One of the types of materials vigorously used in the arrangement of the territory today is rubber tile - a fairly durable and easy-to-use paving surface. Appearing in stores, it almost immediately won a good position among other types of paving.
Such a tile has many advantages, among which there is also an anti-slip feature, it is thanks to this unique advantage that this type of tile can be used all year round. And even if an ice crust appears on such a coating during icing, it is easily removed with a conventional crowbar.
Profitable and long-term material - it's all rubber tiles
Operational period of rubber paving slabs is several years, a material with high strength, even in the presence of frequent mechanical stress, this coating does not deteriorate or wear off. Another great advantage of such a coating is the absence of puddles on it, even after a heavy downpour, even small accumulations of water will be absent on the surface of the rubber tile. The disappearance of puddles is due to the fact that the entire tile has a high porosity, which is why it has a drainage effect.
In addition to the fact that such material will almost always be dry, despite the abundance of heavy rains, it can be used as a coating on any type of base. No matter what this type of tile will be laid on, gravel or asphalt, this tile will stick perfectly. long time, and even after years it will not lose its merits. It is because of such serious advantages that this type of tile is only increasing in popularity. Of course, the cost of such material does not always make it possible for those who wish to purchase it, but this does not mean that one can only dream of a good sidewalk surface near one's house.
It is not necessary to buy, because you can make it yourself
In fact, rubber tiles can be made with your own hands, while the manufactured material will have no worse appearance and quality than similar materials sold on the market, manufactured in production. For self-manufacturing such a durable tile is used rubber crumb, it is made from recycled car tires. Since natural or artificial rubber is present in the manufacture of tires, as a result of their processing, the manufactured rubber crumb, as well as the original products, have wear resistance to various mechanical stresses.
The possibility of processing the original product into a secondary one allows not only to produce a new durable material, but also to safely dispose of the material that has become unusable, in the form of which tires act. And although it is really possible to make rubber tiles with your own hands, it is still worth knowing that in order to achieve what you want, you need special equipment, the cost of which is too high, therefore, it does not make sense to purchase it to make a small amount of tiles.
For the manufacture of the material will have to be well prepared.
Easier to buy right amount such material on the market, but if you plan to open your own business for the production of such quality coverage, then you can the right equipment rent for the first time. For the manufacture of such material, it is necessary to prepare such elements as a heating cabinet, a mixer, a hydraulic press, molds, tables. The process of manufacturing rubber tiles begins with the removal of steel elements present in rubber tires. Then the rubber products are crushed, the maximum size of one particle should not exceed 4 mm.
A polyurethane mixture and a pigment are added to the crushed rubber, after which all these components are thoroughly mixed. The finished mixture is poured into molds and subjected to vulcanizing oppression. The manufacture of tiles can occur in two ways of pressing. During the hot pressing method, the processing takes only 15 minutes at a temperature of 140 degrees. Cold pressing lasts as long as 4 hours at a temperature of 80 degrees. But, despite the existing difference in temperatures and processing times, the end result has no differences and has the same characteristics.
But it is worth considering a small nuance, making rubber tiles with your own hands will be much cheaper when using the hot pressing method, but if production has already been started and productivity needs to be increased, then in this case it is better to use the second cold pressing method.
Many will be interested to know if it is possible to make rubber tiles with your own hands. Each owner of a suburban area has the right to choose materials that, in his opinion, are more suitable for him, taking into account many factors: the location of the site, the landscape, the size - everything matters. A huge role in the choice of finishing materials is also played by what buildings will be located on the site. Now more and more often, instead of conventional concrete paths and sidewalks, rubber tiles are used, the laying of which is very simple and convenient.
Advantages of rubber tiles
Rubber tiles - high quality finishing material most commonly used for exterior finish personal plots, decoration of paths between buildings, and even as a floor covering for playgrounds and poolside areas. The playground must be completely safe, otherwise the children will fill a lot of cones. Shoes when walking or running fast should not slip or, conversely, slip. When the floor is wet, the risk of injury increases dramatically.
Therefore, ordinary asphalt or concrete paving slabs are undesirable as a coating for playgrounds. And the rubber tile meets all safety requirements: it is not only safe, but also helps children learn how to run correctly without fear of falling. It is not for nothing that the tracks at stadiums where track and field competitions are held have a rubber coating. It allows you to increase the grip of the sole of the shoe with the floor, which helps you run faster, and the risk of falling is reduced significantly.
The landscaping of the area in which the pool or home pond is located also has a number of features. After all high humidity, wet feet and shoes can easily lead to injury, as you can easily fall. Rubber tiles can reduce the risk of falls or injury by making them non-slip. In addition, such a coating is very convenient to operate, because it is easy to clean, dries quickly, and if some tile is worn out, it is easy to replace.
The advantages of rubber tiles include beautiful appearance, many colors, different texture solutions. Such a coating has high strength, perfectly dampens sounds, and is very practical to use. Installation and laying of such tiles will not take much time, and its different sizes and colors allow you to make whole drawings and paintings on the floor. It is very easy to store tiles: they do not deteriorate under the influence of moisture or heat.
Wherever there is high humidity - piers, piers, docks - you can and should use rubber tiles. Paths on personal plots can be very effectively finished with such a coating, laying out in the form of a mosaic or various patterns that will look great both in daylight and in artificial light. The improvement of your site will bring great joy if this product of modern technologies is chosen as the main material.
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Tile making
The production of paving slabs is very low-budget, as secondary materials are used for this. Used car tyres, recycled and turned into small compressed crumbs, provide the raw material for the manufacture of this modern miracle. In production car tires use natural materials– rubber, oils and other specific ingredients. Even if artificial rubber is used to reduce the cost of tires, it has almost the same specifications like a natural one. It is very important for environmental protection that car tires get a second life.
By processing them into fine crumbs with a special grinder, adding binders and colors, you can get a coating for outdoor use. The production of a rubber coating is simple and takes place in several stages. At the initial stage, car tires, pre-treated with special compounds for degreasing and removing various contaminants, are processed into fine crumbs. Mechanical grinders are used, since the impact high temperatures at this stage may have a negative impact on further production.
The crumb will be homogeneous, having the same texture and dimensions that do not go beyond the norm. The diameter of the crumb should not exceed 5 mm, minimum size- 1 mm. For further preparation of a homogeneous finely dispersed mixture, color pigments are added to the rubber crumb, which can be used to color the finished product in any color. Binding components are also added so that the mixture becomes homogeneous and one-textured. The final stage of tile production includes pressing the resulting mixture of finished tiles.
There are two types of pressing methods: hot and cold. Both are equally effective, production costs are almost the same. The only difference is in the way they are made. Otherwise, all the qualities and advantages of such tiles are the same: both types are simple and reliable in operation, installation and maintenance. Many users of this coating are sure that tiles made by hot pressing are inferior in terms of their technological and operational properties cold pressed tiles. But it's not.
Numerous testimonies of manufacturers and specialists who used these tiles in their work unanimously claim that there is no difference. Technological process the production of tiles with a hot pressing method includes the product being in an oven for a quarter of an hour at a temperature of 140 degrees. While the cold pressing method involves placing tiles in the same cabinet for a long time, about 4 hours. In this case, the temperature cannot be changed, its constant constant is 80 degrees. At the same time, production costs are almost the same.
In both cases, the energy consumption is the same, but only for different stages production.
The production of rubber tiles in a hot way at cost is several times cheaper than in a cold way, since tiles are made much faster. Therefore, for small enterprises for the production of rubber tiles, it is more profitable to purchase a hot pressing production line to save the budget.
For large enterprises, it is better to use a cold pressing line because it is highly productive. Up to three times more tiles can be produced simultaneously than with hot pressing.
The shapes of tiles can be very diverse, since a huge variety of shapes for them is produced industrially.
Tiles can be just different geometric shapes, or in the form of some shapes or colors.
Landscape designers prefer to deal with tiles with geometric shapes: they are easier to install and create different paths and patterns.
Tiles in the form of flowers or other figures are made to order.
They are practically non-existent in wide production, since they are used only for special projects.
The practice of using rubber coating shows its excellent properties. Rubber tile in many respects outperforms paving slabs and other coatings. It is enough to note its strength, extending the period of use up to two decades.
Choice of premises for production
Tile production needs a special room. It should preferably meet the following requirements:
- total area premises - at least 80 square meters;
- ceiling height - not less than 3 meters;
- the internal temperature of the room is not lower than +15°;
- connection to an industrial power grid - from 20 kilowatts;
- floors with a flat surface;
- distance from the residential sector at least 300 meters.
Raw materials for the production of rubber coating
To establish the production process, you will need to purchase the following materials:
- rubber crumb (color and black);
- dyes;
- polyurethane adhesive.
The main raw material rubber crumb. Mostly, it is a used car tires. The key to the strength and durability of crumb rubber is the high quality of both natural and artificial rubber, as well as emollient oils and fillers that are used in the manufacture of tires.
Rubber crumb is produced as follows. First, waste rubber products are collected at a specially designated site. Then, from the place of storage of crumb rubber, it is delivered by a forklift to the workshop.
There it is loaded into a special plant that processes rubber products. The process of manufacturing crumb rubber of a certain fraction is started. Finished products are unpacked into bags and transported by forklift to warehouses.
Equipment for the production of rubber tiles
When buying this type of equipment, each entrepreneur primarily focuses on the amount of start-up capital. The market today offers a wide range of equipment of this profile.
So, what equipment will you need to open your rubber crumb tile business? The standard technological complex includes the following units:
- Mixers (six pieces). They are needed for the process of mixing various ingredients.
- Heating cabinets (or drying chamber). Here the raw material will be subjected to heat treatment.
- Six fixing stands for tiles.
- Forming tables (you will need three to six pieces).
- Mixer platforms.
- Press (hydraulic model) for the production of rubber tiles. This machine will provide the molding process of products.
- Molds They will serve for the manufacture of the necessary products.
- Conductor. It is necessary for the formation of technological holes.
This is the minimum set of components for the production line, which will allow you to start the process of manufacturing rubber tiles. This equipment will allow to produce products of different thickness and density.
Video: equipment for the production of rubber tiles.
Production technologies
In the production of two-layer tiles, for a softer and cleaner top layer, you will need colored fine rubber. For a dense lower base layer, you will need a black coarse crumb (0.2-1 cm).
The creation of each layer of rubber crumb involves a separate production process. At the same time, it is assumed that the composition of the lower layer may include textile inclusions, metal elements and other impurities.
At the initial stage of production, a mixture is made with the addition of glue and pigment. All ingredients are mixed as thoroughly as possible. Then the resulting raw material is poured into molds having the desired parameters and a given shape.
Formation of products is achieved by pressing. After that, you need to carefully remove the tile from the molds. If the work is done without a flaw, then high-quality tiles are packed and sent to a warehouse or transported directly to the customer.
Rubber crumb tile production methods:
- hot pressing;
- cold pressing.
The first - high-temperature - method is characterized by high productivity, but the tiles obtained by hot pressing lose their durability and acquire the smell of burnt rubber.
With cold pressing, both process productivity and product quality can be achieved. The main thing is to comply with all technological requirements.
Video: comparison of hot and cold pressed rubber tiles.
Stages of production of rubber tiles by cold pressing
- Mixture preparation. A line with six mixers will allow you to thoroughly mix all the components.
- Filling the mixture into molds.
- Pressing process. Molds are loaded into trolleys in ten levels, which are subjected to pressing - squeezing under pressure up to 5 tons.
- Drying. Carts are placed for 4-6 hours in a drying chamber, where the temperature is set to 60 °.
- Unloading carts and removing products from molds.
- Quality control of finished rubber tiles.
Advantages of the cold pressing method
- there is a thorough mixing of all ingredients, which affects the improvement of product quality;
- under pressure, the tile acquires a high density;
- a sauna effect is created in the drying chamber, which contributes to the good absorption of dyes and glue into rubber crumb - this will subsequently affect the strength and flexibility of the tile;
- cold pressed rubber tiles do not have a specific smell and do not suffer from the effects of the external environment.
Profitability of the rubber tile manufacturing process
A mini-factory, where this equipment will be located, can cost a novice entrepreneur in the amount of 2 to 3 million rubles, including VAT and a set of all work to launch the line.
You should not be afraid of the costs of acquiring equipment for the production of rubber tiles and organizing a business as a whole. They redeem themselves pretty quickly. The main advantage of such a line is that it will save on the labor of workers. Three or four operators will be able to serve it.
The profitability of the production of rubber tiles on such equipment will be 40%. With a 22-day work schedule, production output can be increased to 3,000 m2 of tiles per month.
The main thing is the competent operation of the equipment and a thoughtful approach to the production process. With a growing demand for rubber tiles and little market competition, there is every reason to expect the company to be successful.
- When purchasing equipment for the production of rubber paving slabs, you should responsibly approach the issue of choosing a supplier.
- A conscientious supplier will provide information on the location of sales markets and help create schemes for its sales.
- It would not be bad for a novice entrepreneur to acquire a list of documents for obtaining a certificate.
- The supplier can also provide assistance in acquiring the necessary raw materials for the production of rubber coatings.
- You should buy equipment for the production of rubber tiles from a supplier who will not only install it and help with the launch, but also give a guarantee for the implementation repair work in case of force majeure.
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 allow it to be used for organization garden paths, as floor coverings terraces and country houses.
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 country house And 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 settlements are located. 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.
Exist the following options production of rubber tiles:
- Production of tiles at home;
- Production on an industrial scale;
Mini plants
One of the best options is to produce rubber tiles using a mini factory. It is represented by highly profitable and fast payback equipment, which is distinguished by a cold forming method.
For such a plant would need 80-100 sq. m. area and 3-4 workers per shift. In this case, the energy consumption is 15 kW/h. With such a set of equipment, you can offer customers a fairly large range of coatings. Ability to tile different forms, options, 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 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 a good option for those who have capital, but do not have sufficient experience in business 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 trusted 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 choice are warehouse or industrial premises suburban or 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.
- Having a level ground for correct installation equipment.
- The building must be located at least 300 meters from residential buildings.
- Good electrical wiring and connection to the network should 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 enough space, necessary equipment and quality raw materials.
An overview of equipment for the production of rubber tiles is presented in this video:
