Equipment for the production of rubber tiles price. Production of rubber tiles as a business: calculations Cold process rubber tile production technology

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We offer equipment for production rubber tiles and rubber floor coverings based on crumb rubber. All equipment is produced by our company and is fully adapted to the wishes of customers. You can buy the set of equipment you are interested in for the production of rubber tiles and other floor coverings from our company at an affordable price.

On modified lines for the production of rubber tiles offered by our company, you can produce: seamless floor coverings, borders, running paths, paving slabs, paving stones, step overlays, sports, entrance mats based on rubber crumbs and much more.

Equipment for the production of rubber tiles ( rubber coverings) is a popular and highly profitable production, the products of which are in great demand. Rubber tiles are produced using the cold pressing method, which allows us to obtain high quality products.

We suggest studying the characteristics of high-quality equipment for the production of rubber tiles, as well as additional equipment and components necessary for the production of rubber floor coverings.

A set of equipment for the production of rubber tiles "ARFC OPTIMAL" allows you to significantly expand the range of products. This kit can produce up to 7 types of high-quality rubber coatings.

Equipment for the production of rubber tiles

Our company offers equipment for the production of rubber tiles of various capacities. You can buy equipment for the production of products from crumb rubber from us at affordable price. Starting a rubber tile business is easier than you think. Contact our company and our specialists will offer you the necessary set of equipment for the production of rubber tiles, paving stones, borders and seamless coatings based on crumb rubber for children's and sports grounds according to your budget.

Fractional crumb rubber is the basic raw material for the manufacture of tiles and rubber coatings. This raw material is actually taken from waste; more precisely, it is extracted by recycling old worn-out car tires. Car tires are made from fairly expensive high-quality components (various oils, synthetic rubber, fillers), since these products must withstand enormous loads for a very long period of time.

Of all existing species Tire rubber, by its structure, is distinguished by its high strength and durability. Such rubber easily tolerates acid and alkaline solutions on its surface, is very elastic, does not stretch, does not bend and can withstand temperatures from -45 to + 60 degrees.

raw materials:
Automotive crumbs (or crushed rubber - RD) - are obtained by processing worn-out tires of other rubber goods. Its price depends on such indicators as: quality, manufacturing method, dimensions, place of manufacture and sale. In Russia, the retail price for crumbs ranges from 6-15 rubles per kilogram.

Places where crumb rubber is produced:
- factories that process car tires into crumbs as the main raw material;
- for by-product production at rubber goods factories
- factories that retread tires by roughening them (tread treatment), as a production waste.

Crumb rubber fractions used:
Fractions of crumb rubber vary from 0.1 mm to 10 mm and directly depend on their purpose. Thus, small fractions (0.1 - 4 mm) are mainly used in the production of colorless (black) or colored single-layer products. In the manufacture of lower colored layers, mainly larger fractions (2-10 mm) are used. Most often, they are cheaper in comparison with smaller fractions, so they may contain textile or metal inclusions. The production of tiles with two layers (an upper thin colored layer, a lower dark layer with larger fractions of crumbs) is acceptable and relevant when the initial thickness of the product exceeds 1.5 cm.

Layering allows you to reduce the cost of the product due to the following points:
. Inclusion of crumbs into the cheap coarse fraction. Such crumbs may contain textile or other inclusions.
. Save on paint - the bottom layer remains black.
. Larger crumb fractions require a smaller amount of binder for crosslinking, which is carried out by enveloping the surface of the crumb particle
. The absence of a dye allows you to use less binder to crosslink the particles, since the mixture dries out in the colored crumbs.

Equipment and raw materials (prices)

The line that produces rubber coatings has the following set of equipment:

Volcanic press with a capacity of up to 100 m² per day. Price - approximately 350 thousand rubles;

Pressing forms. Cost - 30 thousand rubles apiece;

Drying chamber (for a mini business, it is possible to make it yourself), price from 100,000 rubles.

Raw materials:

Crumb rubber - black (17 thousand rubles per ton), colored (from 23 to 35 thousand);
. polyurethane glue - 140 rub/kg;
. dyes - 7 rubles per kg;

Electricity consumption by the line is 15 15 kW/h.

Coatings can be made:
- both soft and hard in density;
- waterproof, or with water passage (drainage);
- thin and thick;
- as colorless (black), colored, or black with inclusions different color;
- with good grip and more slippery;
- with or without a pattern;
- single-layer or with several layers;
- for laying on a soft base (ground) or hard;
- with or without connections (sleeve, lock).

Rubber paving slabs are often laid parallel to regular paving slabs. It is for this combination that rubber coverings of similar sizes and shapes are created as regular paving slabs.

Premises for a mini tile production workshop.
The criteria by which rubber coatings are produced (provided that the equipment is optimal and has an average level of productivity):

General axioms:

1. Glue consumption.
§ The amount of binder is inversely related to the crumb fraction. The smaller the crumb, the more binder is needed for crosslinking. The larger, the smaller.
§ Dyes dry out the glue. Because of this, its amount in the black coating is smaller.
§ The higher the density of the product, the less glue is needed.
2. Average glue consumption for manufacturing various coatings from 4 to 12% depending on the presence/absence of dye, density of materials, quality of glue, and size of tire chips used.

For example, to make a colored coating Mat 500*500*16mm (from fine crumbs) you need 6% dye and 5% glue from the amount of rubber crumbs.
a) Black coating (crumb size - 4-10mm) - 4% glue.
b) Black coating (crumb size - 2-3 mm) - 5% glue.
c) Black coating (crumb size - 1.2-1.8 mm) - 6% glue.
d) Color coating (crumb size - 1.2-1.8 mm) - 7-9% glue.
3. Water resistance increases, the smaller the fraction of rubber crumb and the higher the pressure.
4. The larger the crumb, the faster the color of the product will be lost due to abrasion.
5. The larger the crumbs, the stronger the coating, but the thickness of the coating must be maintained.
6. Thick coatings (2 cm or more) are best made in two layers. For the upper part, use fine-fraction crumbs; for the lower part, use cheaper coarse-fraction crumbs (5-12 mm) with possible foreign inclusions. Each layer has its own proportions of glue. Each layer is mixed in different containers.
7. It is recommended to produce products of the same thickness on one pressing mechanism, regardless of the configuration, since thickness affects the operating time of the press (than thinner product, the faster its formation takes place).

Additional accessories for production.

Trolley for transporting raw materials (crumbs, dye).
- A trolley with a special tripod to transport containers with glue.
- Scales to weigh components (50 kg electronic scales are best).
- Trowels for uniform laying of coatings.
- Special mugs and scoops for measuring, depending on the standard of the product.
- Mixing glue and dye drill with attachments.

Price for selling rubber plates:

One pack
100 tiles - 57 thousand rubles.

Cost of 1 m² - 1,584 rubles.
Price of 1 slab - 570 rub.
The minimum quantity is 100 slabs (25 m²).

Sales of products.

For coating on production lines, in warehouses, or as a rubber coating for garages;
- used in areas near skating rinks, locker rooms, playgrounds;
- in combination with paving slabs;
- as a coating for various sports complexes or children's playgrounds;
- on farms, livestock production facilities;
- on roofs, terraces
- in baths and other places.

As we can see, the production of such products is part of the ecosystem, producing high-quality safety products - rubber tiles or crumb coating.

Production of tiles from rubber crumbs:

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

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

Rubber tiles are becoming more and more wide application. Today they lay out sidewalks and paths with it. adjacent areas, sports and children's playgrounds, summer cottages, stairs and much more.

The production of rubber tiles is a business for the future. This suggests that the material cannot but be in demand. Therefore, more and more enterprises producing rubber coatings are appearing on the market. Entrance fees to the business start at $150,000. The main costs go to the acquisition of the line, commissioning and development of the 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 low-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 80 mm thick). The average productivity of modern lines ranges from 1000 to 3000 sq.m. per month. It is not difficult to calculate the potential turnover of even a mini-enterprise. It ranges from 1.0 to 4.0 million rubles per month.

Rubber tile production technology

There are two common technologies for producing rubber tiles:

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

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

The hot pressing method is used by those manufacturers who decide to save on purchases. expensive equipment. Today we are actively offering our entrepreneurs lines made in China. Although the lines do have high productivity and are much cheaper than their analogues, the rubber tiles produced using such equipment are of very low quality.

The point is that under the influence high temperatures the tiles get a persistent smell of burnt rubber. As a result, it emits not only bad smell, but substances harmful to humans. In addition, the product obtained in this way will be short-lived, hard and fragile. As a result of operation, such tiles quickly collapse under the influence of environment.

Despite low quality resulting products and questionable safety, many continue to use the hot pressing method. This is explained by two main reasons:

• low cost of equipment, which means a lower entrance ticket to the business;
• lower costs for raw materials, since the process of melting rubber reduces the consumption of polyurethane.

As a result of this, products are obtained at a low cost and a competitive price in the market. But there are no prospects for a business built on this technology. Having purchased tiles once, the client, convinced of the low quality of the products, will no longer place a repeat order.

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

The cold press production process looks like this: in the following way: at the first stage, the components of the future product are mixed using mixers. Next, the raw materials are placed in molds s. 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 forms moves to drying chamber, where the products are kept for 4-6 hours at a temperature of 60 degrees. Upon completion of 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). Crumb rubber is purchased from suppliers. The average price is 19,000 rubles/ton. Polyurethane glue for hot pressing costs from 140 to 170 rubles per kilogram, for cold pressing - from 170 to 200 rubles / kg. You should approach the purchase of this component very carefully, because the strength of the connecting component depends on the quality of the connecting component. finished product.

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

Premises and equipment

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

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

No matter what configuration the line is supplied in, an area of ​​80 sq. m. is required to accommodate it. m. The room must be heated, well ventilated and with sufficient electrical power (machines consume 15 kW/hour).

Production of rubber tiles - video

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

This business plan has been developed taking into account the acquisition of a line for the production of safety rubber tiles of the "ARFC" model. 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. Indicators may vary, so the draft business plan may be changed to take into account the specific conditions of the region.

Rubber Tile Production Project Summary

Project name.

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

Technological solution.

Line for the production of safety rubber tiles.

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

Investment needs:

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

Production time(from the moment of signing the line purchase and sale agreement until commissioning)

20-40 days excluding delivery time

Products that are 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. Tile 350*350 mm, thickness 20 and 30 mm with a pattern on the surface “Grid” and “Cobweb”, with a corrugated base;
3. Paving stones “Brick”, thickness 20 and 40 mm;
4. Coil paving stones, thickness 20 and 40 mm;
5. Paving stones “Wave”, thickness 20 and 40 mm;
6. Rubber curb, length 500mm.

Main consumers of products.

Large consumers include: sports organizations, individuals.

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

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

2. Production of rubber tiles, paving stones and borders that meet the quality requirements of technical specifications finished products.

Description of the rubber tile production project

Objective of the project:

Creation of production of safety rubber tiles using the Alfa-SPK technological line; 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.

As the main consumers - construction organizations, social institutions etc.

Initial data:

The main range of manufactured rubber tiles:

The following items prevail in the total number of orders:

• rubber tiles 500*500 thickness 40 mm
• rubber tiles 500*500, 16 mm thick.

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

Main settings

Work can be carried out in two shifts, the duration of the shift is 8 - 10 hours.

The productivity of one shift is up to 60 m2.

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

The calculation was made taking into account the production of 1320 sq.m. (60 sq.m*22 working days) of 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 the equipment set, not including the cost of commissioning, is: RUB 1,750,000, incl. VAT 18%.

Calculation of the required number of personnel

To implement the project, at the initial stage, the following personnel plan is proposed.

Personnel plan for equipment operation in 1 shift.

Offered average number staff - 3 people.

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

Required production space for placing 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 m2 of production space and a 100 m2 warehouse (may be located outside the premises and not heated). The production premises 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.

• Rubber crumbs
• Polyurethane binder
• Coloring pigment

Average price in Russia:

• Rubber crumbs - 14 rubles. per kg,
• Polyurethane binder - 200 rub. per kg,
• Coloring pigment - 90 rub. 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 crumbs - 25.5 kg * 14 rubles = 357 rubles.
  Polyurethane binder (Glue) - 2.40*200 = 480 rub.
  Pigment - 0.35*90 = 31.5 rubles
  RUB 865.05.
• Products with a thickness of 16 mm (density 850 kg per cubic meter):
  Rubber crumbs - 12.5 kg at a price of 14 rubles. = 175 rub.
  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.

• Thermal 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 42 kW/shift

The cost of electricity for 1 kW/h is 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 PROJECT PROFITABILITY.

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

Minimum productivity of rubber tiles 500*500*40 mm in two shifts = 1,000 square meters tiles

SALE OF 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 PRODUCTION OF RUBBER TILES

The following operating expenses are planned for the operation of a rubber tile production company:

· Expenses for wages personnel, also insurance premiums no more 150,000 rubles per month.

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

· Household expenses, transport services and so on in size 10 thousand. rubles per month;

· Costs for electricity consumption are separately included, which largely depend on production load (average power consumption on production equipment is 10 kW/h - calculated relative to the volume of rubber tile production) at the rate of 4.5 rubles/kW = about 10,000 rubles per month.

Rental payments for a premises of 100 square meters will be 150 rubles/sq.m. per month; = no more than 15,000 rubles per month.

Cost of production of 1000 squares of rubber tiles 500*500*40 mm(glue, crumb rubber, 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 profit).

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

Please pay special attention to the fact that these indicators for the production of rubber tiles are taken in minimum terms. Depending on working conditions, the specifics of the region, seasonality, work on 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

Crumb rubber is considered the main material for creating tiles and coatings. The raw materials are taken from waste, which is obtained by recycling old, worn-out car tires. They are made from durable components that extend 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

Rubber tiles contain crushed pieces of rubber. The products do not break or crumble. Their advantages include:

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

The products can be used in industrial and residential buildings. 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 decoration garden paths, as flooring terraces and country houses.

The products are used on sports and children's playgrounds. The tiles look beautiful in any area. The rubber surface is rough and perfectly repels water. 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. The products are especially interesting for residents of cottage villages. The products are necessary in public and industrial buildings.

The tiles will be in demand among private and wholesale clients. There is a possibility of delivery to markets and stores. Due to high demand, it is possible to supply in large quantities. Only this issue needs to be dealt with in advance in order to think through the advertising campaign.

Business options

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

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

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

Mini-factories

Rubber tile production plant will be the best option. It is highly profitable, developed with quick payback equipment, which operates on the basis of the cold forming method.

To start a business you need 80-100 sq.m. and 3-4 employees per shift. Energy consumption will be 15 kW/hour. In this case, it is possible to offer customers a large range of coatings. Possibility of making tiles various forms, parameters and colors.

Making at home

Rubber production paving slabs can also be done at home. This a budget option. Products will be manufactured for a long time. If there are no assistants, then you won’t be able to produce a lot of products. But then there is the opportunity to work to order. This will be the start for business development.

Industrial business

If you have a lot of capital, you can start the production of tiles from rubber crumbs. In this case, it is possible to specify different parameters and product formats. Various pigments will be required so that customers can get a large number of products. It is important to first resolve issues with sales and advertising of goods. Many workers are also needed.

Franchise

Such a production of paving slabs from rubber crumbs can be opened if you have the funds, but no experience in running a business. 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 cost of production of black and multi-colored rubber tiles differs significantly. If the dye contains adhesive composition, the cost increases. Therefore, colored products will be expensive. Retail price paving slabs will cost about 1,500 rubles per sq.m. The manufacturing technology involves the following stages:

1. Preparation. Metal bead rings are removed from old car tires. Mechanical processing is then carried out using cryogenic technology. The result will be crumbs with a fraction of 1-4 mm.
2. Getting the mixture. In this case, special mixers are used. A polyurethane binder is required 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. Nowadays hot and cold pressing are in demand. With the hot manufacturing method production lines are 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 tiles from crumb rubber. It should be purchased from a trusted supplier. The launch of a full-fledged plant occurs only if there is:

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

Equipment for the production of rubber tiles will cost approximately 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 binding component will be glue. You should purchase raw materials from a reliable supplier. Its average price is 19 thousand rubles per ton.

The cost of hot-pressed polyurethane glue is 140-170 rubles per 1 kg. And for glue for cold pressing you will have to pay 170-200 rubles. Such products must be reliable, since this affects the strength of the products. Dyes are used in the manufacture of tiles. They are required to give the product the required 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 production facility in an industrial area. The object should be located a short distance from major cities. It is important to consider rent and transportation.

The area is determined by the number and size of equipment, production volume. For a mini-workshop you need a room of 100 sq.m. minimum height - 3 meters. You need to choose a heated room where there is water and 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. m. Premises for office and workers are required.

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 of creating products. In this case, you can proceed in two ways - find a technologist or independently train employees in this activity. But then you need to be a professional yourself.

Seasonality plays an important role. Rubber tiles are used outdoors and in car service centers, garages, animal facilities, as well as areas near swimming pools and gyms. It is advisable to open a business in late winter and early spring. In the fall, the products will also be in demand, as the streets are being improved.

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

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

The production of rubber tiles is a popular industry. If you approach business organization wisely, you can make it profitable in a short time. The main thing is to have everything necessary to produce quality products.