home Credit Production of crumb rubber as a business. Business plan for recycling tires into crumb rubber with calculations

Production of crumb rubber as a business. Business plan for recycling tires into crumb rubber with calculations

Reforms in the field of environmental protection, which began to be implemented in last years are gradually tightened.

What should natural resource users expect? A complete ban on the disposal of waste tires and car tires is introduced.

This position of legislators should stimulate the development of the industry recycling of waste, the opening of new industries for their modification.

Deserves close attention. low cost, easy way Recycling tires requires the use of special equipment.

Let us consider in more detail the popular types of machine tools and the production lines formed from them, the characteristics of these units and how much they cost.

The technology for the production of crumb rubber from used machine tires is a process of successive grinding of raw materials into small pieces, followed by grinding them into a fine fraction.

Manufacturers offer a wide range of machines for the production of crumb rubber, prices depend on the performance of the equipment.

Single shaft shredders

The principle of operation of a single-shaft plant is based on the grinding of raw materials successively lowering and rising low-speed cutting shaft.

The operation of a rubber shredder is as follows:

Tires are fed into the chamber of the raw material loading shredder, where, under the action of a hydraulic press, they are fed to rotating knives.
The press moves from top to bottom, returning to its original position after reaching the maximum degree of pressure on the shaft.
The crushed raw materials are pressed through special sieves placed under the shaft.

Fastening double-sided knives to screws allows them to be reused after one of the edges is worn out. This design feature allows increase standard service life tire crushers.

Among the advantages of single-shaft rubber shredders, the following can be distinguished:

simple design;
ease of operation;
the possibility of individual use and inclusion in the production line;
processing of thick raw materials.

An example of such equipment is a single-shaft machine for processing rubber and tires into chips from Netmus; the price of the presented equipment varies in the range 120,000 - 2,800,000 rubles.

Twin shaft rubber shredders

Two-shaft tire shredders are designed for cutting raw materials into pieces no larger than 5x5 cm. The shredder blades can process tires from both passenger cars and heavy vehicles.

Principle of operation machine as follows:

A tire is fed into the raw material receiving chamber. The size of the window allows you to load the entire product, the only requirement is the preliminary extraction of the cord.
The shafts of the tire grinder into crumbs rotate in opposite directions. Hooks placed on the rotors grab the raw material and tear it apart.
The crushed raw material is sifted through a sieve, which is a rotating drum. Particles that exceed the size of the sifter cell are thrown into the loading chamber for re-processing.
The finished material after sorting into fractions falls on the conveyor belt and is fed to packaging.

Benefits of using twin-shaft machine for the production of crumb rubber:

the possibility of processing large-sized raw materials;
no need to regrind the blades of the knives when reinstalling them.

The performance of the rubber processing machine directly depends on dimensions end products. So, in the manufacture of tapes and pieces measuring 5x5 cm, the output of 1 machine will be 2 tons / hour and more, with more thorough grinding - up to 2 tons / hour.

No special skills are required from the personnel serving the machines.

Number of auxiliary workers for work in 1 shift - 1-2 people: 1 person - for loading raw materials, 1 person - for reception finished products.

Double shaft tire crusher supplies Russian company TechnoService LLC.

Tire Shredding Plant

Let's consider tire shredding installations on the example of UPSHK equipment from the Tekhnoresursy company.

The installation is a rotating crown with 25 knives mounted on it, brought to a tire clamped in a special cartridge.

Manufacturing process as follows:

Feeding the tire to the clamping drum.
Installing and fixing the tire in the drum manually, or using the lifting mechanism of the installation.
Turn on the drive and start rotating the drum. The unit control system provides 3 rotor speeds. It is advisable to choose them depending on the outer diameter of the tire.
Approximation of the cutting crown rotating in reverse side in relation to the drum. The speed of movement of the crown is set by the attendants and depends on the desired size of the fraction of the finished product - the slower the movement, the finer the rubber crumb.

Rubber is removed from the tire, starting with the outer layer, and before reaching the layers of the cord.

Textile cord can be crushed together with rubber, metal cord is the boundary beyond which the use of the machine is prohibited.

Benefits of using the machine:

successfully replaces the whole tire shredding line;
competitive price;
ease of transportation;
fast installation;
instant connection to the power supply system;
the possibility of processing tires of various sizes;
short term cost recovery.

Maintenance of the installation is carried out by one worker. The production technology itself is very simple and does not require additional training.

For a month, one installation is capable of producing 34 tons of clean rubber crumb.

Prices for such equipment for processing rubber into crumbs start from 770 000 rub.

lines

Integrated approach to problem solving tire recycling is provided by lines for grinding used tires into crumbs.

The complete set of equipment offered by various manufacturers differs little from each other:

bead ring removal device;
guillotine for grinding tires into a tape;
machine for squeezing steel cord;
rollers for the manufacture of crumb rubber;
magnetic and air separators;
vibrating sieve.

Technology tire processing is as follows:

Separation of tires by weight and diameter, cleaning from large contaminants.
Installing the tire in a vise to separate the bead ring from the rubber.
Cutting the resulting rubber into ribbons about 4 cm wide.
Dividing strips into small pieces.
Grinding blanks into crumbs with subsequent supply of products to the conveyor.
Product cleaning in the separation chamber. With the help of the magnetic fields created by the installation, the metal cord particles are separated from the total mass of the crumb. In the air cleaning chamber, due to the formed vortex flows, the final separation of impurities from rubber particles occurs.
Sorting of the obtained products into size fractions.

The finished crumb is packed and can be sent for sale. Larger particles are returned to the conveyor and subjected to repeated grinding.

The line capacity is from 500 kg of raw materials per hour.

To maintain the line, 2-3 people will be required for 1 work shift, while special training in the skills of working with the equipment is not required.

On the market production equipment tire processing lines are presented by manufacturers different countries. Consider the distinctive features of individual brands of equipment.

Tire processing line from the Novokuznetsk company ALPHA SPK "ATR-250" declared by the manufacturer as fully automatic. Human participation is required only if it is necessary to grind especially large tires. Equipment price starts from 5,000,000 rubles. You can study the supplier's offer in more detail on the website.

Factories

Mini-factories for the production of crumbs from rubber tires - best option for those who want to organize the processing of raw materials on a large scale.

Such production will have not only a personal, economic, effect, but also a social one.

New jobs will be created, social tension will decrease.

Benefits of using mini-factories for the production of crumb rubber:

low energy consumption, and hence the cost of produced crumbs;
compactness;
ease of maintenance;
excellent quality of grinding raw materials, allowing you to set up production in one cycle;
environmental friendliness.

Compact rubber grinding plants "ATR-300" from the company ALFA SPK capable of producing up to 350 kg of tire crumbs. The equipment crushes rubber tires with a mechanical crusher.

The crumb produced using this technology is of high quality, which means it is of great value to end users of the product.

The miniplant is equipped with the following equipment:

Miniplant works like this:

Visual inspection of raw materials for the presence of impurities that can disable the equipment.
Grinding large pieces of raw materials with a hand tool. Small tires are fed into the loading chamber as a whole.
Shredding rubber shredder equipment into smaller fractions. At this stage, the raw material is cleaned from metal impurities.
Feeding raw materials into a compartment with a rotating knife element for grinding raw materials to the right sizes. Cleaning of metal cord particles is an additional option launched by the system at this stage of rubber processing.
Receipt of raw materials into the separation compartment, where the final cleaning of crumb rubber from impurities takes place.
Passing finished products through vibrating screen cells for sorting by fractions.

The price of such a mini-factory - RUB 9,800,000. The productivity of the mini-plant for the production of crumbs of three fractions is up to 350 kg per 1 working hour. 3-4 people are enough to service the equipment. On the need for special training for service personnel the equipment manufacturer does not explicitly state. All questions of interest can be asked on the site.

Pay attention to tire recycling plants from EcoStep.

In the line of equipment there are models designed for both beginner entrepreneurs and more experienced tire processors.

The advantage of the equipment declared by the manufacturer is European quality and reliability.

Tire recycling plants model KPSh from the company Doza-gran recycle tires into 3 fractions, including rubber dust.

On the company's website, you can calculate the required equipment performance depending on your needs and end goals.

Cost of equipment - from 8,300,000 rubles.

Another manufacturer of tire processing equipment is Europlit.

The equipment of the NEO line presented by it allows you to independently adjust the desired parameters of the final product.

Comparative characteristics and prices

Equipment brand	Characteristic		Price	Link to the website of the manufacturer (supplier)
Mini plant "ATR-300"	Energy consumption, kW/h	80-120	9.8 million rubles	alfaspk.ru
		500
	Output, kg/hour.	350
	Formation of by-products (additional income)	Yes
		120
	Shop LxWxH, m	20x4.5x4.2
	Number of workers, pers.	3-4
Plant Bio-KPSh	Volume of processed raw materials, t/year	720-3000	From 8.3 million rubles	dozagran.com
	Production output, t/year.	650-2700
	Power consumption, kW/h	180-430
Line NEO-300	Output, kg/hour.	300	On request	epilit.ru
	Power consumption, kW/h	55
	Number of workers, pers.	3
	Shop LxWxH, m	33x6x3
	Obtaining by-products (additional income)	Yes
Line NEO-500	Output, kg/hour.	500	At buyer's request
	Power consumption, kW/h	90
	Number of workers, pers.	3
	Shop LxWxH, m	41x6x4
	Additional products	Yes
Line NEO-1000	Output, kg/hour.	1000	Reported upon buyer's request
	Electricity consumption, kW/h	180
	Number of workers, pers.	5
	Shop LxWxH, m	43.75x8x4
	Additional products	Yes
ECO STEP 500	Energy consumption, kW/h	100		eco-step.ru
	Output, kg/hour.	350
	The volume of processed raw materials, kg / hour.	500
	Number of workers, pers.	4
	Maximum diameter of recycled tires, cm.	150
	Shop LxWxH, m	30x10x5
ECO STEP 700	Power consumption, kW/h	100	Provided upon buyer's request	eco-step.ru
	Output, kg/hour.	350
	The volume of processed raw materials, kg / hour.	500
	Number of workers, pers.	4
	Maximum diameter of recycled tires, cm.	150
	Shop LxWxH, m	30x10x5
Line LT400	The volume of processed raw materials, kg / hour.	250	52 thousand dollars	best-china.ru
Line LT450	The volume of processed raw materials, kg / hour.	500	59 thousand dollars
Line LT560	The volume of processed raw materials, kg / hour.	1000	74 thousand dollars
Line LPSH-300	The volume of processed raw materials, kg / hour.	500		www.uas.ru
	Release of a crumb, kg/hour.	300
	Maximum inner diameter of tires, cm.	150
	Power consumption, kW	From 100
	Number of workers, pers.	2-3
	Opportunity to earn additional income	Yes
	Room size, m 2	200
LPSH-200	Room size, m 2	40	RUB 1.853 million	www.uas.ru
LPSH-200		up to 200	RUB 1.853 million
LPSH-400	Room size, m 2	From 120	5.781 million rubles
LPSH-400	The volume of processed raw materials, kg / hour	Up to 400	5.781 million rubles
LPSh-600	Room size, m 2	From 150	RUB 6.135 million
LPSh-600	The volume of processed raw materials, kg / hour	Up to 600	RUB 6.135 million
LPSh-800	Room size, m 2	From 200	RUB 8.800 million
LPSh-800	The volume of processed raw materials, kg / hour	800-1000	RUB 8.800 million
LPSh-1500	Room size, m 2	From 250	RUB 11.105 million
LPSh-1500	The volume of processed raw materials, kg / hour	up to 1500	RUB 11.105 million
KGSh-1500	Room size, m 2	From 200	RUB 14.156 million
KGSh-1500	The volume of processed raw materials, kg / hour	up to 1500	RUB 14.156 million
"ATR-250"	Power consumption, kW/h	80-100	5.6 million rubles	alfaspk.ru
	Room size, m 2	80
	The volume of processed raw materials, kg / hour	Up to 300
	Crumb volume, kg/h	Up to 250
	Number of workers, pers.	3-4
UPShK-1200	Power consumption, kW/h	5	0.77 million rubles	stanki-ru.ru
	Installation size, LxWxH, m	1.8x1.2x2
	The volume of processed raw materials, kg / hour	35-52,5
	Number of workers, pers.	1
UPShK-2000	Power consumption, kW/h	8	0.87 million rubles
	Installation size, LxWxH, m	2.5x1.7x3.2
	The volume of processed raw materials, kg / hour	87,5
	Number of workers, pers.	1
UPShK-2200	Power consumption, kW/h	8	1.12 million rubles
	Installation size, LxWxH, m	2.8x1.8x3.4
	The volume of processed raw materials, kg / hour	100
	Number of workers, pers.	1
UPShK-2700	Power consumption, kW/h	11	2.25 million rubles
	Installation size, LxWxH, m	3.0x2.0x3.4
	The volume of processed raw materials, kg / hour	112,5
	Number of workers, pers.	1
Single shaft machine Model 800		400-600	1.285 million rubles	darex.pro
	Receiving chamber size, see	147.5x80
	Total number of knives	49
	Power consumption, kW	22-37
		Up to 4
Single shaft machine Model 1000	Equipment productivity, kg/h	600-800	1.41 million rubles
	Receiving chamber size, see	147.5x100
	Total number of knives	68
	Power consumption, kW	37-45
	Finished product size, see	Up to 4
Single shaft machine Model 1300	Equipment productivity, kg/h	700-900	RUB 1.845 million
	Receiving chamber size, see	147.5x130
	Total number of knives	91
	Power consumption, kW	45-55
	Finished product size, see	Up to 4
Single shaft machine Model 1800	Equipment productivity, kg/h	1400-1800	2.75 million rubles
	Receiving chamber size, see	147.5x180
	Total number of knives	130
	Power consumption, kW	75-90
	Finished product size, see	Up to 4
Tire Crusher #1	Equipment productivity, kg/h	2000	Provided upon buyer's request	texservis.com
	Finished product size, see	Noodles -5, chips - 5x5
	Receiving chamber size, see	120
	Total number of knives	22
	Machine dimensions (LxWxH) see.	630.3x280x366.7
Tire Crusher #2	Equipment productivity, kg/h	Before 2000	Provided upon buyer's request
	Fraction of finished products, see	Noodles -4, chips - 4x4
	Receiving chamber size, see	75x22x6
	Power consumption, kW	58
	Machine dimensions (LxWxH) see.	282x230x258
Single Shaft Shredder 3E WT 2260	Total number of knives	34	0.998 million rubles	pragmat.ru
	Rated power, kW	18,5
	Productivity, kg/hour	200-300
	Machine dimensions (LxWxH), m	1.774x1.359x1575
Two-roll crusher DDR-300	Power consumption, kW	60	Provided upon buyer's request	tet-ua.com
	Productivity, kg/hour	300
	Receiving window size, see	60x70
	Maximum tire diameter, cm.	600
Two-roll crusher DDR-500	Power consumption, kW	60	Provided upon buyer's request
	Productivity, kg/hour	500
	Raw material receiving chamber limit, see	75x80
	Maximum tire diameter, cm.	750
Two-roll crusher DDR-750	Power consumption, kW	90	Provided upon buyer's request
	Productivity, kg/hour	750
	The size of the window for laying tires, see.	82x100
	Maximum tire diameter, cm.	870
Two-roll crusher DDR-1000	Power consumption, kW	90	Provided upon buyer's request
	Productivity, kg/hour	1000
	Receiving chamber size, see	85x130
	Maximum tire diameter, cm.	1200

findings

Tire recycling equipment is a real find for those who want to set up a recycling business.

Affordable price, simple installation and maintenance, a wide scope of use of the resulting products - the reasons to consider this type of production as a priority for start-up entrepreneurs, as well as master additional view activities of established businessmen.

In contact with

The industrial business idea of launching a mini-factory for the production of crumb rubber by recycling tires attracts with an excellent ratio of large cash turnover and short payback periods. And most importantly, recycling is the production of money from garbage. Your attention is invited to a business plan for the production of crumb rubber with calculations and analysis of opportunities. For example, it is worth paying attention to the additional income from the extraction of metal from tire cords, in which it is already 7%. What other useful secrets this production keeps, we will consider in more detail.

Tire crumb mini-factory

How to correctly calculate the rate and volume of production of rubber crumb from recycled car tires? The answer to this question is not so simple. The production of rubber crumb depends on many nuances. There are two key factors which formed the basis of the attractiveness of this activity in terms of investment. They will help answer this question.

Factor #1: Industrial Small Business Entry Threshold

First of all, you need to properly assess your financial reserves that you own (own savings and possible loans). It is worth noting that this type of industry is possible with different investment volumes, which means that such a business scales well. With small investments in the initial phase, income can be minimal, taking into account regular expenses for electricity, transportation costs, salaries of employees, taxes, etc. It is worth noting here that this concept of a business idea underlies the recycling of waste (used car tires). And according to tradition, in order to get gold from garbage, you need to do a lot of work. Therefore, too little investment significantly increases the risks. It is possible to start production on a large scale through the design of a specialized enterprise with large areas, for example, several hundred square meters, which will cost big investments. Make the optimal choice of investment strategy in favor of the golden mean between these boundaries.

Factor #2: Small Business Manufacturing Capacity

In case you have about $17,000 of money, the choice should not be an issue. For this money, you can purchase a production line for processing tires into crumbs with a minimum configuration and a capacity of 100 kg / hour. In this case, the most important thing will be finding and renting a warehouse with an area of about 100 m 2 and a production room with an average area of 40 m 2, plus a few more small storage rooms. In this case, the production of crumb rubber can start from a production volume of 800 kilograms of the finished product daily (100 kg / hour in 1 work shift).

What you need to process tires into crumb rubber

The minimum complete line for processing tires into crumb rubber includes the following equipment, which can be found on the Internet at prices:

Bead cutting machine - $ 2,150
Tape cutter - $ 2,700
Shredder for shredding rubber - $ 7,650
Circular sieve - $ 1,000
Conveyor with magnetic separator - $1,000
Bead ring processing machine - $2,500

TOTAL: $17,000

Technology for the production of crumb rubber by recycling tires

Video clip, which schematically in the form of 3D animation shows the technological process of tire recycling by grinding into rubber crumb:

As you can see in the video, the production process is extremely simple.

If you decide to conduct this activity on a more serious level, an analysis of the sales market in the region where you are going to launch your project will be necessary. Without this work, it is unlikely that the products will generate a profitable income. Will have to include in the business plan the costs of marketing research sales market for finished products in a particular region.

What is the need for this product and in what distribution channels can it be sold? Who else is interested in this industry and what is the competition in the market?

The answers to these questions need to be taken into account and, obviously, to calculate the development opportunities economic activity over the next few years. It is unlikely to accurately foresee the subsequent course of events, but approximate calculations will indicate at least the direction in which it is worth moving. Such determination is better than blind action.

Business plan for the production of crumb rubber with calculations

In the production of crumb rubber, used, old, defective car tires were used. For obvious reasons, one should not even talk about the search for raw materials and their price. Old tires can be found in large quantities. You can buy them for a minimal fee, and sometimes you can pay for shipping to your company.

The production of crumb rubber, as already mentioned, is quite affordable for small businesses. The $17,000 production line can quickly process a wide variety of tires: car, bus and other tires.

AT this moment There are two main methods by which crumb rubber is produced:

mechanical crushing.
Crushing by shock wave method.

Shock wave crushing of rubber into crumbs is a relatively young method of tire processing. The most popular mechanical crushing.

The production of rubber crumb using a shock wave requires a special approach. In particular, it is necessary to have equipment in which the products will be located, similar to refrigerated pantries, which are quite expensive. The advantageous possibility of installing equipment for the production of rubber crumb from tires using the shock wave method on smaller production areas is noticeable. You can save on monthly rent. At the same time, the cost electrical energy will be less than with an analog installation. But all the same, such equipment is fully justified for large and medium production volumes, since it is very expensive.

The manufacture of crumb rubber can start with a small production volume and at a relatively low cost. Enough 40 square meters of production space with a ceiling height of 3m. A direct rubber crumb production line will be installed, a 380 volt power supply will be connected and 2 workers will control the operation of the semi-automatic equipment.

The best option during the period of reaching the payback point of the business is to work continuously for a whole week. To do this, three work shifts should be organized. As a result, the staff will consist of eight persons. In addition, you should take care of the places of storage of raw materials and finished products. In this case, the space for storing tires should take out four, and even five times more. In this regard, the surface of the room for raw materials (tires) may require up to 100m 2, and for the storage of finished rubber crumb - 20m 2.

On this basis, the cost of 100 kilograms of products per hour will change and change. AT this business plan Let's define monthly fixed costs:

Purchase of tires at a price of $40 per 1 ton - $960 (requires 24 tons of raw materials per month).
The cost of renting a warehouse will be about $400-600 per month.
The salaries of workers who maintain the production line are $300-$700 per month;

It's a good idea to give customers the opportunity to recycle tires for money. Having your own collection point will help not only to reduce transport costs for the delivery of raw materials, but also immediately receive preliminary additional income, which is described below.

If the production line produces 100 kilograms per hour, working without interruption, then in a month the amount of finished products will carry out 24 tons of crumb rubber (100 kg * 8 hours * 30 days = 24000).

Taking into account the average retail price of crumb rubber in the amount of $0.28 per kilogram, we get the income per month dirty in the amount of $6720 (0.28 * 24000).

It is also worth noting that during production, metal remains in the waste (wire in the tire courts). Its volume is about 7%.

Interesting fact! According to Goodyear Tire and Rubber, the average tire weight is about 22 pounds (up to 10 kg). At the same time, it contains 0.68 kg of steel cord (it serves as a reinforcing for the rubber structure in tires).

On the one hand, this is industrial waste, and on the other hand, positive side- this is a significant additional profit: 0.7 kg of metal wire and tire steel cord. And that 0.7 * 10 tires / hour * 8 hours * 30 days = 1680 kg of metal from 24 tons of tires - monthly!

The average price of scrap metal is about $200 per ton. As a result, we will receive an additional $336 profit from the sale of metal cord wire. It is worth considering how to organize your acceptance of car tires for recycling for money.

This amount of benefit is sometimes a more economically justified income received in the process of implementing this activity.

Tire recycling products

Where is rubber crumb from tire recycling used? This unique and durable building material is indispensable in the following industries:

Production paving slabs from crumb rubber.
When covering roads, asphalt and concrete fences on roads with the addition of crumbs.
In the production of safety coating for sports, playgrounds and gyms.
in landscape design.
Production of hydrophobic materials.
The granules are used in the construction industry for the production of rubber plates, palettes, roofing materials and the like.
Granules of rubber crumb are also used in the production of rubber mats for pedestrians.
Rubber crumb found use in filtration different kind liquids, creating thermal insulation of industrial premises.

In order to minimize the risk, it is possible to expand the scope of rubber crumb manufacturing. So, it is possible to produce rubber plates or other shells of this material. The need for these products does not depend on the need for crumbs. Therefore, in one enterprise you can create two completely different areas of activity.

One of the big expectations of the industry is the production of crumb rubber. We have this type of industry today is not particularly developed.

Do not forget about such an important component, which is the sale of finished products. The popularity of crumb rubber as a building material is growing. There are more and more new competitors on the market. As a result, if you have the right approach to selling this product, you can easily adjust the sales channels. This type of production does not require special skills, it is technologically simple.

Depending on the amount invested in the product, the payback period can stretch from six months to two years. Relatively short payback periods are the next plus in the interests of this type of activity. Consequently, the high demand for the product (like all building materials), minimization of risks and the mentioned thresholds for entering the production technology - makes it attractive from the point of view of investment.

Crumb rubber production: registration of an enterprise + purchase of equipment + rent of a workshop + personnel for working at the plant + crumb production technology + product sales + calculation of profit and payback.

The most enterprising people live in Russia, who can make money even from garbage. One of such activities is the production of crumb rubber.

In this business proper management cases, you can recoup all investments in a short time, as well as get a big income. In addition, you can extract additional funds from the fact that you will take the metal from the tire cords.

Read about everything in detail in the article below.

Project Scale and Crumb Rubber Business Registration

Initially, you must decide what scale your project will take. It is possible to open the production of rubber crumb both with minimal investment and with a large start-up capital.

Realistically evaluate your capabilities. Of course, the less you invest in the business, the less profit will be. But spending millions is not worth it, because each new business is a risk. Find the golden mean. In our business plan, we will just describe how to open our own production with an average starting capital.

If you plan to open a huge plant and attract financial injections from the state or investors, you will need to create a limited liability company.

And for a small workshop in which you have invested your savings, it will do legal form IP. Within 5 working days you will receive a certificate of registration individual, as individual entrepreneur, + certificate of entering data into the USRIP.

To do this, you must submit the following package of documents to the Federal Tax Service:

Passport and TIN.
Application in form No. P21001.
You need to enter the activity code according to OKVED 25.13 "Production of other rubber products" in the application.
Make an application for the transition to the USN.
Pay the state duty and provide a receipt with documents (800 rubles).

Unfortunately, this collection of documents is not over. falls within the scope of Federal Law No. 89 “On production and consumption waste”. According to Art. 5 of this law, waste classes 1-4 (which includes tires) are subject to licensing.

What you need to do to get a license for the production of crumbs:

Register an individual entrepreneur or LLC.
Lease officially or buy a room for production.
Purchase certified equipment.
Obtain an opinion from the SES and the Fire Service.
Accept verification from Rospotrebnadzor and receive a certificate.
Submit an application to the State Ecological Expertise at the place of registration of the enterprise and receive a positive conclusion.
Send a package of documents containing all conclusions, a lease agreement for premises and a certificate for equipment to the Federal Territorial Authority for Supervision of Natural Resources.

If all documents are in order, you will receive a license. It's not free. If you do everything yourself, you will have to pay about 300,000 rubles. This will take a long time - about 2-3 months. But you cannot skip this step - without a license, your production of crumb rubber will not be legal, and when checking the IP, you will be fined a large amount.

Equipment for the production of crumb rubber

With 1 million rubles, you can afford to buy a small line for the production of crumb rubber, which can process up to 100 kg of material in an hour of work. But it is important to understand that such equipment, although affordable, will produce only crumb. In addition, not all tires can be recycled by the technician.

It is better to buy a complete line with a capacity of 400 kg / h. Such equipment for the production of rubber crumb is automatic, workers will only supply tires and receive crumb rubber and bead rings at the output.

If you want to make additional products from raw materials (which will become a source of additional profit), buy a complete set of crushed tile presses.

Of course, you can buy equipment cheaper, for example, not as powerful or second-hand, but then you will not receive a guarantee for the equipment, you will not be able to "accelerate" production at full capacity. Few raw materials will be obtained, so it will have to be sold at retail and at a reduced price.

Requirements for the premises for the production of crumb rubber

The area of the rented premises will depend on the equipment for the production of crumb rubber.

Based on our business plan, the equipment will occupy 150 m2. Except himself production shop, it is necessary to prepare additional warehouses for raw materials and finished products, a room for staff, an office for the director and a bathroom.

How general requirements should correspond to the room in which rubber crumb will be produced:

Ceiling height up to 5 meters.
The distance from residential buildings is 300 meters, it is best to rent a workshop outside the city.
Temperature within 15°C.
Industrial grounded electrical network - 380V.
Flat floor, the presence of cosmetic repairs.
Conducted water, ventilation, gas, fire protection system, factory air filter.

Depending on the region, remoteness from the settlement, the availability of repairs in the premises, the price for renting an object will be within 100,000 rubles / month.

Staff in the shop

Thanks to the automated equipment for the production of crumbs, it is not necessary to hire highly specialized personnel.

Our plans are to produce 400 kg of crumbs in 1 hour of work and, at the same time, to additionally engage in the production of tiles from recycled material. The shop will work at first only 5 days a week for 8 hours a shift. With an increase in the number of orders, you can hire more workers and introduce additional shifts.

So, first of all, be sure to hire technologist. He will monitor the equipment and the correct production of tiles. In order for nothing to “leave” without a trace behind the territory of the plant, you need to hire accountant, which will monitor the supply and quantity of products produced.

Hire driver with a truck (if the production does not have its own transport), which will transport the goods and supply raw materials.

And the sales manager can be taken over by the shop manager.

№	staff member	Quantity	General salary (rubles/month)
TOTAL:			170 000 rubles/month
1	Technologist	2	20 000
2	Accountant	1	16 000
3	workers	6	90 000
4	Cleaning woman	1	8 000
5	movers	2	20 000
6	Driver	1	16 000

All employees need to pass a medical examination to make sure they can work in hazardous crumb production. Buy them respirators and overalls.

For the technologist and accountant, you need to allocate an office with a computer, a desktop, a filing cabinet and office supplies.

Preparing an office for a technologist and accountant, purchasing overalls, lockers for workers will cost about 100,000 rubles.

Rubber crumb production technology

Crumb rubber is a product that we get after processing car tires and other vehicles.

Tires are made on the basis of synthetic and natural rubber, metal cords, emollient oil, filler, etc. The tire itself is very elastic, resistant to various temperature extremes, alkalis and other acids, it does not wear out for a long time.

After the tire is processed into crumbs, only metal particles are removed from its composition, and all other components remain unchanged.

Since the crumb is a secondary material, it is several times cheaper than the primary rubber raw material, and in terms of quality they are on the same level. This is what makes this production very promising.

Let's take a look at the steps of the production process:

Tires must first be prepared, remove dirt and other foreign particles.
From the tires you need to remove the metal part - the cord.
The raw material must be cut into strips according to the specified parameters, which depend on the equipment.
Then the tapes are crushed at normal temperature - 20-30 degrees above Celsius.
Then crushing takes place high temperatures– 100 °С.
The machine interrupts the rubber again, but already at a low temperature.
The “ozone knife”, which is in the equipment, frays the rubber again, which contributes to the material being completely destroyed.
If you produce not only crumbs, but also tiles, then crumbs are poured into the press and, using cold or hot pressing, the tiles are compressed to a given thickness and density. As a rule, it should be 1-4 mm thick.
The finished product - chips or tiles - is packed in polyethylene manually or using a packaging machine.

Production of crumb rubber tiles and other applications of the material.

When planning any business, we ask ourselves the question: who will become our buyer, will there be a demand for products?

Let's name a few industry branches where I use crumb rubber:

Today, the crumb is used to cover roads, sidewalks, as an additional material.
Rubber crumb is placed in street gyms (volleyball, basketball courts, children's complexes) in order to protect the territory from injury.
Paths are laid out with such material when forming landscape design.
Crumb today is used in construction, for the manufacture of roofing materials, palettes, etc.
A crumb can create thermal insulation in industrial workshops, etc.

We want to focus on a separate industry -. To make it, you will only need a press. But the cost for finished tiles will be many times higher than just raw materials from recycled tires.

The crumb will be bought only by those who can process it into another product. By tiling, you will increase the offer. Every resident of the settlement where the plant is located can become your buyer, because this material is easy to put at home, like a sidewalk.

To get to know about you, be sure to take care of advertising. The most effective way is to make a website, promote it and order contextual advertising.

This will require additional financial investment:

website purchase - up to 5 thousand rubles,
hiring an SEO-optimizer or WEB-programmer - from 25 thousand rubles / month.

If there is not enough finance, then you need to use the "old" method - call potential clients personally, place advertisements in the media and on billboards in the region. Although, it is worthwhile to understand that this will not cost much less.

Equipment for processing tires into crumb rubber.

Production technology of rubber tiles.

Detailed profitability calculation

Most important point in any business plan, it is the calculation of profit and the estimated time frame for full payback.

To begin with, we will divide all our costs into two columns - permanent financial investments and one-time expense items.

Let's calculate how much crumbs and tiles we can produce at the factory, and what will be the profit with the full sale of goods:

Our equipment can process 400 kg of rubber tires of different sizes in 1 hour of operation. The workshop operates 8 hours 24 days a week. We will need to purchase approximately 80 tons of material.
A ton of tires costs about 4 thousand rubles. We will need to purchase raw materials for 320,000 rubles.
From a ton of tires, we will extract approximately 100 kilograms of metal (depending on the tire model and its size).
At the output, we will get 70 tons of crumb rubber. Half can be used for the production of tiles.
The weight of 1 m2 of tiles is from 22 kg, and its cost on the market is 1,600 rubles. Our enterprise will be able to make 1,590 m2 of rubber crumb tiles in 1 month of work. With full implementation, the income will be up to 2.5 million rubles.
Rubber crumb is cheaper, 1 ton - 17,000 rubles. Profit from the sale of crumbs - 595,000 rubles.
We have an income of 3,000,000 rubles. Of these, we pay tax (180,000 rubles) and a communal apartment (from 150,000 rubles). In addition, you need to buy raw materials, provide workers wages, buy containers, give money for transportation (payment for gasoline), for rent and advertising.
Net profit from the production of crumb rubber and tiles will be approximately 1.9 million rubles. Thus, the cost of organizing a business can pay off in six months of successful work.

Crumb rubber production This is a profitable business, but you need to invest a lot of money in it.

Our business plan is based on approximate calculations, in practice you may encounter many problems - products are not sold in full, equipment breaks down, competition is growing, etc. But it's worth the risk to rise and become successful businessman.

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

Modern production of rubber crumb from tires is easy to organize if there is quality equipment. Most often, it is sold in ready-made kits, which greatly simplifies the opening of your own business. However, just one mixer is enough to get started. How to choose equipment, what characteristics to pay attention to and how much money will you have to spend on it?

Rubber crumb is most often made from old car tires. This is promising business in the field of secondary raw materials. Car tires belong to waste of the 4th hazard class. This category also includes, for example, batteries, plastic containers, sand and wood chips contaminated with oils or petroleum products.

Tires must be disposed of according to special rules: motorists must take them to special centers and pay for processing. In practice, most car owners neglect these rules. As a result, tires end up in ordinary landfills, or lie in forests and along highways for years.

Such waste does not pose a great danger to humans, but does not naturally decompose in nature. They must be disposed of in a special manner. The simplest recycling of worn tires is grinding to the state of crumb rubber. But rubber crumb is not waste, but a very valuable resource, which can be used in production.

Most often, recycled tires are used to make rubber tiles, an anti-slip finishing material needed to cover indoor and outdoor surfaces. The quality properties of rubber tiles are very good, and the fact that they are made from recycled materials only adds to their value.

Why Tire Recycling Business is Profitable

Starting your own business in the field of rubber crumb and tile production has many prospects. With relatively low investment, most of which the price of equipment will be, such a business promises to reach a net profit after a few months of work.

The production of crumb from automotive rubber is beneficial for several reasons. First, this highly profitable business. The entrepreneur, in fact, uses waste as a raw material (which can even be delivered to him for free), and at the output he has a high-quality and sought-after building material.

Secondly, in most regions this niche is free. Complex enterprises for the processing of this type of waste is a novelty for Russia. Therefore, businessmen who manage to open production in their city earlier than others have high competitive advantages.

Thirdly, the problem of recycling old tires is very acute. They do not decompose in the natural environment, pollute environment, lie in landfills for years or, worse, remain where unscrupulous car owners left them. This is a headache for regional authorities and environmental structures. For this reason, an entrepreneur who promises to solve the problem of old tires has the right to count on state support.

Technique for rubber crumb: mixer or mixer

The main apparatus, which is necessary for the processing of automotive rubber and similar waste to the state of rubber particles, is a mixer or mixer. The cost of equipment for the production of crumb rubber, that is, such a mixer, starts from 60 thousand rubles.

The price depends on the manufacturer, power and load of the device. Such a mixer grinds tires to a state of particles from 1 to 5 millimeters, if necessary, mixes them with glue and dyes - to obtain a rubber coating or a mixture for tiles.

The principle of operation of the mixer for tires

The principle of operation of such a mixer is quite simple. Cleaned, fat-free rubber tires (or similar waste) are immersed in the machine's tank. If it is not a crumb that is being prepared, but a mixture for coating or tiles, glue and, if necessary, dyes are added to the rubber. Next, the mixer mixes all the components.

Workers unload the crumb or mixture from the tank (remove the removable tray), and new raw materials are loaded into the tank. The processing speed of one batch directly depends on the power of the mixer engine. On average, one batch lasts 2-3 minutes, so during the working day you can get several dozen batches of crumbs of 50-70 kilograms.

The main apparatus that is necessary for the processing of automotive rubber and similar waste to the state of rubber particles is a mixer or mixer.

Types of mixers

Most devices on the market are divided into 2 types:

screw - grinding of raw materials occurs with the help of a knife;
bladed - the blades grind the raw material to the state of crumbs.

Fundamentally according to quality characteristics they do not differ. Screws are usually more mobile: they can be used not only in the workshop, but also on site, when laying a seamless rubber coating. Vane machines are equipped with larger tanks and produce large batches of particles.

Choosing a mixer: what to look for

How to choose a crumb rubber mixer? Novice entrepreneurs do not yet know all the intricacies of the work ahead, so they often make the wrong choice. When buying, pay attention to the following details and characteristics:

The ratio of tank volume and power. The larger the load, the more powerful the mixer must be. Otherwise, it will grind raw materials poorly, overheat and wear out. For example, for a standard 70-liter tank, the power should be above 1.5 kW.
Belt driven mixers last less. The belt spins and impairs mixing, and wears out over time.
Faucets with removable tanks are not as convenient as it seems at first glance. The fact is that the large weight of a full tank (about 70 kilograms) makes it difficult to quickly and easily unload the crumb. In addition, the mixture of them must be poured into separate containers (if it is already mixed with glue and dyes, this is doubly difficult).
It is preferable to choose devices with removable trays. Included in such mixers are 2-3 removable containers. They are convenient to get and use in further work - when laying the coating or pouring raw materials into molds.
It is better to choose mixers with vertical loading of raw materials, this is the most convenient and fastest option for workers.

Companies and suppliers of mixers

There are a wide range of crumb rubber mixers on the market. Manufacturers from Europe, China and Russia offer different models according to different prices. Practice shows that most Chinese-made mixers are significantly inferior in terms of quality and operating time.

On the net you can find a lot of feedback from entrepreneurs about Chinese mixers that have worked in their production for only a few months. Most likely, during this time the device will only have time to pay for itself and will not bring a significant profit to the owner. It is better to stay on more reliable, albeit more expensive options.

Among manufacturing firms can be called:

"Europlitgroup";
"Mosreduktor";
"Technoline";
EcoGold;
Rezina-eco.

Each manufacturer has a website where you can study the proposed equipment, clarify all the conditions and guarantees, and also consult with a company representative. On average, a good rubber mixer can be purchased for 60-100 thousand rubles.

Most often, rubber particles are used for the production of tiles or seamless coatings.

How to use crumb rubber

Most often, rubber particles are used for the production of tiles or seamless coatings. But in the early stages, while there is no other necessary equipment and employees, you can sell crumb rubber directly - the demand for it is also quite high.

The second option is also good because it does not burden the entrepreneur with additional costs for glue and dyes. That is, it significantly reduces the cost of production. Even having just one mixer and several batches of old tires can bring the first income..

What else do you need to buy for the production of crumb rubber

To begin own business you can even have one mixer for tires. With the help of this equipment, seamless rubber coatings for stadiums, swimming pools, playgrounds are produced. This is a very cost-effective business that will help not only to recoup the money spent on the device, but also to earn money to expand production.

Next, you can think about the finished line for the production of rubber tiles. Many manufacturers offer entrepreneurs sets of equipment in different variations: from mini-workshops for 2-3 employees to full-fledged lines for 15-20 workers. The cost of kits starts from 250 thousand rubles and can reach 1.5 million rubles.

Do I need licenses and permits for waste disposal?

Car tires are classified as conditionally hazardous waste, and therefore the question may arise: is it necessary to obtain a permit to work with them? For the production of crumb rubber, no special licenses are required, since this process is not waste disposal, but their mechanical processing.

Conclusion

There are many models of equipment for the production of crumb rubber on the market at a price of 60 to 100 thousand rubles. Even one mixer or mixer will be enough to start your own business: you can sell crumbs to other manufacturers or make seamless coatings.

Such a business is promising, as it solves the acute problem of recycling car tires. An entrepreneur who has established this production will not lack raw materials and will have the right to count on the support of regional authorities for assistance in solving environmental problems.

There are millions of cars in the world. Hundreds of thousands of used tires made from synthetic rubber end up in landfills every day. High Quality. Unacceptable extravagance. And then an idea came into someone's bright head how to start the production of many useful things from this actually gratuitous raw material: a rubber coating for sports complexes, playgrounds, ice rinks, paving slabs, soft roofs, temporary road blocks, etc.

Crumb rubber coatings last at least 20-40 years. They wash well, absorb noise, it is pleasant and comfortable to play sports on them. These coatings are great for shops, offices, industrial premises. When walking on them, the legs rest, the load on the joints is reduced.

But first, inner tubes and tires need to be turned into a convenient raw material, which, using a simple technological process turns into finished goods. The production of rubber crumb (or crushed rubber), which is formed by recycling tires, is the first stage, which makes it possible to earn money by investing little money.

Equipment for the production of crumb rubber

Rubber crumb is produced in various fractions - from 0.1 to 10 mm, depending on the need. A crumb of small diameter (up to 4 mm) is used in single-layer products. Sometimes two layers are used in rubber coatings - the lower one using large fractions and the upper one using fine, more expensive ones.

Equipment for the production of crumb rubber is a whole technological line. It includes two sections: on one, the tires are prepared for processing, on the second, they are directly abraded. The following actions are performed in the process:

The raw material is cut into strips;
Ribbons wear out;
Pass through a vibrating sieve;
Passes through magnetic as well as air separators;
The resulting crumb is transported on conveyors to the storage of raw materials.

There are many technological lines for the production of crumb rubber on the market. They have different capacities, levels of automation and prices. A beginner manufacturer will have enough of a line that processes up to 5 tons of raw materials per day. The machine will require a room with a small area for installation, has an acceptable price. A successful combination of cost and quality provides equipment for the production of rubber crumb of Chinese or Korean production.

The opportunity to expand the scope of activities and reach the level of production of finished products provides the production of rubber crumb tiles. These products are in demand both in the improvement of settlements (coverings for sports and playgrounds), and in the decoration of commercial and industrial premises, and often individual plots.

Rubber tiles are produced by hot forming. The equipment that will be required is a volcanic press (price up to 350 thousand rubles), a pair of raw material mixers (100 - 200 thousand rubles each) and a drying chamber (from 100,000 thousand rubles). Consumables: black or colored rubber crumb, polyurethane adhesive, dyes.

The production of tiles from crumb rubber is carried out in the form of mats measuring half a meter by half a meter. Their thickness is different and depends on the operating conditions. In order to save Supplies the tile is made two-layer: from above a color layer, from below black. In this case, the dye consumption is reduced. Plus, it is possible to use crumbs of cheaper large fractions in the lower layer, which often contain remnants of metal or textile reinforcement.

The uniqueness of the material allows you to vary the characteristics of crumb rubber coatings in terms of hardness, water permeability, color, patterns, type of connections, and adhesion level. The product range will depend on the set of mold kits. Commonly used kits are "Mat" and "Dovetail". Other kits can also be used.

When planning the organization of production, it is necessary to provide space for both the production line (from 70 square meters) and two warehouses (for raw materials and finished products). In the production of rubber crumb coatings, a work shift will require from two to four people (depending on the complexity of the line). The average electricity consumption will be up to 52 kW.

In the process, rubber crumb, dye and glue are mixed until a homogeneous mass. The resulting mixture is dosed, poured into mold matrices, smoothed with a trowel. Hydraulics compresses the material in the mold and the shaping process begins. When the timer is triggered, the molds open automatically with finished products.

Crumb rubber production - business plan

As in any responsible business that requires costs, when working out the organization of the production of crumb rubber, a business plan is necessary. First of all, you will need to take into account the costs of acquiring equipment, raw materials, renting premises for production and warehouses, salaries to employees and marketing options.

As practice shows, with a capacity of 100 kg. rubber crumb per hour in three shifts, the payback of equipment, depending on the amount of invested funds, is up to six months to two years, with an average price of finished crumb from 6 to 15 rubles per kilogram.

Crumb rubber production equipment - price

The cost of the rubber crumb production line is from 1,200,000 rubles. Start-up and commissioning will also require costs. You should not save on quality by purchasing used machines.

As practice shows, it is better to purchase the simplest line and start with the production of 800 - 2400 kg of crumb rubber per day. If things go well, we can expand.

A simple technology for the production of crumb rubber provides indisputable prospects. There is still little competition in the market. The areas in which raw materials are used are expanding, and therefore the need for crumb rubber is increasing.