Equipment for rubber tiles. Rubber tiles with their own hands. Making rubber tiles with your own hands Making rubber tiles from tires

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:

hot pressing method;
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 trade-off for quality is higher equipment costs and lower 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

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 fast 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:

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.
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.
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.

Many people dream of starting their own business, but they decide to invest in the production of a unit. It is much easier and more reliable to engage in the resale of Chinese goods, and if this type of activity is to your liking, then it is better to master it than to try to figure out how to set up the production of rubber tiles and paving stones with your own hands. For people who are fond of making paving slabs, on the contrary, it will cause genuine interest and a desire to create, that is, to create real masterpieces from simple plain rubber raw materials. This article will detail how to make this type of business the most profitable.

Rubber paving slabs: properties and applications

To produce competitive products, it is necessary to study not only the main technical parameters of the product, but also to figure out how to improve the properties of the product. A businessman must become an expert in the production of rubber paving slabs, and it is necessary to start from the basics. This type of product has the following properties:

These qualities distinguish this type of building materials from similar products. Rubber paving slabs can be used for:

Arrangement of children's playgrounds.
Covering platforms and steps in front of the house.
Erection of elements of landscape design.
Laying sites near car washes, swimming pools, showers.
Floor coverings for industrial enterprises.
Arrangement of a site with anti-slip properties near the entrance to shopping centers and shops.

Products made under high pressure can also be used for laying in a garage or car park. Such rubber plates have increased strength and density up to 1000 kg / m3, which allows them to withstand the weight of a truck without changing the geometry.

Considering the great demand for rubber tiles, it can be said with confidence that with a properly developed business plan and a competent marketing policy, an entrepreneur will return the invested money in the shortest possible time and will receive high profits for many years.

Raw materials for rubber tiles

In order to open a mini-factory for the production of rubber tiles, it is necessary to develop a plan for the supply of raw materials in advance. This type of building material consists of 90% rubber, so the development of a business plan should begin with finding out all the possible options for the supply of crumb rubber. You can get enough of this material as follows:

Purchase ready-made crumb rubber.
Make your own raw materials.

In the first case, raw materials are purchased from suppliers who are currently present on the domestic market in sufficient quantities to select the material at the most appropriate price and delivery method.

The second option involves the purchase of equipment for the production of crumb rubber. Despite the apparent complexity of the event, even for small tile factories, this method of obtaining raw materials will significantly increase the profitability of the business. Crumb rubber is obtained by recycling old car tires. It will not be difficult to acquire enough material for processing even in a relatively small settlement. It is enough to organize the acceptance of recyclable materials from the population, as well as to agree with the owners of tire shops on the acceptance of tires, the technical indicators of which do not allow the product to be used for its intended purpose.

Rubber crumb is the main, but not the only component of paving slabs. In order to form a homogeneous mass from rubber crumb with reliable fastening of each particle of the raw material to each other, a polyurethane binder is used. Such glue will allow you to securely fix the rubber crumb in the product, but only on condition that a high-quality one-component substance was purchased. European-made products are famous for their good quality, therefore, in order to purchase a binder, an agreement should be concluded with reliable foreign suppliers.

To give products greater aesthetics, a pigment dye is added to the rubber mass. For the manufacture of multi-colored rubber tiles, as a rule, powder dye is used, the main component of which is iron oxide.

Properly selected raw materials will make it possible to produce high-quality rubber tiles, therefore, if you have a desire to engage in this type of business for a long time, it is recommended that you spare no time for careful selection of product suppliers. When making crumbs yourself, you also need to take into account some of the nuances. In this case, it is necessary to use only automobile tires as the main material for processing, while avoiding the ingress of such inclusions as metal cord elements into the finished rubber raw material.

Equipment for the production of rubber tiles

Making rubber crumb tiles with your own hands is possible only if machines are purchased that will automate the tile production process as much as possible. For this purpose, special equipment is used, with the help of which raw materials are kneaded, compacted and molded into rubber mass. A novice businessman who has decided to invest in the production of crumb rubber tiles cannot do without purchasing the following equipment:

Mixer.
Press.
Thermal cabinet.
Forming table.
Tile stand.
Press form.
Mixer platform.
Conductor.

Each machine or device is designed to perform a specific function, so before you buy equipment for the production of rubber tiles, you need to learn the basic principles of such devices. A correct understanding of the functioning of the equipment will allow not only to select high-quality products in order to organize a mini-production of rubber tiles and paving stones, but also to optimize the initial financial investment as much as possible.

Crumb rubber tile production line

The mixer is necessary for mixing crumb rubber, polyurethane adhesive and dye. An entrepreneur needs not only to choose a high-quality mechanism that does not require too burdensome maintenance during operation, but also to choose a device that is suitable in terms of volume. For a small mini-workshop, focused only on the production of rubber paving slabs, a mixer with a working volume of 40 liters is enough. If you plan to open a large plant for the production of rubber building materials, then you will need to purchase several devices with a volume of more than 100 liters.

The standard design of the mixer is an open barrel, inside which, with the help of a special rotating knife, the raw materials are mixed. For easy movement around the workshop, such products have 4 wheels at the bottom of the structure. You can buy a rubber crumb mixer both domestic and imported. Russian-made products, as a rule, are not inferior in quality to the best European samples, while the price of products will be significantly lower, due to the absence of the need for customs clearance of goods.

The press is one of the most expensive elements of the rubber tile production line, but without this device it is impossible to produce a quality product of the required density. The average productivity of this type of machine is 100 m2 per day, which is a good indicator for a small production. If you want to expand your business, it will be enough to purchase a few more machines and properly install the equipment in the workshop. You can buy a press both from domestic equipment manufacturers and from reliable foreign suppliers.

Such elements of the production line as: oven, molding table, tile stand, mold, mixer platform and conductor must also be optimally selected. Typically, companies involved in the sale of equipment for the production of rubber tiles have in their assortment everything you need to install a turnkey mini-factory. By purchasing a ready-made line, an entrepreneur often manages to significantly save money and time. In addition, with the "wholesale" purchase of equipment, the intermediary can provide services for the installation of the production line, as well as for its maintenance.

Technology for the production of rubber tiles

The production technology of rubber tiles is not difficult. Currently, cold and hot methods of manufacturing this type of material are used.

Cold way.

This option for the production of tiles is the most labor-intensive, but the quality of the products is at a high level, and by reducing the cost of paying for electricity and purchasing more expensive equipment, the profitability of the business will be very high.

The process of manufacturing rubber products by this method is carried out in several stages:

Prepare the mixture. To do this, mix polyurethane glue, rubber crumb and dye in a mixer.
Subject the mixture to high pressure in a cold press.
Send the "semi-finished product" to the drying cabinet.
Lay out the tiles on a special table to complete the drying process at room temperature.

If the technological process has not been disturbed, then a high-quality rubber product of the required color will be obtained at the output.

Hot way.

The initial stage of production of rubber tiles using heat treatment is identical to the above-described technology for manufacturing such products in a cold way, but then the process is greatly simplified. For the production of material it is necessary:

Mix raw materials in a mixer.
The material is put into molds and pressed on a special machine under high pressure and temperature.

After the end of the pressing cycle, such products do not require further processing and are completely ready for use. The method of hot pressing can significantly speed up the production process, but the product loses its frost-resistant properties as a result of such processing. This option for making rubber tiles is most suitable for laying indoors, as well as for arranging outdoor areas in the southern regions of the country.

Calculation of production profitability

The rubber tile business is a very profitable business, but before you purchase equipment, rent or build a room to house a work shop, you need to draw up a detailed business plan. As a rule, such a document is a description of possible expenditure transactions in the organization of the production process, as well as a calculation of the estimated amount of money raised from the sale of the finished product. The price of equipment is not low, therefore, before starting your business, you need to acquire initial capital.

For the purchase of equipment, an entrepreneur needs to spend:

Mixer - 90,000 rubles.
Press for rubber tiles - 300,000 rubles.
Form for tiles - 3,000 rubles. (need to purchase at least 30 pieces)
Drying chamber - 100,000 rubles.
Auxiliary equipment - 70,000 rubles.

The last category includes: scales, carts, spatulas and tables. You can do without a drying chamber if you produce rubber tiles only in a hot way. The price of the mixer, in this calculation, is given subject to the simultaneous mixing of no more than 40 liters of the working mixture. For large production volumes, you will need to purchase a more powerful device.

The total cost of equipment for mini-production will be 650,000 rubles. Unfortunately, this amount alone is not enough to open your own business. To accommodate the equipment, it is necessary to rent a room that is suitable in terms of area and availability of communications. If the premises are rented outside the city limits, then the monthly expenses will be about 50,000 rubles.

In addition, you will need to hire workers:

Manager.
Accountant.
2 - 3 workers.

About 200,000 rubles will be required to pay wages every month.

The acquisition of raw materials will also require significant cash outlays before the company receives the first income. The average cost of materials is:

Rubber crumb - 25,000 rubles / t.
Glue - 250 rubles / kg.
Dye - 15 rubles / kg.

In addition to the listed expenditure items, the entrepreneur will need to pay utility bills, and before starting work, register an individual entrepreneur or LLC.

In total: in order for a rubber tile plant to start functioning, an initial capital of at least 1 million rubles is required.

The income of the enterprise is formed by the sale of finished products. At present, the wholesale of rubber tiles is about 1000 rubles/m2. Even with the minimum performance of the equipment, the revenue will be at least 100,000 rubles per day. If the production of paving slabs from crumb rubber is carried out seven days a week, then the monthly revenue will be 3 million rubles.

The total monthly expenses will be about 1.5 million rubles. Thus, the entrepreneur will return all the money spent within the first month and make a profit.

In practice, it is not always possible to recoup the production of paving slabs from crumb rubber in such a short time. Usually, at least 3 months are needed for this purpose. This is due to marketing problems and the presence of competition. In order to speed up the process of bringing new products to the market, it is recommended to spend money on advertising in various media. Usually, small expenses aimed at conveying information to a potential client are more than paid off, due to the possibility of selling more goods on the market.

Rubber crumb is the basic raw material that makes it possible to make tiles and coverings from rubber.

In fact, this raw material is taken from waste, which is obtained by processing old worn-out car tires.

Car tires are made from high quality components that increase the life of the finished rubber tile.

The rubber tile differs in the increased durability and high strength characteristics. Such a coating easily tolerates the ingress of alkaline and acidic solutions, stretches well, but does not bend. It withstands a fairly wide temperature difference, which makes it one of the best finishing materials.

Project description

Rubber tile is represented by a set of crushed pieces of rubber. It doesn't break or crumble.

There are the following Benefits this coverage:

Rubber tiles can be used not only in industrial, but also in residential areas. It is used in warehouses and garages. At the same time, it does not lose its appearance for a long time when interacting with the environment and various substances.

Impeccable characteristics make it possible to use it for organizing garden paths, as floor coverings for terraces and a country house.

The rubber tile is as a safe covering on sports and children's playgrounds. It looks aesthetically pleasing on any site, as there is a choice among a large number of shades. The rubber surface has a rough surface and excellent water repellency. As a result, puddles do not appear on it after rain. In winter, a layer of ice does not appear on it.

Relevance of business development

These products are widely demanded among a wide range of consumers. It can be used for a country house and a personal plot. Residents of cottage settlements are especially interested in rubber tiles. It is also in demand in industrial facilities and public buildings.

The tile is popular not only among private buyers, but also among wholesale customers. It can be supplied to the construction markets and specialized stores. Due to the wide demand, it can be supplied in large quantities. But it is advisable to resolve issues with the supply of tiles in advance.

If you plan to supply tiles in small quantities, advertising in local newspapers where cottage villages are located is effective. If you are planning to create a large production, it is better to find wholesale buyers in advance and reach preliminary agreements, you can even conclude.

The production technology of this type of coating is described in the following video material:

If you have not yet registered an organization, then the easiest this can be done using online services that will help you generate all the necessary documents for free: If you already have an organization and you are thinking about how to facilitate and automate accounting and reporting, then the following online services come to the rescue, which will completely replace an accountant at your plant and save a lot of money and time. All reporting is generated automatically, signed with an electronic signature and sent automatically online. It is ideal for an individual entrepreneur or LLC on the simplified tax system, UTII, PSN, TS, OSNO.
Everything happens in a few clicks, without queues and stress. Try it and you will be surprised how easy it got!

Options for opening this business

If you are attracted to the production of rubber tiles, there are several options for its production. The main difference is the volume of production and the cost of its organization.

Exist the following options production of rubber tiles:

Production of tiles at home;
Production on an industrial scale;

Mini plants

One of the best options is to produce rubber tiles using a mini factory. It is represented by highly profitable and fast payback equipment, which is distinguished by a cold forming method.

For such a plant would need 80-100 sq. m. area and 3-4 workers per shift. In this case, the energy consumption is 15 kW/h. With such a set of equipment, you can offer customers a fairly large range of coatings. It becomes possible to make tiles of different shapes, parameters and colors.

Production at home

This is the most budget option. This results in high-quality products with a large time investment.

If you can't get help, the amount of material produced will be small. But in this case, you can work under the order. This rubber tile manufacturing option is a great start for a promising one.

Instructions for this type of production are set out in the following video clip:

Production on an industrial scale

This is a great option for those who have a lot of capital. With this production option, it is necessary to lay down various parameters and tile formats.

Provide a variety of pigments to offer your potential customers a wide range of products. Here it is important to think over in advance the issues of marketing and advertising products. You will also need to hire a large number of employees.

Franchise

This is a good option for those who have capital, but do not have sufficient business experience and their own developments.

To do this, you need to choose a successful company offering the production of rubber tiles on a franchise basis. At the same time, the company offers you regular consultations and advice on organizing a business.

You will use trusted suppliers of raw materials and equipment. You will also be given the opportunity to attract customers according to proven schemes.

Production technology

The production of black and multi-colored rubber crumb tiles is different. When the adhesive composition is added to the dye, the cost increases. For this reason, colored products are more expensive. So, the retail price of paving slabs is 1,500 rubles per 1 sq. m.

Manufacturing technology includes next steps:

Preparatory. At this stage, metal bead rings are removed from used car tires. Then, with the help of cryogenic technologies, they are subjected to mechanical processing. As a result of grinding, crumb rubber is obtained with a fraction from 1 to 4 mm.
Making a mixture. Here special mixers are used. Thanks to the use of a polyurethane binder, a homogeneous mixture is prepared. Colored pigments are added to it, which allow you to give the coating various shades.
Pressing. Thanks to the use of a vulcanizing press, it becomes possible to obtain products of the desired density and thickness. Today, hot or cold pressing is used.

With the hot production method, production lines cost 4 times cheaper. And with an increase in production, it is enough to buy an additional mold or an additional press. The cold method allows you to increase work productivity.

Equipment overview

The best option to start production is to purchase equipment from one reliable supplier.

To start full production you will need the following equipment:

Mixer for mixing;
Hydraulic Press;
A set of molds for the production of finished products;
Thermal cabinet;
Fixing stands for tiles;
Forming table;
Conductor for technological holes;
Mixer platform.

Full cost The set of equipment includes about 2 million rubles. At the same time, commissioning works are also carried out here.

Purchase of the necessary raw materials

The main raw material for the production of rubber tiles is rubber crumb. And glue is used as a binder. Rubber crumb can be purchased from a reliable supplier. Its average cost is 19 thousand rubles per ton.

Polyurethane glue for hot pressing costs 140-170 rubles per 1 kg. Glue for cold pressing costs 170-200 rubles per 1 kg. Be especially careful when buying glue. In many ways, the strength of the finished tile depends on it.

Dyes are also actively used in the production of tiles. They allow you to give products the desired shade and aesthetic appearance. Depending on the chosen shade, the dye can cost 80-190 rubles per 1 kg.

Premises selection

When choosing a production facility, the best choices are warehouse or production facilities in the suburbs or in industrial areas. Ideal are premises located in a slight distance from big cities or metropolitan areas. The cost of rent and convenient transport interchange are important.

Room area depends on the quantity and dimensions of the equipment, as well as on the planned production volumes. For a mini-factory, a workshop of 100 square meters is enough. m. The minimum ceiling height should be 3 meters. It is important that the room is well heated and supplied with water. A connection to a power supply with a voltage of 380 V is required.

It is also necessary to allocate separate areas for finished products and raw materials. For this, a warehouse is used. It does not require a room, and the area of \u200b\u200bthe room should be at least 100 square meters. m. Separate premises for the office and staff will be required. In advance, you need to take care of the requirements of the SES and the fire department.

Allocate norms to which the premises for work must correspond:

Ceiling height from 3 meters.
Heating in the cold season at a level of not less than +15 degrees.
The presence of a flat base for the correct installation of equipment.
The building must be located at least 300 meters from residential buildings.
Good electrical wiring and connection to the network must be at least 20 kW.

Possible risks of this enterprise

There are not only advantages of producing rubber tiles, but also possible risks. First of all, this production is associated with a shortage of specialists who are well acquainted with the production technology. The problem can be solved in two ways - to find a good technologist or personally teach employees how to work. But in the latter case, you yourself need to have sufficient knowledge and skills.

Seasonality has a significant effect. Rubber tiles can be used not only on the street, but also in the premises of garages and car services, premises for keeping animals, as well as near swimming pools and in sports halls. It is optimal to start production in late winter and early spring. In autumn, you can sell the maximum production for the improvement of the streets.

For the good functioning of enterprises, it is necessary to maintain the availability of raw materials at a sufficient level. As a rule, for an average production, the stock should be about 100 tons. If it is not provided at the proper level, the production process may stop.

The biggest risk is the possibility of equipment failure. It is for this reason that it is recommended to be vigilant when choosing and purchasing equipment. Every day of equipment downtime can result in losses and expenses for paying staff without real work.

In addition, it is important to ensure the timely sale of products.

Financial part

Calculation of the cost of production per 1 square. m. rubber tiles with a thickness of 40 mm and with dimensions of 500x500 mm will be as follows:

Thus, expenses amount to 776 rubles. The market value is 1350 rubles per 1 sq. m. m. of finished products.

The approximate daily profit is 16.5 thousand rubles. And the monthly amount is 360 thousand rubles. is 145 working days with a profitability of 40%.

As a result, the production of rubber tiles remains relevant and in demand. With a competent approach and the availability of initial capital, you can successfully implement this business in the shortest possible time. The main thing is to have a sufficient area, the necessary equipment and high-quality raw materials.

An overview of equipment for the production of rubber tiles is presented in this 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 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

Street paving slabs (gray or black);
Tiles for the garden plot (most often green, the same color as the grass);
For playgrounds (colorful, bright);
For sports grounds (with markings corresponding to different sports);
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:

hot pressing technique.
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 won’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:

Mixing glue and rubber crumbs in special industrial mixers (preparation of raw materials).
The resulting mass is placed in prepared molds.
The press forms plates with a pressure of more than 5 tons.
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).
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.

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.

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.

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 salaries.

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.

Useful article? Don't miss out on new ones!
Enter your e-mail and receive new articles by mail