Rubber tiles produced by hot and cold methods. rubber tile business
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:
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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.
Exists 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:
In this way, 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:
Fractionated crumb rubber is the basic raw material for rubber tiles and flooring. This raw material is actually taken from waste, or rather, it is obtained by processing old worn tires from cars. Car tires are made from fairly expensive high quality components (various oils, synthetic rubber, fillers), as these products must withstand huge loads for a very long period of time.
Of all the existing types of rubber, tire rubber, in its structure, stands out for its high strength and durability. Such rubber easily tolerates the ingress of acid and alkaline solutions on its surface, is very elastic, does not stretch, does not bend and is able to withstand temperatures from -45 to + 60 degrees.
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raw material:
Automobile crumb (or crushed rubber - RD) - is mined as a result of the processing of worn tires of other rubber goods. Its price depends on such indicators as: quality, method of manufacture, dimensions, place of manufacture and sale. In Russia, the retail price per crumb fluctuates between 6-15 rubles per kilogram.
Places of rubber crumb production:
- factories that process car tires into crumbs as the main raw material;
- for side production at RTI factories
- factories that restore tires by roughening them (tread processing), as a waste product.
Used crumb rubber fractions:
Fractions of crumb rubber vary from 0.1 mm to 10 mm and directly depend on their purpose. Thus, fractions of a small type (0.1 - 4 mm) are mainly used in the production of colorless (black) or colored single-layer products. In the manufacture of the lower colored layers, mainly fractions of a larger nature (2-10 mm) are used. Most often, they are cheaper compared to smaller fractions, as they may contain textile or metal inclusions. The production of tiles with two layers (the upper thin colored layer, the lower dark layer with large crumb fractions) is acceptable and relevant when the initial thickness of the product exceeds 1.5 cm.
Layering allows you to reduce the cost of the product due to the following points:
. Inclusion in the composition of a cheap large fraction of crumbs. Such a crumb may contain textile or other inclusions.
. The housekeeper on the paint - the bottom layer remains black.
. Larger crumb fractions require a smaller amount of binder for their crosslinking, which is carried out by enveloping the surface of the crumb particle
. The absence of a dye allows the use of less binder for crosslinking the particles, since the mixture dries out in the colored crumb.
Equipment and raw materials (prices)
The line, which produces rubber coatings, has the following set of equipment:
Volcanic press with a capacity of up to 100 m² per day. Price - about 350 thousand rubles;
Press molds. Cost - 30 thousand rubles a piece;
Drying chamber (for a mini business, it is possible to make it yourself), price from 100,000 rubles.
Raw material:
Rubber crumb - black (17 thousand rubles per ton), colored (from 23 to 35 thousand);
. polyurethane glue - 140 rubles / kg;
. dyes - 7 rubles per kg;
Consumption of electricity by the line - 15 15 kW/h.
Coatings can be made:
- both soft and hard in density;
- waterproof, or with the passage of water (drainage);
- thin and thick;
- as colorless (black), colored, or black with patches of different colors;
- with good grip, and more slippery;
- with or without a pattern;
- single-layer or with several layers;
- for laying on a soft base (soil) or hard;
- with connections (sleeve, lock) or without them.
Paving rubber tiles are often laid in parallel with conventional paving slabs. It is for this combination that rubber coatings of similar sizes and shapes are created as ordinary pavement tiles.
A room for a mini tile production workshop.
Criteria for the production of rubber coatings (provided that the equipment is optimal and has an average level of performance):
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1. The area occupied by the technical line - 70-100 m² (not counting the warehouse); Equipment and materials are placed by sectors: |
General axioms:
1. Glue consumption.
§ The amount of binder is inversely related to the crumb fraction. The smaller the crumb, the more binder is needed for crosslinking. The larger, the smaller.
§ Dyes dry the glue. Because of this, its amount in the black coating is smaller.
§ The higher the density of the product, the less glue is needed.
2. The average consumption of glue for the manufacture of various coatings is from 4 to 12%, depending on the presence / absence of dye, the density of the materials, the quality of the adhesive, and the size of the tire crumb used.
For example, to make a color coating Mat 500 * 500 * 16mm (from crumbs of fine fraction), you need 6% dye and 5% glue from the amount of rubber crumb.
a) Black coating (crumb size - 4-10mm) - 4% glue.
b) Black coating (crumb size - 2-3 mm) - 5% glue.
c) Black coating (crumb size - 1.2-1.8 mm) - 6% glue.
d) Color coating (crumb size - 1.2-1.8 mm) - 7-9% glue.
3. Water resistance increases, the smaller the crumb rubber fraction and the higher the pressure.
4. The larger the crumb, the faster the color of the product will be lost due to abrasion.
5. The larger the crumb, the stronger the coating, but the thickness of the coating must be observed.
6. Thick coatings (2 cm or more) are best made in two layers. For the upper part, use a crumb of a fine fraction, for the lower part - a cheaper crumb of a large fraction (5-12 mm) with possible foreign inclusions. Each layer has its own proportions of glue. Each layer is kneaded in different containers.
7. On the same pressing mechanism, it is recommended to produce products of the same thickness, regardless of the configuration, since the thickness affects the time of the press (the thinner the product, the faster its formation).
Additional accessories for production.
Trolley to transport raw materials (crumbs, dye).
- Trolley with a special stand to transport containers with glue.
- Scales to weigh components (preferably 50 kg electronic).
- Trowels for uniform laying of coverings.
- Special mugs and scoops for measuring, depending on the standard of the product.
- Mixing glue and dye drill with nozzles.
Price for the implementation of rubber plates:
One pack
100 tiles - 57 thousand rubles.
The cost of 1 m² is 1,584 rubles.
The price of 1 plate is 570 rubles.
The minimum lot is 100 slabs (25 m²).
Sales of products.
For coating on production lines, in warehouses, or as a rubber coating for garages;
- use in areas near ice rinks, locker rooms, playgrounds;
- in combination with paving slabs;
- as a covering for various sports complexes or children's playgrounds;
- on farms, livestock facilities;
- on roofs, terraces
- in baths and other places.
As you can see, the release of such products is part of an ecosystem, dealing in high-quality safety products - rubber tiles or crumb coating.
Production of crumb rubber tiles:
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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 analogues, rubber tiles on such equipment are of very poor quality.
The fact is that under the influence of high temperatures, the tile gets a persistent smell of burnt rubber. As a result, it emits not only an unpleasant odor, but substances harmful to humans. In addition, the product obtained in this way will be short-lived, hard and brittle. As a result of operation, such a tile quickly collapses under the influence of the environment.
Despite the poor quality of the resulting products and questionable safety, many continue to use the hot pressing method. This is due to two main reasons:
- low cost of equipment, and hence a lower entry ticket to the business;
- lower raw material costs, since the consumption of polyurethane is reduced in the process of melting rubber.
As a result, products are obtained with low cost and competitive price in the market. But there are no prospects for a business built on this technology. Having bought a tile once, the client, convinced of the low quality of the products, will no longer make a second order.
The cold pressing method allows you to get rubber tiles of a completely different quality. Products using this technology are more elastic, flexible and durable. The price for quality is higher equipment costs and reduced line productivity. The difference in price compared to hot presses can be hundreds of thousands of dollars.
The production process by cold pressing is as follows: at the first stage, the components of the future product are mixed using mixers. Next, the raw material is put into molds. Then the molds are loaded under the press, where the molds are compressed with a load of 5 tons. At the next stage, the trolley with molds moves to the drying chamber, where the products are kept for 4-6 hours at a temperature of 60 degrees. After drying, the finished tiles are unloaded onto a special table for quality control.
Raw materials for the production of rubber tiles
The main raw materials for the production of rubber tiles are crumb rubber and polyurethane binder (glue). Rubber crumb is purchased from suppliers. The average price is 19,000 rubles/ton. Polyurethane adhesive for hot pressing costs from 140 to 170 rubles per kilogram, for cold pressing - from 170 to 200 rubles / kg. The purchase of this component should be approached very carefully, because the strength of the finished product depends on the quality of the binder component.
To give products an aesthetic appearance, dyes are actively used in the production of tiles. Depending on the type of color, the cost of the dye varies from 80 to 190 rubles/kg.
Premises and equipment
The price of a set of equipment depends on the production technology. A mini-factory for the production of rubber tiles by hot pressing will cost from 1.5 to 2.5 million rubles. Practically, 90% of line suppliers are Chinese manufacturers. The capacity of the hot pressing line is from 50 to 100 sq.m. per shift and can be serviced by 4-5 workers.
The cost of a set of equipment using cold forming technology starts from 3.5 million rubles. The production line consists of a hydraulic press, mixers, a heating cabinet, a mold, stands for fixing tiles, molding tables, an electric heater and auxiliary equipment (scales, trolleys, working equipment).
Whatever configuration the line is supplied with, it will require an area of 80 sq. m. The room must be heated, well ventilated and with sufficient electrical power (machines consume 15 kW / h).
Production of rubber tiles - video
With the rapid growth in demand for rubber tiles, there is a low number of manufacturers on the market. This means that your rubber tile business will develop with little competition, and therefore has a chance of early success.
Where is rubber tiles used?
Initially, the production of rubber tiles was organized in order to cover playgrounds with a non-traumatic coating. Then it began to be used on other sports grounds, halls and even in swimming pools. Today, the use of tiles has expanded significantly.
The main advantages of this coverage are:
- non-slip surface;
- demonstrates high orthopedic and soundproof properties;
- resistant to temperature extremes, frost-resistant;
- does not lose aesthetic properties during prolonged use;
- easy to install, easy care;
- does not break, does not crumble, durable;
- service life - at least 10 years;
- variety in color and shape.
Production room
To start the production of crumb rubber tiles, you need to find a suitable room. The main requirements for it are as follows:
- ceiling height - from 3 m;
- heating, so that the temperature inside the room is from 15 ° C;
- industrial power grid (from 20 kW);
- flat floor for equipment installation;
- total area - from 80 sq. m.
- the workshop is located at least 300 meters from residential buildings.
Raw materials for production
The production of rubber tiles will require the purchase of such materials:
- dyes (7 rubles/kg);
- polyurethane glue (140 rubles / kg);
- rubber crumb: colored - 23-35 thousand rubles / ton, black - 17 thousand rubles / ton.
The main raw material is crumb rubber. Today, the production of crumb rubber uses mostly used tires. Other used rubber products are sometimes used. The production of crumb rubber is as follows. On a special site near the place where the production of crumb rubber takes place, all used rubber products are stored. From there, they are delivered by forklift to the workshop and loaded into special equipment for the processing of rubber products. There, the production of rubber crumb of the established fraction takes place, which is packed in bags and transported to warehouses by the same forklift. At this stage, the press is not needed.
The production of crumb rubber can be organized independently. This will greatly reduce the cost of your business, focused on the production of rubber coatings. But at first, contractors can be found for the production of crumb rubber.
Technology for the production of rubber tiles
Depending on what coatings are planned to be produced, crumbs of a certain fraction are used. For example, if a two-layer tile is produced, then the top layer is prepared from fine colored rubber. Lower, main and dense - from black large (2-10 mm). For each of the layers, a separate production of rubber crumb is provided. At the same time, the top layer is softer and cleaner. The composition of the bottom may include metal elements, textile inclusions, and so on.
The first stage of production involves the preparation of the mixture. Glue and pigment are added to the raw materials, and all this is well mixed. To make the desired tiles, raw materials must be poured into molds. They have the appropriate shape and size. Then a special press produces the formation of products. After this, the product must be removed from the molds and inspect how well the work has been done. High-quality tiles are packed and sent to the warehouse.
Equipment for the production of rubber tiles
If your business plan involves the production of raw materials, you will need equipment for the production of rubber crumb. It can be made in two ways: classic mechanical or new, shock wave. For mechanical equipment for the production of crumb rubber will be cheaper. It can be installed in any workshop. Under the second method, it is necessary to convert the room, but the equipment will require less space, and productivity will be higher.
Be sure your spending plan should include the purchase of equipment for the production of rubber tiles. It includes the following components:
- drying chamber (from 100 thousand rubles);
- two mixers for raw materials (100-200 thousand rubles);
- molds (30 thousand rubles / piece);
- volcanic press, which produces up to 100 m² of tiles per day (350 thousand rubles).
This should be your equipment procurement plan. But today, companies offer ready-made production lines that can be operated in one or two shifts. Their productivity can be a minimum of a thousand or a maximum of 3 thousand m² per month. The cost of such a line is from 2 million rubles. It consists of:
- fixing stand;
- Press forms;
- molding table;
- heating cabinet;
- Hydraulic Press;
- vibrating table;
- screw conveyor;
- cutting machine;
- cyclone;
- wheel bead cutter;
- chip-producing machine;
- belt conveyor;
- shredding machine.
The main advantage of the line is saving on the labor of workers. 3-4 operators can serve it.
Also, the cost plan should include the purchase of additional equipment:
- trolley for transportation of raw materials;
- trolley for transporting glue;
- electronic balance;
- trowels, scoops, mugs;
- drill with nozzles.
Staff
Separately, the business plan provides for the formation of staff. It directly depends on the number of shifts for which production is designed. With continuous work, you can work in three shifts all week. Then 8 workers should be involved in the production.
Financial plan
The expenditure plan includes:
- rent of premises - 3-6 thousand rubles;
- delivery and installation of equipment - from 2 thousand rubles;
- equipment - 70-150 thousand dollars;
- salary - 5 thousand dollars (including accounting and sales department);
- purchase of crumbs (black - 17 thousand rubles / ton, non-ferrous - 23-25 thousand rubles).
The income plan consists of selling tiles for about $500 per ton. It is possible to produce 72 tons of products per month in three shifts. In addition, the income plan can include the sale of metal, which is collected during the processing of tires. This is another 3.6 thousand dollars (about 18 tons per month). In total, the revenue part will be about 36 thousand dollars.
As statistics show, investments can pay off in six months, and on average - in a year.
How to organize the production of rubber tiles - a popular durable building material? For the Russian market, this is a fairly new line of business, promising to recoup the invested capital in six months. What equipment is required, how many employees will work in production and what makes rubber tiles successful in the market - we tell below.
This is a fairly new type of building material, widely used for finishing a variety of surfaces. The raw material for such tiles is crumb rubber, which is obtained, as a rule, during the processing of used car tires.
This type of material is distinguished by several useful and even unique properties at once:
- Environmental friendliness. The basis of rubber tiles is rubber waste, most often recycled car tires. The law requires you to take them to special processing centers and pay for disposal. But in practice, motorists refuse to act legally. Waste tires end up in regular landfills, where they pollute the environment for decades. Considering the complexity of recycling such types of waste for mass consumers and the unwillingness to pay for it, organizing the acceptance of tires for recycling for a small fee will arouse significant interest.
- The service life of the rubber coating reaches 15-20 years. It withstands frosts down to -40 degrees and heat over +40 degrees without deformation. Does not fade in the sun and is not affected by any other natural factors. Moisture quickly evaporates from the low-porous surface of the tile. An ice crust does not form on it, snow does not stick and is easily peeled off.
- Rubber crumb products and coatings from it are safe from the point of view of injuries, as they have a non-slip rough surface (especially textural varieties) even when wet. Therefore, they can be widely used in sports facilities or playgrounds.
- Rubber tiles are easy to lay on their own, and you can use them immediately after installation (unlike, for example, concrete, which will dry for several days).
- Sound absorption - the coating of rubber particles absorbs sounds and noise, therefore it is often used for finishing industrial premises.
- Modern tiles are not only gray-black, but also of any color and size, which allows them to be used in landscape design and for design solutions.
As for the disadvantages of rubber tiles, among them are poor fire resistance and higher cost compared to other types of coatings. The benefits clearly outweigh the drawbacks, so rubber coating is rapidly gaining a leading position in the market of finishing materials.
Smooth varieties of tiles should not be used for finishing outdoor areas and places where constant humidity is expected (by the pools) - it is better to prefer options with a pronounced texture.
In workshops and warehouses where there is a high risk of fire, it is also advisable to completely abandon the crumb rubber coating in favor of ceramic tiles.
Where is rubber tiles used?
A number of various positive properties provided rubber tiles with popularity in various fields. Among the areas of use of this material are:
- decoration of street alleys, adjacent territories, pedestrian and bicycle paths;
- coating of running tracks in stadiums;
- finishing the paths to the pools, floors in the gyms;
- flooring in workshops, garages;
- decoration of playgrounds, outdoor play areas.
Among the potential customers of such coatings are both private retail customers planning the improvement of courtyards or summer cottages, as well as sports organizations, management companies, state and municipal institutions (through the public procurement system).
The high price of rubber tiles is justified by its multiple positive characteristics and a multi-stage manufacturing process.
How much does rubber particle coating cost
The high price of rubber tiles is justified by its multiple positive characteristics and a multi-stage manufacturing process. For the manufacture of color options, a variety of dyes are also used, which increase its cost.
On average, the price of a gray-black tile is 1,500 rubles per square meter. The cost increases depending on the shade and texture of the coating. In addition to color, the price of a rubber tile is affected by its shape and texture (smooth - cheaper, embossed - more expensive), as well as thickness (the thicker, the higher the cost).
What are the stages of the technological process of coating production
The production of rubber tiles includes several stages:
- Procurement of raw materials, for example, recycling of old car tires to the state of crumb rubber. The particle diameter must not exceed 4 mm.
- Preparation of a mixture for future coating. Obtained by mixing in a certain proportion of rubber particles, binders and dyes (optional).
- Filling the mixture into molds and pressing.
- Heat treatment and drying for 6 hours. After pressing, the rubber tiles are placed in the so-called "drying chamber", where the temperature is maintained at about 60 degrees and high humidity. Under such conditions, all components (particles and binders) are tightly bound to each other as a result of chemical reactions.
- Unloading the finished tiles from the molds, cutting and drilling if necessary. Sometimes, at the request of the customer, special holes are drilled in the finished rugs, which simplify their installation.
- Quality control, delivery of products to customers or retail outlets.
Equipment for the production of rubber tiles
Now let's consider what equipment for the production of rubber tiles on an industrial scale needs to be purchased by a start-up enterprise. The list will be quite extensive, and its total cost is approaching two million rubles.
- Equipment for processing tires (other raw materials) into crumb rubber. Mixers or mixers are usually used, which are installed on special tables. The price depends on the capacity and volume of loading.
- An apparatus for making a rubber compound that mixes crumbs with binders and dyes.
- Compression molds (from 20 pieces) and a molding table - here the mixture is loaded into molds and completed. It is advisable to purchase several types of molds: the simplest smooth, textured, "sports mats". For a small enterprise, 3-4 mold options are enough, for larger ones - about 10.
- Hydraulic Press.
- Thermal chamber - for drying prepared rubber tiles. The purchase of such a chamber is preferable to the organization of drying in a separate room, since the chamber stably maintains the required temperature and humidity.
- Scales.
- Related equipment - trolleys, mounting tools, temperature sensor (if necessary), storage containers.
- Equipment for cutting and drilling finished rugs.
- Packaging technology (optional).
The most profitable option for purchasing equipment for the manufacture of rubber crumb coatings is to purchase a ready-made kit. Currently, many companies offer different sets of all the necessary equipment at a price of 480 thousand rubles (the most minimal set), as well as deliver to the workshop and even install the entire set.
In addition to saving on equipment and shipping, this option guarantees:
- reference and training information (good companies always come with it);
- saving time on independent search and installation of equipment;
- 1 year warranty;
- the ability to quickly repair or replace faulty equipment.
Currently, there are two main methods for the production of rubber tiles, divided depending on the course of the technological process into "hot" and "cold".
Hot and cold pressing: what to choose
Currently, there are two main methods for the production of rubber tiles, divided depending on the course of the technological process into "hot" and "cold". As the names suggest, they differ in the temperature at which molds are pressed. Each has advantages and disadvantages. Which one is better in today's world?
In the more common "hot" pressing, the rubber compound in the mold is exposed to ultra-high temperatures, which melts all the components and binds them together. The only advantage of this method is the higher production speed., because after a hot press, the tiles dry much faster. But practice shows that "hot" tiles are less durable, less durable and also retain the persistent smell of burnt rubber forever.
Cold pressing takes longer than hot pressing. But tiles produced in this way are stronger, operate without wear much longer, and do not have an unpleasant odor. The fact is that at lower temperatures and prolonged pressure (about 5 tons), all components of the rubber mixture bind to each other much more strongly. In modern conditions, "cold" technology is more promising and therefore preferable for novice manufacturers.
What should be the workshop for the production of rubber tiles
If an entrepreneur purchases a ready-made kit and installation of equipment, it is not necessary to think over the layout of the premises on your own. Otherwise, explore the options for floor plans on the Internet. The main recommendations are as follows:
- The total area of the workshop should not be less than 100 square meters, and the ceiling height should not be less than 3 meters.
- All communications must be connected to the workshop, especially a stable power supply (all equipment and, most importantly, the drying chamber are powered by electricity). The room must be equipped with exhaust ventilation.
- Good access roads for trucks, a convenient area for unloading and loading products.
- The room should be divided into working areas: a storage area for raw materials (not only crumbs, but also, for example, used tires, binders and dyes), a mixture preparation area (grinding and mixing); area for working with molds, a drying chamber, a warehouse for finished tiles.
- To start work, the workshop must pass sanitary and fire safety checks. Without appropriate permits, production should not be started.
The basis of rubber tiles is a crumb, obtained, as a rule, from recycled car tires.
Raw materials for rubber tiles: where to buy and how to save
The basis of rubber tiles is a crumb, obtained, as a rule, from recycled car tires. A good option would be to organize a collection point for unwanted tires for a nominal fee next to the production workshop. However, only this option will not provide the entrepreneur with a sufficient amount of raw materials.
Therefore, the crumb, like all other components (glue, dyes), should be purchased from wholesale suppliers. Currently, it is more convenient to order all raw materials via the Internet. The price of a ton of crumbs starts from 15 thousand rubles, glue - from 150 to 200 rubles per 1 kilogram, and various dyes - an average of 150 rubles per kilogram.
Rubber flooring workers
To maintain the production line, 3 employees are needed at the same time:
- a worker at the preparation of the mixture;
- an employee working with molds and operating the dryer control panel;
- loader.
Special education for such production is not needed, specialized training in working with equipment and compliance with the technological process is enough. The workers are either supervised by a shift supervisor or a technologist who controls production and product quality.
Costs and payback: how much finance is required to start production and when they will pay off
Starting the production of rubber tiles, including renting a workshop, purchasing raw materials and equipment, requires up to 2 million rubles. You can reduce costs by ordering a ready-made set of equipment from one manufacturer or by finding alternative options for obtaining raw materials (for example, receiving old tires).
For a standard 8-hour working day, a medium-sized workshop produces about 50 square meters of rubber coating, that is, for 20 working days (per month) - 1000 square meters. One meter of finished material costs from 1,500 rubles, that is, you can earn at least 1.5 million rubles per month. With similar rates of production and sales, it is possible to recoup the entire invested capital in 4-6 months.
The payback of a business directly depends not only on the well-established technological process, but also on distribution channels. The more of them, the better. Such an enterprise should:
- accept orders from private clients and commercial firms;
- produce products for building stores or organizations (preferably several);
- participate in tenders in the public procurement system.
If the volume of the drying chamber and storage space allows, to increase productivity, work can be organized in 2-3 shifts. Such rates will make it possible to recoup investments and reach net profit much faster.
Conclusion
The production of rubber tiles promises entrepreneurs good profits, work in a niche with stable demand and growth trends in production. The creation of such a business will require about 2 million rubles, but with the right organization of sales, they will return in six months.
