Rubber tiles with their own hands. Do-it-yourself production of rubber tiles. Mini business: production of crumb rubber tiles How to organize the production of rubber tiles

Rubber tiles - the know-how of the last few years. It is just beginning to conquer the construction market, but it already claims to become the number one coating in the near future for the improvement of suburban areas. But what benefits can an entrepreneur take from this trend?

The manufacture of this building material is a new, low-competitive, but promising area of ​​production. A guarantee of business success is the advantages of manufactured products over other types of coatings. Rubber crumb tiles:

• safety;
• durable (its service life is at least 20 years);
• has anti-slip properties.

In addition, it does not crumble and does not crack at low temperatures, and, due to the elasticity of the material, frost is very easily chipped from it. The tile is able to pass water through itself, and therefore, with proper installation, there are no puddles on its surface. The range of rubber tiles is wide: it is made in different colors, sizes, can vary in thickness, shape and even the pattern that decorates the surface.

All this allows you to use the coating:

• on playgrounds;
• in kindergartens;
• on sports grounds;
• when making country paths;
• for arrangement of sites near ponds, fountains, pools;
• in garages;
• in car services;
• in areas where animals are kept.

Potential buyers of products are:

• private persons;
• building stores;
• construction companies;
• organizations involved in the improvement of the city.

Stages of production of rubber tiles

1. Preparation of a mixture, including crushed rubber crumb, coloring pigment and glue in mixers.
2. Putting the finished mixture into molds.
3. Pressing and molding in a hydraulic press.
4. Heat treatment, which gives the products the necessary technical characteristics.
5. Unloading molds.
6. Quality control and packaging.
7. Shipment to the warehouse.

Minimum equipment package to start a business

The best option for starting a crumb rubber tile business is to purchase the entire line of equipment from one supplier, for example, from EcoStep, which is the largest supplier of crumb rubber in Russia, which offers several modifications of mini-factories that differ in productivity and the number of types of products produced. products.

To launch a full-fledged business, the company recommends purchasing an EcoStep mini-factory as standard. It includes the following types of equipment:

The total cost of the equipment set, including VAT and commissioning, is 1,970,000 rubles.

Calculation of the cost price of rubber tiles at EcoStep mini-factory

Although the set of equipment provides for the possibility of manufacturing 14 types of products, the most popular products are EcoStep rubber tiles 500 mm x 500 mm, 40 mm thick.

In the total volume of orders, it occupies 70%, and therefore the calculation of the cost, and in the future, the profitability of production, is best done based on the cost of producing tiles of the specified format.

Product Feature

Name: safety rubber tiles EcoStep 500*500*40 mm.

Material characteristics:

• size 500*500*40mm
• tile weight - 7 kg.
• weight 1m 2 - 28 kg.
• number of pieces in one m2 - 4 tiles

Parameters of the mini-factory

• Work is carried out in 2 shifts.
• The duration of the shift is 8 hours.
• Productivity of 1 change - 45 m 2 .
• During the day, the plant produces - 90 m 2 of finished products.
• The average monthly productivity of the plant when working in 1 shift is 990 m 2 of finished products (with 22 working days).
• The average monthly productivity of the plant when working in 2 shifts is 2,500 m 2 of finished products (with 22 working days).

payroll fund

The site will require 4 people: three workers and a shift supervisor. Their salary will be 17,000 rubles and 20,000 rubles, respectively. Thus, the wage fund when working in 1 shift is 71,000 rubles per month, in 2 shifts - 142,000 rubles per month.

Labor costs per 1 m 2 of products is 71000/990 = 71.71 rubles

UST (Unified Social Tax) - 34%, which is 24.38 rubles. in the cost of 1m 2 of finished products.

Requirements for production and storage space

To accommodate the EcoStep mini-factory, a heated room with an area of ​​at least 100 m 2 with a ceiling height of at least 3 meters is required. To accommodate a warehouse, a room with an area of ​​100 m 2, possibly unheated, is required.

At a rental rate of 150 rubles/m 2, the cost of renting premises per month will be 30,000 rubles, which is 15.15 rubles. per 1 m 2 of finished products.

Consumables costs

• Crumb rubber - 16 rubles / kg
• Polyurethane binder - 149 rubles / kg
• Coloring pigment - 80 rubles / kg.

Cost calculation

Calculation of the cost of materials for the production of 1 m 2 of EcoStep 500 x 500 rubber tiles 40 mm thick.

Material name	price, rub.	Consumption, kg	Cost, rub.
Rubber crumb

Taking into account other costs for the implementation of activities, it is possible to determine the cost of 1 m2 of rubber tiles.

cost of 1 m2 of rubber tiles EcoStep 500 x 500 40 mm thick.

Business profitability for the production of rubber tiles at the EcoStep mini-factory on the example of the production of EcoStep 500 x 500 tiles with a thickness of 40 mm *

* Please note that all calculations presented in the table are conditional and are given as an example of the potential profitability of this type of activity. The moneymaker factory recommends that you independently calculate the payback of the project before starting any activity.

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 the development, it is necessary to deal with the products themselves: what is a rubber tile and who needs it. 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 relevant 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 stronger. 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 on 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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To order

We bring to your attention an example of a typical business plan for the creation of the production of safety rubber tiles produced on the equipment of the Alfa-SPK company.

This business plan has been developed in view of the acquisition of an ARFC model safety rubber tile production line. The draft business plan is based on the current situation in the tire recycling market in Russia, price and tariff indicators are given taking into account the economic characteristics of the regions. The indicators may vary, so the draft business plan may be modified to take into account the specific conditions of the region.

Summary of rubber tile production project

Project name.

Production of safety rubber tiles, various sizes (with and without pattern).

Technological solution.

Line for the production of safety rubber tiles.

The equipment was purchased by Alfa-SPK, OOO, Novokuznetsk.

Investment needs:

RUB 1,750,000, incl. VAT 18%.

Production time(from the moment of signing the contract for the sale of the line to commissioning)

20-40 days excluding delivery time

The product that is the subject of the project.

1. Tiles 500 * 500 mm, thickness 16, 30 and 40 mm with technological holes for fastening with plastic bushings, with a smooth surface and a corrugated base;
2. Tiles 350 * 350 mm, thickness 20 and 30 mm with a pattern on the surface "Grid" and "Gossamer", with a corrugated base;
3. Paving stone "Brick", thickness 20 and 40 mm;
4. Paving stone "Coil", thickness 20 and 40 mm;
5. Paving stone "Wave", thickness 20 and 40 mm;
6. Rubber curb, length 500mm.

The main consumers of products.

Large consumers include: sports organizations, individuals.

Participation in the placement of state orders for the purchase of floor coverings in the construction of sports facilities is a separate area of ​​building a sales system.

1. As a technological solution, it is proposed to use a line for the production of rubber tiles on the equipment of Alfa-SPK, which has the following advantages: low energy consumption, high product quality, maintainability, and a small number of maintenance personnel.

2. Production of rubber tiles, pavers and curbs that meet the quality requirements of the specifications for the finished product.

Description of rubber tile production project

Objective of the project:

Establishment of the production of safety rubber tiles using the production line "Alfa-SPK"; production of a final product that is in demand on the market and ready for use in various areas of production of goods and services.

The main consumers are construction organizations, social institutions, etc.

Initial data:

	Name	Unit measurements
	Raw Mixer
	Thermal chamber 3000x4000 mm
	Press hydraulic PG-9ti with pressure control
	Mold trolleys
	Temperature control panel
	temperature sensor
	Matrix for making technological holes in tiles
	Metal table for layout
	Stands for mixers
	Mold kit
	Mounting tools	set
	Work tool	set
	Forming table
	Technical data sheet, Technology and recipe, Educational videos

The main range of manufactured rubber tiles:

The following items prevail in the total mass of orders:

• rubber tile 500*500 40 mm thick
• rubber tile 500*500 16 mm thick.

These two positions account for about 90% of all orders and are distributed on average in the following percentages: 70% - 40 mm and 30% - 16 mm. For averaging the calculations of production indicators, these indicators are taken as the basis.

	Rubber tiles 40 mm thick.		Rubber tiles 16 mm thick.
	Product Features		Product Features
	tile weight		tile weight
	number of pieces in 1 m 2		number of pieces in 1 m 2

Main settings

Work can be done in two shifts, shift duration - 8 - 10 hours.

The productivity of one shift is up to 60 m 2 .

Thus, up to 120 m 2 of finished products are produced in 2 shifts.

The calculation is made taking into account the production of 1320 sq.m. (60 sqm*22 working days) rubber tiles per month in two shifts.

The line capacity at full load is more than 1300 sq.m. per month.

Initial investment

The total cost of a set of equipment, not including the cost of commissioning, is: RUB 1,750,000, incl. VAT 18%.

Calculation of the required number of personnel

For the implementation of the project, at the initial stage, the following personnel plan is proposed.

Personnel plan for equipment operation in 1 shift.

The average number of staff is proposed - 3 people.

*The wage fund is per month at the rate of 1 shift - 75 000 rub.

Necessary production areas for the placement of equipment for the production of rubber tiles

To accommodate equipment and storage areas for raw materials and products, it is necessary to provide about 100 m 2 of production space and 100 m 2 of a warehouse (it may be located outdoors and not heated). The production room must be heated.

Finished products are stored in the workshop, and then moved to the warehouse.

At a rental rate of 150 rubles per sq.m. the cost of renting production space will not exceed 15,000 rubles.

COST OF ENERGY AND MATERIALS.

Raw materials for the production of safety rubber tiles.

• Crumb rubber
• Polyurethane binder
• Coloring pigment

Average price in Russia:

• Crumb rubber - 14 rubles. per kg
• Polyurethane binder - 200 rubles. per kg
• Coloring pigment - 90 rubles. per kg.

CALCULATION OF THE COST OF MATERIALS PER 1 sq.m.

• Products with a thickness of 40 (density 850 kg per cubic meter):
  Rubber crumb - 25.5 kg * 14 rubles = 357 rubles.
  Polyurethane binder (Glue) - 2.40 * 200 = 480 rubles.
  Pigment - 0.35 * 90 = 31.5 rubles
  RUB 865.05.
• Products with a thickness of 16 mm (density 850 kg per cubic meter):
  Rubber crumb - 12.5 kg at a price of 14 rubles. = 175 rubles.
  Polyurethane binder (Glue) - 1.15 kg at a price of 200 rubles = 230 rubles.
  Pigments - 0.35 kg * 90 = 31.5 rubles
  Total cost of materials: RUB 436.05

ELECTRICITY CONSUMPTION.

• Heating cabinet - 25 kW/shift

• Hydraulic press. - 2 kW/shift
• Mixing system - 10 kW/shift
• Lighting - 5 kW/shift

Total electricity consumption for 1 shift is 42kW/shift

The cost of electricity for 1 kW / h - 4.5 rubles.

Thus, the cost of electricity is 84 kW (2 shifts) x 22 days = 1,848 kW/month.

The cost of electricity when working in two shifts will be 8,316 rubles.

CALCULATION OF PROFITABILITY OF THE PROJECT.

For the convenience of calculating the profitability of the project, we take as a basis the average production of rubber tiles.

The minimum output of rubber tiles is 500*500*40 mm in two shifts = 1,000 square meters of tiles.

SALE OF MANUFACTURED PRODUCTS.

Rubber tiles (1000 square meters at an average tile price of 1600 rubles per square meter.) = 1,600,000 rubles

Total: 1,600,000 rubles

PRODUCTION COST PLAN FOR THE PRODUCTION OF RUBBER TILE

For the functioning of the company for the production of rubber tiles, the following current expenses are planned:

Staff salaries and insurance premiums, not more than 150,000 rubles per month.

· Expenses for communication services in the amount of 10 thousand. rubles per month;

Household expenses, transportation services and so on in the amount of 10 thousand. rubles per month;

Separately, the costs for electricity consumption are taken out, which largely depend on the load of production (the average electricity consumption for production equipment is 10 kW / h - calculated relative to the volume of production of rubber tiles) at the rate of 4.5 rubles / kW = about 10,000 rubles per month.

Lease payments for a room of 100 square meters will amount to 150 rubles/sq.m. per month; = no more than 15,000 rubles per month.

Production cost of 1000 squares of rubber tiles 500*500*40mm(glue, rubber crumb, dye) = 865 500 rubles.

Total: Cost part =1,060,500 rubles per month.

TOTAL REVENUE.

Profit 1 600 000 - Expenses 1 060 500 = 539 500 rubles(minimum monthly income).

Total: Payback of the project is 4 months when working in two shifts.

Please pay special attention to the fact that these figures for the production of rubber tiles are taken in minimum terms. Depending on the working conditions, the specifics of the region, seasonality, the performance of laying seamless rubber coatings and other factors, this figure can be significantly increased.

Business for the production of rubber tiles and other products based on crumb rubber

Production of rubber tiles at the enterprise

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.

Rubber crumb is considered the main material for creating tiles and coatings. Raw materials are taken from waste, which is obtained by recycling old, worn-out car tires. They are made from durable components that prolong the life of the finished rubber tile. The products are strong and durable. You can open the production of rubber tiles. This business has its own characteristics, which will be discussed in the article.

Description

The composition of the rubber tiles includes crushed pieces of rubber. Products do not break or crumble. Their advantages include:

• excellent wear resistance;
• resistance to natural factors;
• can be used at -40°С and up to +70°С;
• practicality;
• hygiene;
• tiles do not deteriorate from the sun;
• installation can be done independently.

Products can be used in industrial and residential facilities. They are ideal for warehouses and garages. Rubber tiles do not deteriorate from environmental influences and from various aggressive chemical components. It is suitable for decorating garden paths, as a floor covering for terraces and a country house.

Products are used on sports and children's playgrounds. Tiles look beautiful in any area. The rubber surface is rough and water repellent. As a result, there are no puddles on it after the rain. And in winter there will be no ice on it.

Business Relevance

The finished product will be in demand among different classes of consumers. It is needed for country houses and personal plots. Particularly interesting products for residents of cottage settlements. Products are needed in public and industrial buildings.

The tile will be in demand among private and wholesale customers. There is a possibility of delivery to markets and shops. Due to the high demand, it is possible to supply in large quantities. Only this question must be dealt with in advance in order to think over an advertising campaign.

Business options

If you are interested in the production of rubber tiles, then you can choose from several options for starting a business. The difference is in production volumes and costs. The following types of production are possible:

• mini plant;
• production at home;
• work in industrial conditions;
• franchise.

Each option has its own nuances that are important to consider before starting a business.

Mini plants

A rubber tile factory would be the best option. It is highly profitable, developed with quick payback equipment that operates on the basis of a cold forming method.

To start a business, you need 80-100 sq.m. and 3-4 employees for 1 shift. Energy consumption will be 15 kW/h. In this case, it is possible to offer customers a wide range of coatings. It is possible to manufacture tiles of various shapes, parameters and colors.

Making at home

The production of rubber paving slabs can be carried out at home. This is a budget option. Products will be manufactured for a long time. If there are no assistants, then it will not be possible to produce a lot of products. But then there is the opportunity to work under the order. This will be the start for business development.

industrial business

If you have a lot of capital, you can open the production of crumb rubber tiles. In this case, it is possible to lay different parameters and formats of products. A variety of pigments will be required so that customers can get a large number of products. It is important to first resolve issues with the sale and advertising of goods. It also needs a lot of workers.

Franchise

Such a production of paving slabs from rubber crumb can be opened if there are funds, but there is no business experience. It is important to choose a successful company that offers to purchase a franchise. The company will advise and provide advice on business organization. Proven suppliers of raw materials and equipment are provided. And proven schemes are used to attract customers.

Technology

The production of black and multi-colored rubber tiles at cost is significantly different. If there is an adhesive composition in the dye, the cost increases. Therefore, colored products will be expensive. The retail price of paving slabs will be about 1,500 rubles per sq.m. Manufacturing technology involves the following steps:

1. Training. Metal bead rings are removed from old car tires. Then, using cryogenic technologies, mechanical processing is carried out. The result is a crumb with a fraction of 1-4 mm.
2. Getting a mixture. In this case, special mixers are used. A polyurethane binder is needed to create a homogeneous substance. Colored pigments are added to it, which give the coating different shades.
3. Pressing. A vulcanizing press is used, which is required to obtain products of the required density and thickness. Now hot and cold pressing is in demand. With the hot manufacturing method, production lines cost 4 times cheaper. And to increase production, you need to purchase a mold. The cold method increases productivity.

Equipment

To open a business, you need equipment for the production of crumb rubber tiles. It should be taken from a trusted supplier. The launch of a full-fledged plant occurs only if:

• mixing mixer;
• hydraulic press;
• mold kit;
• heating cabinet;
• fixing stands;
• molding tables;
• conductor;
• mixer platforms.

Equipment for the production of rubber tiles will cost about 2 million rubles. The price includes all commissioning activities.

Purchase of raw materials

To start the production of rubber tiles, you need to buy raw materials - crumb rubber. And the adhesive will be the binder. Buy raw materials from a reliable supplier. Its average price is 19 thousand rubles per ton.

The cost of hot-pressed polyurethane adhesive is 140-170 rubles per 1 kg. And for cold pressing glue you will have to pay 170-200 rubles. Such products must be reliable, as this affects the strength of products. Dyes are used in the manufacture of tiles. They are required to give products the desired shade and attractive appearance. The cost of the dye is in the range of 80-190 rubles per 1 kg.

room

It is advisable to choose a warehouse or industrial premises in an industrial area. The object should be located in a small distance from large cities. It is important to take into account the lease and transport interchange.

The area is determined by the number and size of equipment, production volume. A mini-workshop requires a room of 100 sq.m. at least 3 meters in height. You need to choose a heated room where there is water, electricity with a voltage of 380 V. You will need rooms for finished products and raw materials. It is also important to have a warehouse with an area of ​​100 sq. m. Premises for the office and employees are needed.

Risks

This production has not only advantages. There are also a number of risks. This is due to the lack of specialists who know the technology for creating products. In this case, you can act in two ways - to find a technologist or to independently train employees in this activity. But then you have to be professional.

Seasonality plays an important role. Rubber tiles are used on the street and in the premises of car services, garages, facilities for animals, as well as areas near swimming pools and in sports halls. It is advisable to open a business in late winter and early spring. In autumn, the products will also be in demand, as streets are being improved.

The enterprise will function normally only if there is always the required amount of raw materials. For an average production, a stock of 100 tons is needed. The risk is equipment failure, so you need to be especially careful when purchasing it.

If we calculate all the costs, then the market price of products will be equal to 1350 rubles per 1 sq.m. The daily profit will be about 16.5 thousand rubles, and 350 thousand per month. The payback period reaches 145 working days if the profitability is 40%.

The production of rubber tiles is a highly demanded industry. If you correctly approach the organization of a business, then it will be possible to make it profitable in a short time. The main thing is that there is everything necessary for the production of quality products.