crumb rubber mixed with glue. Everything seems to be simple. But, as is often the case, the complexity lies in the details.

1. Rubber crumb.

In general, it is not difficult to find a supplier of crumb rubber. This recyclable material is available in abundance today, because it is made from car tires that have served their time.

A ton of such regenerated rubber crumb will cost 19-20,000 rubles (multi-colored is a little more expensive). A special polyurethane composition adapted for cold pressing can be found on the market at a price of 170-210 rubles per kilogram. A similar option for a hot tile release technique is 140-180 rubles for the same weight.

2. Glue.

Note that in this case, it is not so much rubber that is important as glue.

The characteristics of recycled tires are approximately the same. But the glue, which will bear the entire load in the future with changes in temperature and humidity, may be different.

Therefore, it is worth choosing glue with great attention in accordance with the price / quality ratio. If you have just started your business, then it is better to buy polyurethane from several manufacturers to check which one you can trust.

3. Other consumables.

By the way, dyes should also be included in the list of consumables. Of course, you can buy multi-colored crumb rubber in advance.

But, firstly, it is more expensive, and secondly, you never know in advance what color the buyer will like this season. A suitable dye costs 80 - 200 rubles per kilogram.

Equipment, workshop premises and other components of the industrial production of rubber tiles

We have already understood from reading the previous sections that in the production of tiles it is not so much the raw materials that are important as the equipment - it is this that accounts for the largest share of the costs.

According to market players, for one small workshop for 3-5 workers, it is necessary to purchase equipment for 1,500,000 - 4,000,000 rubles.

Everything here is also very ambiguous. Hot pressing equipment is cheaper, and cold pressing equipment is more expensive. The most expensive is the installation of an entire assembly line for cold pressing. At the same time, these lines are also very different in price, because some are more automated, while others are less.

On average, you need to focus on 2-2,500,000 rubles of initial investment:

Equipment	Sum	Qty
Raw mixer (mixer)	100-200 000 rubles	2
Volcanic press (capacity approx. 100 sq. m.	From 350 000 rubles	1
Press forms	OK. 30,000 rubles / piece	From 2 pcs.
Drying chamber (heating cabinet)	From 100 000 rubles	1
Forming tables, trolleys, scales, etc. auxiliary equipment	From 50 000 rubles

Equipment for the production of rubber tiles (tape assembly)

If you need a more serious production, then you cannot do without an assembly line. Here is what is included in this equipment:

Name	Qty
Fixing stand	1
shredding machine	1
Cyclone	1
Belt conveyor	1
Chips production machine	1
Wheel bead cutter	1
screw conveyor	1
Press forms	1-2
Cutting machine	1
Thermal cabinet	1
Hydraulic Press	1
vibrating table	1
Forming table	1

The necessary equipment should also include the presence of a car, otherwise how are you going to deliver tons of tiles to the assembly site?

The cost of the assembly line is about 3,500,000 - 4,000,000 rubles, although incomplete lines can be found on the market for 2,000,000 rubles.

Note that almost all assembly lines presented in Russia are made in China. The exception is only the most expensive units. To work on such a line, 3-5 people are needed, depending on the level of automation of production and its volume.

Speaking of volumes - the average assembly line produces from 1000 to 3000 square meters. m of rubber tiles per month. To produce the same volume of products in the usual way, at least 7-8 people will be required. That is, already serious savings on wages.

Another important point: to accommodate an automated line for the production of rubber crumb tiles, a minimum of 80 square meters will be required. m. of free space, as well as access to voltage lines with a power of 15 kW per hour (this is how much the machines consume). This is not to mention the ventilation system - the pairs of heated rubber and glue are quite toxic, although with the proper level of respiratory and eye protection they will not cause much harm.

Staff

As already mentioned, such an enterprise can produce 1,000-3,000 square meters. m. rubber tiles. However, an important nuance is that the maximum scale of production can be achieved only when working in three shifts. Equipment does not care - it does not get tired, but people get tired.

A minimum of three operators is required to operate one automated tape. When working in three shifts, it turns out that the staff should be 9 people. If the scale of production is larger, then 4-5 people will be needed in one shift.

However, you should not immediately set yourself up for emergency work in such an intensive mode. Immediately after starting a business, the main problem will not be to produce tiles, but to sell them.

Thus, you will not need three shifts of workers. But over time, when you acquire contacts, form your well-established sales scheme and start scaling your business, then you will need to recruit staff.

We present to your attention a detailed video

about the production of rubber tiles

We consider the income and expenses of the business for the production of rubber tiles

Finally, we have reached the culmination of any business plan - the calculation of profits. To determine how much we have earned from the company of our rubber dream, we must first accurately calculate the cost of consumables and the salaries of employees.

Let's assume that we will work in one shift. The salary fund for three people is about 75,000 rubles. They must work in a room of 80 sq. m - which means that its rent will cost 10 - 15,000 rubles.

For the production of 1 sq. m rubber tiles of medium thickness (40 mm) we need the following consumables:

480 Dye
0.35*90 rub.31.5

With a production volume of 1000 sq. m. per month we receive an amount of about 865,000 rubles. To this should be added electricity and other utility costs - about 8,000 rubles per month.

Total expenses per month - 950,000 - 1,000,000 rubles.

What are the incomes?

Rubber tiles 40 mm thick cost 1350 - 1650 rubles per 1 sq.m. Taking into account inflation, when calculating it is worth taking the amount that is greater, because. the constant rise in prices is the only thing that every Russian can be sure of (check the Rosstat website if you don’t believe it).

So, the minimum volume of 1,000 sq. m tiles, we can sell for 1,600,000 rubles. With the help of simple calculations, we can determine that the net profit will be at the level of 600,000 rubles per month. It is not surprising that this business is considered very attractive - not every production area can boast of such indicators.

If we assume that on rubber tile production equipment we spent about 3,000,000 rubles, then business payback is approximately 4-6 months.

It is also necessary to take into account that we took the minimum volume of production. If you can immediately find a buyer for 3,000 sq. m. tiles, then pay back the production three times faster - in a couple of months. However, in business, the saying is always relevant: we hope for the best, but prepare for the worst.

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When you step on such a coating, which is not made of stone or concrete, you understand how far the construction industry has moved forward. Increasingly, such paving slabs began to occur, in the manufacture of which crumb rubber was used.

And it should be noted that such a coating cannot but cause feelings of admiration. And judging by the practice of its application, the material has characteristics that are in no way inferior to other building resources involved in this area. And there is no need to talk about the comfort of use.

Convenience is at a high enough level

On that pavement, which was laid out of cobblestone or asphalt, walking is not very pleasant. And a material such as rubber allows the legs to bounce, creating a cushioning effect. Also, do not forget about the healing effect that is characteristic of such a coating.

With it, you can reduce the rather large loads that come on the spine. In the event that the material to be laid in its thickness reaches about thirty centimeters, there is still such a useful parameter as safety. This factor makes it possible to use rubber near swimming pools or playgrounds. But it is worth noting that it will be quite difficult to choose equipment for the production of rubber tiles.

Material advantages

If you want to start your own business, then you should know that in Russia there are not so many companies that supply high-quality equipment. Therefore, the choice is not very large, if you need a domestic production line.

However, these companies are also approached by many entrepreneurs who are engaged in the production of rubber coatings. And there is nothing strange here. This is due to the fact that rubber has a fairly high resistance to a variety of natural influences. Even after a harsh winter, rubber tiles will serve properly, without any problems. Such a parameter as durability is at a fairly high level.

The role of the supplier in the business organization

If your company is only at the stage of formation, then you will need to purchase at least a minimum complex. When purchasing equipment for the production of rubber tiles, it is necessary to thoroughly approach the choice of a supplier.

It is necessary to pay attention not only to the products that will be presented, but also to the possibility of training. Or at least provide an appropriate tutorial with which you can set up equipment for the production of rubber tiles.

In some situations, the most responsible suppliers can provide all the necessary information on how to find a sales market or establish a sales scheme for an already manufactured product. Also, a novice entrepreneur may ask for a list of documentation that is required in order to obtain a certificate. Do not forget to purchase all the necessary raw materials. This question can also be addressed to suppliers.

A huge role is played by such a moment as repair. It is best to purchase equipment for the production of rubber tiles from a supplier who agrees to carry out repairs in which case, as well as install it in a rented room and help with the start-up.

What to Consider When Buying a Processing Line

You will need to purchase all the necessary tools that will help you install and start the line. As a wonderful bonus, training of personnel before starting the equipment can act. It is understood that as a result of such training, a part of the skills related to the quality manufacture of products will be transferred.

Those organizations that supply equipment for the production of rubber tiles can provide the raw materials necessary to start the operation of the enterprise. We are talking about crumb rubber, polyurethane binders, pigments, etc.

At first, suppliers can offer orders to the entrepreneur or invite them to participate in projects for the manufacture of products. In other words, if you belong to the category of novice businessmen, then it is advisable to think about seeking support.

What equipment will need to be purchased?

So, in order to launch your enterprise, you will need to purchase the following equipment for the production of crumb rubber tiles:

1. Mixer. This setting is needed in order to establish the procedure for mixing the components.
2. You will need to purchase a heating cabinet. With it, the raw material is subjected to heat treatment.
3. Accessory equipment is a tile fixing stand (needs 6 pieces), a molding table (needs to purchase 3 copies) and a mixer platform (3 pieces).
4. Press for the production of rubber tiles. It is necessary to choose a hydraulic model. The machine is necessary to ensure the molding of products. Also, to set up the implementation of this procedure, molds will be required. With the help of them, you can take on the manufacture of various products.
5. You should purchase a conductor, thanks to which it will be possible to form technological holes.

This is the minimum technological line that you will need to buy without fail in order to start the rubber tile production process. On average, the cost of a small plant, where all the necessary equipment will be installed, will vary from two to three million rubles. This amount includes VAT, as well as all work related to the launch of the line.

Conclusion

The technology for the production of rubber tiles is not very complex. Any entrepreneur can handle this. Therefore, if you are interested in this field of activity, then you should not be afraid of the costs of purchasing equipment and organizing the entire business as a whole. All this will quickly pay off with a competent approach to the production process.

The practice of using rubber coating shows its excellent properties. Rubber tile in many respects outperforms paving slabs and other coatings. It is enough to note its strength, extending the period of use up to two decades.

Choice of premises for production

Tile production needs a special room. It should preferably meet the following requirements:

• the total area of ​​the premises is not less than 80 square meters;
• ceiling height - not less than 3 meters;
• the internal temperature of the room is 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 the production process, you will need to purchase the following materials:

• rubber crumb (color and black);
• dyes;
• polyurethane adhesive.

The main raw material rubber crumb. Mostly, it is a used car tires. The key to the strength and durability of crumb rubber is the high quality of both natural and artificial rubber, as well as emollient oils and fillers that are used in the manufacture of tires.

Rubber crumb is produced as follows. First, waste rubber products are collected at a specially designated site. Then, from the place of storage of crumb rubber, it is delivered by a forklift to the workshop.

There it is loaded into a special plant that processes rubber products. The process of manufacturing crumb rubber of a certain fraction is started. Finished products are unpacked into bags and transported by forklift to warehouses.

Equipment for the production of rubber tiles

When buying 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 rubber crumb tile business? The standard technological complex includes the following units:

1. Mixers (six pieces). They are needed for the process of mixing various ingredients.
2. Heating cabinets (or drying chamber). Here the raw material will be subjected to heat treatment.
3. Six fixing stands for tiles.
4. Forming tables (you will need three to six pieces).
5. Mixer platforms.
6. Press (hydraulic model) for the production of rubber tiles. This machine will provide the molding process of products.
7. Molds They will serve for the manufacture of the necessary products.
8. 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 to produce products of different thickness and density.

Video: equipment for the production of rubber tiles.

Production technologies

In the production of two-layer tiles, for a softer and cleaner top layer, you will need colored fine rubber. For a dense lower base layer, you will need a black coarse crumb (0.2-1 cm).

The creation of each layer of rubber crumb involves a separate production process. It is assumed that the composition of the lower layer may include textile inclusions, metal elements and other impurities.

At the initial stage of production, a mixture is made with the addition of glue and pigment. All ingredients are mixed as thoroughly as possible. Then the resulting raw material is poured into molds having the desired parameters and a given shape.

Formation of products is achieved by pressing. After that, you need to carefully remove the tile from the molds. If the work is done without a flaw, then high-quality tiles are packed and sent to a warehouse or transported directly to the customer.

Rubber crumb tile production methods:

• hot pressing;
• cold pressing.

The first - high-temperature - method is characterized by high productivity, 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 by cold pressing

1. Mixture preparation. A line with six mixers will allow you to thoroughly mix all the components.
2. Filling the mixture into molds.
3. Pressing process. Molds are loaded into trolleys in ten levels, which are subjected to pressing - squeezing under pressure up to 5 tons.
4. Drying. Carts are placed for 4-6 hours in a drying chamber, where the temperature is set to 60 °.
5. Unloading carts and removing products from molds.
6. Quality control of finished rubber tiles.

Advantages of the cold pressing method

• there is a thorough mixing of all ingredients, which affects the improvement of product quality;
• under pressure, the tile acquires a high density;
• a sauna effect is created in the drying chamber, which contributes to the good absorption of dyes and glue into rubber crumb - this will subsequently affect the strength and flexibility of the tile;
• cold pressed rubber tiles do not have a specific smell and do not suffer from the effects of the external environment.

Profitability of the rubber tile manufacturing process

A mini-factory, where this equipment will be located, can cost a novice entrepreneur in the amount of 2 to 3 million rubles, including VAT and a set of all work to launch the line.

You should not be afraid of the costs of acquiring equipment for the production of rubber tiles and organizing a business as a whole. They redeem themselves pretty quickly. The main advantage of such a line is that it will save on the labor of workers. Three or four operators will be able to serve it.

The profitability of the production of rubber tiles on such equipment will be 40%. With a 22-day work schedule, production output can be increased to 3,000 m2 of tiles per month.

The main thing is the competent operation of the equipment and a thoughtful approach to the production process. With a growing demand for rubber tiles and little market competition, there is every reason to expect the company to be successful.

1. When purchasing equipment for the production of rubber paving slabs, you should responsibly approach the issue of choosing a supplier.
2. A conscientious supplier will provide information on the location of sales markets and help create schemes for its sales.
3. It would not be bad for a novice entrepreneur to acquire a list of documents for obtaining a certificate.
4. The supplier can also provide assistance in acquiring the necessary raw materials for the production of rubber coatings.
5. You should buy equipment for the production of rubber tiles from a supplier who will not only install it and help you launch it, but also give a guarantee for repairs in case of force majeure.

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

Raw materials for tiles

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

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

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

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

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

Necessary equipment

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

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

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

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

But at the initial stages of production, auxiliary equipment can be dispensed with. To purchase a complete set of equipment, you will spend from $26,500 to $39,500.

Advice! If you plan to make tiles for your own needs, then all the necessary equipment can be rented.

Manufacturing technology

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

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

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

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

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

Process steps

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

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

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

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