Business plan for recycling tires into crumb rubber with calculations. Production of crumb rubber from tires: technologies and methods Equipment for the production of rubber crumb from tires

How to make rubber crumb with your own hands - methods, features

Due to the increase in the number of road transport, the amount of waste began to increase exponentially, so the ecological situation was under great threat. Every year, thousands of tires are taken to landfills and landfills, where they become a source of negative impact on the entire environment.

Car tires belong to the 4th class of waste by danger, since in the process of decomposition they release carcinogenic and toxic substances that can destroy the shell of the biosphere. Recycling requirements have become more stringent over the past few years (particularly in large cities) and the recycling of rubber products is regularly checked.

What is crumb rubber made from at home?

According to the rules fire safety and it is completely forbidden to store tires due to the fact that they are prone to spontaneous combustion. Active people who have a basic knowledge of physics as well as carpentry skills can turn rubber waste recycling into main source income. Rubber crumb, which will be obtained through recycling, will act as a secondary raw material for the manufacture of new goods. Let's look at how to make crumb rubber from wheels yourself and how to expand this business to a business scale.

Rubber crumb is made from car tires, which have become unusable, since they lend themselves much better to the mechanical type of impact, and it is also easier to extract metal wire (cord) from them. Recycling used tires makes it possible to obtain crumbs with the desired diameter and at the same time waste raw material to a minimum. Volumetric figures carved from car tires are often used to decorate courtyards of residential areas or garden plots. Often you can see flower beds, not very high fences, or fences on the playground, which are made of tires.

Note, that with the help of a large rubber crumb, you can lay out tracks in a private house and summer cottage, and this will help to give them an aesthetically beautiful view. Also, with the help of rubber coatings, which have excellent noise-absorbing and waterproofing properties, sports grounds and children's areas are equipped.

Recycling small amounts of rubber at home

In order to make rubber crumb with your own hands in a small amount, you do not need a large amount of raw materials, as well as special equipment. You can use improvised tools, such as scissors, an ax or a guillotine cutter. A well-sharpened knife is also perfect for cutting an old tire.

Tire recycling steps for small crumbs at home:

But in order to be able to work with a large amount of waste for personal and commercial purposes, financial investments will be required - for the purchase of special equipment, renting a room for processing raw materials. The cost of units that are offered from direct manufacturers will depend on the configuration and power. Imported and domestic manufacturers provide full-cycle waste rubber recycling lines, but if you have a good knowledge of physics, then you can make your own tire crumb recycling equipment and it will meet all your needs.

Capable of creating crumbs from a car tire

What are the ways to get crumb rubber?

Cooling of raw materials with liquid nitrogen to a brittle state and further grinding. This type of processing will require the use of special freezers, as well as cooling the raw material to a temperature of -70..-90 degrees, which is simply impossible at home.
Grinding of rubber products on a specialized line of a full cycle of processing. This method is used for industrial production, in which the production of crumb rubber is carried out on a large scale, and also requires large financial investments.
Recycling of rubber products into homemade device, i.e. crushers. If you have welding and milling equipment, you can make a chopper with your own hands. If this is not possible, then the parts should be ordered in the workshop according to your own scheme. The cost of a do-it-yourself device will be much less than finished equipment.

Note, that if you are going to be recycling rubber waste on a regular basis, you will need a spacious and well-ventilated area to install all the equipment and store a huge amount of rubber waste. The advantage will be the location of the production premises in the industrial zone.

Unit device

The design features of the grinder are distinguished by the fact that they have a knife mechanism (shredder), which makes it possible to process tires, tubes and other rubber elements. With this method of grinding, the material is able to fully maintain its own molecular formula, and will not lose its elasticity properties. The performance of the equipment will depend entirely on the power indicators.

The main components of the unit for the processing of rubber products are:

Electric motor - helps ensure the rate of recycling of rubber waste, the recommended engine power is approximately 4 to 5 kW.
Box with cutting discs - helps to grind the raw material to the required size.
The grate that calibrates the crumb - allows you to adjust the diameter of the resulting rubber crumb.
Worm gear - eliminates the possibility of jamming of the raw material, as well as its jamming.
Device frame - ensures the stability of the machine.
Bunker for loading.
Guide tray.

In general, the mechanism of the machine will be placed in a housing, on top of which a loading hopper will be installed. Before immersing the material, be sure to remove all foreign objects from the metal (nails, spikes, etc.). Tires should be cut into strips to help reduce recycling time. Now let's take a closer look at how to make crumb rubber from tires using a special mechanism.

Box of cutting discs

The main part of the device is precisely the shredder installation. The box contains steel, heat-treated milling discs with a high level of strength. They are sufficiently resistant to wear and do not require frequent replacement during the operation of the machine. The manufacture of the structure will require accurate hole calculations, as well as various cutting discs, so it is better to entrust such work to the designer.

Grids for crumb calibration

Under the box where the milling shafts are located, a sizing grid should be installed, which allows you to adjust the diameter of the rubber crumb, which is obtained during the grinding of the tire inside the shredder.

Worm gear

A mechanical type gearbox will convert the angular velocity using a worm gear, which will allow processing rubber material with varying degrees of elasticity without hanging and winding. The mechanical gears of rotary motion should be set between 25 and 36 units, which will ensure a high level of device performance.

Machine frame

The safety of processing work will be guaranteed by the frame of the machine, which is made of profile material. It will ensure the stability of the position of the working device during grinding and loading of raw materials inside.

Hopper loading

The machine necessarily has a hopper, which is required in order to load tire raw materials, which, for convenience, are located at the top of the body and near the guide tray. They will ensure a uniform flow of raw materials into the shredder (i.e. shredder), and will also prevent the formation of congestion during operation.

Device that cuts tires

In order to cut the tires and remove the metal cord, structures made from a carrier frame and a rack are used. The housing will house systems for clamping the bar, which will rotate with the bar when cutting. The design strut has a wedge-shaped knife that is built into a specific tire size. This technology of installation of the structure will help save time on preparing the material for consumption for further grinding inside the shredder.

tire shredding

The technological process of grinding involves the following actions:

Sorting of tire raw materials, as well as removal of foreign metals (thorns, nails, etc.).
Removal of cord from metal.
Cutting tires into strips.
Grinding of raw materials in a shredder.
Calibration of the resulting crumb.

Each of the five points is important in its own way.

Recycling

Now that you know how to make crumb rubber out of wheels yourself, let's find out what it is used for. It is often used for various areas of production, sold to the public, or used for personal purposes. A surplus of worn tires and other rubber products will ensure that material is always available for use. The cost of crumb rubber for the most part will depend on the diameter and quality of the resulting granules. At the moment, powdered crumbs, as well as granules with a diameter of 0.2 to 0.4 cm, are in great demand. raw materials.

Rubber crumb is used to make the following products:

Rubber Shoes.
Roll covers.
Fuel.
Pavement tiles.
Insulation and rubber seals.
Volumetric figures that were cut from used tires.
Paths for a garden / suburban area, a private house.
Noise-absorbing and waterproofing coatings for sports and playgrounds.
Asphalt mixes.
Technical rubber products.
Seamless rubber flooring.

At the moment, the recycling industry is considered promising enough to open own business as competition is low and demand for recycling services is increasing. Even with small amounts of work, all financial investments that will be spent on equipment will pay off in record time. short time. Recycling tires inside the crusher is recognized as the best and most environmentally friendly way for recycling, which allows you to make a profit with a small investment.

And a little more about the tire recycling business

So, you have learned how to make crumb rubber with your own hands, but let's take a closer look at how to turn recycling into your own business. Since old tires are waste, a license is required to work with them. It should be issued at your own expense, and this should be taken into account in advance. The second point is to receive a package of documents from the sanitary and epidemiological station.

In order to receive all the papers, you will need:

Install filters.
Choose the right location for the processing plant. Recycling should be carried out as far as possible from a residential building, as well as social facilities such as schools, kindergartens, and others.

Also, be sure to register the company with a government agency and tax office, conclude an agreement on the supply of electrical energy and resolve the issue of fire safety.

Premises selection

Recycling car tires requires a huge area, you must have at least 500 m 2. In addition, an area is required to store the finished crumb rubber as well as the raw material. Also remember that the processing plant must be located as far as possible from settlements, otherwise you will receive massive complaints and you may be closed without explanation. The requirements for the processing line are ideally met in individual areas, for example, located in an industrial area or somewhere on the outskirts. Land in an industrial zone is worth its weight in gold, so it will be cheaper to buy or rent a production facility, which should have convenient access routes.

Equipment

In general, equipment can be divided into 3 groups:

Equipment from Europe that meets all modern requirements. It is extremely efficient and reliable.
Heavenly equipment. PRC products most often have dubious quality, as well as a short service life. Naturally, if you buy Chinese products from well-known brands, then the quality will be excellent, then the price will be like that of European instruments.
The middle link will be Europe and China will be a reliable unit made in Russia. Price domestic technology will be 2-3 times lower, and 2 times higher than in China.

These are a few options for those who don't want or can't make their own equipment. I would also like to note that rubber processing can be both crumbly and diesel fuel, but the latter material will require large financial investments. The process consists of sorting and future grinding of raw materials, and then the selected material is loaded into a reactor that is able to extract fuel from secondary raw materials, which can be liquid, metal cord or gas. The finished product can be used for further processing.

Staff

For an enterprise where you can make crumb rubber, you will need:

Driver with own truck. You can also buy your own car park and just hire drivers.
Accountant.
A person who helps with sales finished products.

To select employees, it makes sense to apply to a special company, but you will conduct the decisive interview yourself. Tire recycling in Russia is a growing business, and most companies will be happy to take future employees on training courses. You can either train people yourself, or hire professionals who have already worked in this area.

Profitability

Before you make a purchase and start doing everything according to a business plan, calculate all the costs. Tires are practically garbage, but recycling equipment costs a lot of money. The total cost will be about 3 million rubles, so it would be more expedient to find an investor in order to implement the business plan. The cost of cleaners should be added to the amount, without which SanPiN will not give permission to operate a miniature plant. The cost of raw materials will be minimal, it can be bought almost for nothing. You will be surprised, but certain organizations themselves are willing to pay for the disposal of old tires.

Today, the processing of used tires into rubber crumb can become an enterprise that brings a good income to the owner and has a good prospect.

Business idea: recycling old rubber into granules

Mini production of rubber crumb from tires as a business is an enterprise, the opening of which does not require special knowledge and the use of sophisticated equipment. In this case, the payback depends on the amount of invested funds. The time for reimbursement of costs is from 2 to 12 months.

Our business valuation:

Starting investments - from 2,000,000 rubles.

Market saturation is low.

The complexity of starting a business is 6/10.

lack of monopoly on this type of activity;
a small number of competitors;
constantly growing demand for these products;
relatively low costs at the first stage;
quick payback;
expanding the scope of rubber granules.

All this indicates the absence of problems related to the sale of products and the possibility of establishing large-scale production in the future. Based on the above advantages, the rubber granulate plant is quite an attractive investment project.

The use of crumb rubber

Granules are used in many industries. The main consumers of products are:

construction companies;
manufactures engaged in the manufacture of sports coatings;
manufacturers of road surfaces, which include modifiers with crumb rubber;
enterprises producing rubber products;
companies whose field of activity is servicing the oil industry.

Also, rubber granules are used in the manufacture of bituminous mixtures and mastic, noise and heat insulation materials. The sale of rubber crumb can be carried out from the manufacturer wholesale and retail, through an online store or a special website of the company, as well as under an agreement with enterprises.

Conditions for opening a profitable production

The success of an enterprise whose activity is the processing of tires into crumb rubber depends on many aspects. But the main thing is the correct calculation of production standards, in which it is necessary to take into account the availability of start-up capital and the possible volume of sales.

Scopes of a rubber crumb

Based on the amount of money, the entrepreneur can:

open a mini-factory for the production of crumb rubber, with a minimum output;
organize large-scale production with specialized enterprises located on an area exceeding 1,000 m2;
choose the middle option.

Any of the solutions under consideration will require an analysis of the market in the opening region. In this case, one should take into account the demand for products, the presence of competitors, the price threshold, and so on.

Raw material for making rubber granules

Recycling car tires into rubber crumb is not considered a costly production. This is due to the low cost of equipment and raw materials. Often, enterprises organize the acceptance of car tires for processing on the territory production shop. This saves money on material transportation. Sometimes entrepreneurs find an opportunity to get raw materials for free, spending money only on its delivery.

Consumables can be:

worn tires, tyres, air chambers;
old fabric or metal-reinforced rubber.

Stages and methods of processing worn rubber into crumb

The processing of tires and tires into pellets consists of the following steps:

removal of metal elements from tires and tires;
cutting rubber into tapes of a given width;
production of blanks from tapes;
crumb production;
separation of the finished product into fractions.

A fully automated rubber crumb production line does not require direct human involvement in the manufacturing process. And the simplicity of the technology allows even a beginner who does not have special knowledge and experience to cope with the organization of the mini-workshop.

To date, there are two methods of processing:

mechanical;
shock wave.

Before you buy equipment for the production of rubber crumb from tires, you need to choose the most suitable way to manufacture products. For this, each of the processes should be considered in detail.

shock wave technology

The technology for the production of crumb rubber by the shock wave method was developed not so long ago and therefore is not widely used at the moment.

The advantages of the method are the following factors:

equipment installation does not require a large area;
minimal energy consumption.

When choosing shock wave technology for tire recycling, it is important to remember that such production is organized in specially prepared premises and requires the purchase and installation of expensive cold rooms. Such equipment for the production of crumb rubber will fully justify itself in large or medium-sized enterprises. The main disadvantage of the method is the need to apply mechanical action to obtain granules of the required fraction.

Mechanical method of crushing tires

The mechanical method of recycling used tires and tires into pellets is more popular among manufacturers and is suitable for opening a mini-production. The technology consists in a multi-stage mechanical action on the material: cutting, chopping, squeezing, grinding, grinding, etc. There are several types of mechanical action:

crushing at normal temperature;
crushing at high temperature(above 100 degrees);
grinding with low temperature, which ensures the fragility of the material;
grinding with an "ozone knife", when ozone accelerates aging and contributes to the rapid self-destruction of the material;
crushing with a powerful hydraulic press.

The most common is the first method, which has the following advantages:

thermal oxidation and the effect of devulcanization are excluded, when the structure of the material becomes plastic, and not elastic;
low energy consumption, providing a low cost of finished products.

Equipment for recycling used tires into pellets

Production line for processing tires into crumb rubber

The modernized line for processing tires into crumb rubber provides the preparation and abrasion of raw materials, and consists of the following devices:

machine for punching side rings;
hydraulic shears (or press guillotine, mechanical cutter) for cutting material into strips;
shredder crusher, grinding rubber into pieces (chips) ranging in size from 2x2 to 10x10 cm;
a mill is a machine equipped with reinforced structural elements that can withstand heavy loads created during the operation of the rotor, as well as square knives;
magnetic or air separator that removes steel;
vibrating sieve, with which the product is classified into the desired fractions;
mechanical conveyor.

The price of equipment for the production of crumb rubber, presented on modern market in a large assortment, depending on the performance, the country of the manufacturer, automation.

Entrepreneurs who open a small workshop should pay attention to an ergonomic and inexpensive machine for the production of rubber crumb, the capacity of which allows processing up to 5,000 kg of raw materials per day.

In order to save money, many people buy used equipment for recycling tires into crumbs. To exclude the possibility of breakdowns and repair costs, it is necessary to carefully inspect the unit, clarify with the owner the reason for the sale, require a technical passport and other documents. Otherwise, the entrepreneur runs the risk of buying low-quality equipment that either will not work at all or will require preliminary repairs.

You can save on the cost of equipment by purchasing equipment delivered to the Russian market from China. The advantage of such a transaction is the optimal ratio of price and quality.

It should be remembered that the productivity, and hence the success of the enterprise, depends entirely on the quality of the equipment.

Financial part

Prices for equipment for processing tires into crumbs vary from 1,350,000 rubles. and higher. It is necessary to take into account the payment for the installation and launch of the line - this will amount to about 150,000 rubles. Examination and written execution of documents cost from 120,000 rubles.

For example, for a mini-production, a simple line installed on 60 m2 and serviced by 2 employees (6 people in three shifts) is enough. Such equipment is connected to a 380V power supply and produces up to 100 kg of crumb rubber per hour. It is important to organize the warehousing of raw materials and storage space for finished products.

Based on this:

rent of production premises - from 50,000 rubles;
fund wages(based on 8 people) - from 250,000 rubles;
expenses for taxes, transportation, etc. - from 130,000 rubles.

As a result, the minimum monthly expense will be 430,000 rubles. And the total cost of opening and the first month of operation of the enterprise will be at least 2,000,050 rubles. But with an uninterrupted production process, all investments will pay off within 1-2 months of the workshop operation.

The monthly output will be 72,000 kg: 100 kg x 24 hours x 30 days. The cost of rubber crumb is an average of 25,000 rubles. for 1 ton. It follows from this that the expected profit will be equal to 1,800,000 rubles. per month.

Residual metal, the volume of which is about 20%, can be handed over as scrap and get about 150,000 rubles for it.

The total profit can be 1,950,000 rubles. per month.

With the expansion of production, it is possible to consider the production of coatings or plates from rubber crumb.

Crumb rubber, even after its complete grinding, retains the same properties as solid rubber:

has a noise-absorbing effect;
it is resistant to damage;
has a low weight;
safety;
environmentally friendly and non-toxic;
has an anti-slip effect;
waterproof;
heat-resistant.

What is crumb rubber for?

For the production of ecological floor coverings for various purposes;
for sealing;
For decoration of figures on children's playgrounds;
for the manufacture of car parking posts and fencing curbs;
Fill punching bags;
during the construction of roads;
production of heaters.

This range of applications for rubber granules can be continued, as they are an indispensable material in many areas of production and construction.

Types of crumb rubber

One of the types of crumbs produced by RBXGroup is shavings. The rubber is cut into oblong chips. Most often, this type of grinding is used to make the bottom layer of the floor covering.

Cuboid crumb - granules after cutting have a more regular shape. Due to the small number of voids when pressing this type of rubber, the product is more rigid and durable. Most often, the cuboid shape is used for the manufacture of seamless flooring.

Ragged shape - the surface area of the granules is larger compared to the previous types of crumbs, and the material products are softer.

Rubber crumb coating price per 1m 2

Rubber crumb for sports grounds is one of the most demanded products of our company. We produce granules that meet the requirements of the Ministry of Sports of the Russian Federation for laying on outdoor training and workout grounds. In RBX, you can buy a ready-made coating for playgrounds made of crumb rubber in the form of plates with a Dovetail lock and rubber granules of any fraction.

The post has been changed:

Business plan for opening the production of crumb rubber

Rubber is one of the most durable, sought-after and durable materials with numerous advantages and is used in various fields activities. It is flexible, flexural and resistant to abrasion or chemicals. It is used to create coatings, tires or other popular goods, so the production of crumb rubber is a profitable and stable business that brings a significant income to the owner.

General description of the project

The success and efficiency of activities depends on various factors. To do this, a competent business plan is prepared in advance, marketing research is carried out, and approximate opening costs are calculated.

By default, the activity is launched taking into account the following factors:

a mini-factory is opened, producing a minimum volume of products;
sales channels are being established, not only in one region, but also in nearby cities;
business expands due to the demand for goods.

To achieve a high result, it is necessary to create high-quality products, attract customers and offer them low prices.

Industry Analysis

Before starting work, it is necessary to carefully study the existing market in order to determine the effectiveness and feasibility of opening a new organization.

Market analysis in the region

For this, marketing research is used, and the entrepreneur can do this work on his own or contact specialized companies offering these services. Based on the information received, it is determined:

target audience, and it includes various construction companies, factories that manufacture sports or road surfaces, firms that create rubber products, as well as organizations that serve the oil industry;
demand for products;
presence and number of competitors;
opportunity for growth.

If you do not pay enough attention to research in advance, then it is likely that after opening a business you will encounter numerous difficulties, pitfalls and problems that were not foreseen in advance.

Competitor analysis

There are not many enterprises specializing in the manufacture of crumb rubber, so many regions are completely free from competition. Each such organization has both pluses and minuses, so it is important to study them:

competitive advantages;
main disadvantages;
offered prices;
the quality of the goods sold.

Based on the data obtained, such a strategy for the new company is determined, which will attract many buyers.

Risk Analysis

Before opening a business, its advantages and disadvantages are certainly studied in order to assess the opportunities and risks:

Risks	Advantages
Frequent checks from government agencies	No monopoly
Negative attitude from the residents of the region	Low competition
Difficulty in finding suitable premises for work, located at a considerable distance from residential areas	High demand for manufactured products
The need to work for several regions at once to increase profits	Fast payback
High initial investment	Opportunity to grow and expand your business

Marketing plan

Rubber crumb is used for the production of coatings, fences, platforms, high-quality waterproofing or other products, so there are quite a few distribution channels. In order for a new manufacturing company and its products to become known and in demand immediately after opening, the following promotion methods are used:

creation of a business card site;
direct visit to the manager of the organization of potential clients for personal communication;
location of information on large billboards in the city or in various media.

The application of these methods in combination will lead to the rapid popularity of the new plant, so a large base of regular wholesale buyers will be organized.

Possible raw material channels are discussed in the following video:

Production plan

The entrepreneur is obliged to understand tire recycling technology, after which a room is selected and equipment for work is purchased.

Variants of rubber crumb production technologies

This product can be manufactured using various technologies. Used as raw materials are old rubber tires or other rubber products. To receive raw materials, reception points are created directly at the plant or in the city.

The technology of work is divided into stages:

all metal elements are removed from tires or other objects;
rubber is cut into tapes of optimal length and width;
blanks are made from tapes;
a crumb is created;
the finished product is sorted into groups according to a certain fraction.

The production process is carried out on automated lines, so no human intervention is required. One of the processing methods is selected:

Shock wave. The process is carried out using equipment that does not take up much space and does not consume a lot of electrical energy. However, the work will require refrigerating chambers, which have a high cost. This technology is usually used large enterprises who have the means to purchase expensive equipment.
Mechanical. Most often chosen by novice entrepreneurs, and also ideal for mini-production. The procedure assumes that different mechanical influences act on the material, so it is first cut, then chopped, and then squeezed and crushed, after which it is ground. Crushing can be carried out at normal, high or low temperature. Ozone can also be used to speed up the process of rubber degradation. A hydraulic press is used for pressing.

The choice of technology depends on the available finances and the possibility of purchasing equipment.

Required premises

The production facility should be located away from residential areas. It is advisable to choose a building whose size will be at least 200 square meters. m., otherwise it will not be possible to arrange all the necessary equipment.

A standard rubber processing line covers approximately 150 square meters. m.

During the operation of the plant, the rubber heats up, so volatile substances with a specific smell are released into the atmosphere, so a high-quality ventilation system is certainly created in the room, and special cleaning devices are installed.

Equipment

The production of crumb rubber is carried out using a special line. It does not require human regulation. Consists of several elements:

bead cutting machine - 260,000 rubles;
equipment for processing rings - 300,000 rubles;
tape cutter - 350,000 rubles;
shredder for grinding raw materials - 2.5 million rubles;
impact crusher - 700,000 rubles;
vibration separator - 350,000 rubles;
electrical equipment - 300,000 rubles;
sieve - 300,000 rubles.

If you purchase all the elements separately, then their cost will be significant. If you buy a full-fledged line, then it will cost about 1.5 million rubles. In this case, the release of the minimum amount of products that can be provided by several regions is ensured.

Useful tips on choosing equipment, see the following video:

You can see a good example of the operation of a tire recycling line here:

Raw material channels

The raw materials are tires and rubber reinforced with metal. The following channels are used to receive it:

purchase through intermediaries;
opening of own reception points;
cooperation with factories and companies, in the course of which a lot of rubber waste remains;
establishing contacts with automobile workshops.

Opening your own collection points is considered the most profitable, since the owners of old tires are ready to sell them at a low price.

Business expansion opportunities

The development of the enterprise begins after receiving a sufficiently high profit. To do this, it is allowed not only to produce crumb rubber, but also to carry out the process of creating various products from it. Most often chosen:

creation of coatings for playgrounds or sports facilities;
the formation of rubber tiles suitable for interior or exterior decoration of various structures and adjacent areas.

With such a business development, an increase in profit from the operation of the plant is ensured, and not only large organizations, but also individuals who want to ennoble the area next to a private house.

organizational plan

Production requires professional workers. The business is documented, and a schedule for opening a case is also being developed.

Required personnel

A large manufacturing company needs a large number of employees, since the efficient operation of the enterprise requires:

maintenance personnel regulating the operation of the equipment, and two workers are enough per shift;
technologist;
accountant;
director;
sales managers;
driver to deliver goods to buyers.

You can hire employees on your own or using the services of recruitment agencies.

Business registration

Since it is planned to work mainly with big companies, it is desirable to initially register entity. For this, an LLC is selected, and to open it you will need:

application for opening an organization;
charter;
payment of state duty (4 thousand rubles);
a letter of guarantee on the presence of a legal address;
a protocol or decision on the creation of an LLC, as well as an agreement on its establishment;
form the authorized capital (at least 10 thousand rubles).

Registration can be simplified by contacting intermediary companies with this. For the official operation of the plant, you will have to issue a license for the activity.

Opening schedule

You can open a similar production company in three months:

market analysis and marketing research - 1 week;
search for premises - 1 week;
business registration - 2 weeks;
indoor repairs - 4 weeks;
purchase and installation of equipment - 2 weeks;
advertising and purchase of raw materials - 2 weeks.

After the implementation of all stages, the direct production of crumb rubber begins. Sales managers at this time are required to find customers.

Financial plan

To open such a company, approximately 2 million 250 thousand rubles will be required:

rent of premises per month - 200,000 rubles;
carrying out repair work and installing the necessary communications - 400,000 rubles;
purchase of equipment - 1.5 million rubles;
registration and obtaining a license - 100,000 rubles;
advertising - 50,000 rubles.

Monthly expenses will be approximately 550 thousand rubles:

lease payments - 200,000;
wages of employees - 200,000;
utility bills - 5,000;
transportation costs - 40,000;
taxes and other payments - 100,000.

In a month, the proceeds from the sale of products is approximately 900 thousand rubles. with the expectation that at least 100 tons of material will be sold. Net profit will be about 450 thousand rubles. The invested funds pay off within six months of successful work, which shows the high profitability of the project. back to contents

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 should correctly 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.

Business plan: crumb rubber

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 large areas, for example, several hundred square meters, which will be worth a large investment. Do optimal choice investment strategies 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 m2 and a production room whose area should be an average of 40 m2, 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 is shown schematically in the form of 3D animation technological process tire processing by crushing into crumb rubber:

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 the 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 of 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 production area 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 100m2, and for the storage of finished rubber crumb - 20m2.

On this basis, the cost of 100 kilograms of products per hour will change and change. In this business plan, we will determine the fixed costs for the month:

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.

Rubber tiles - the know-how of the last few years. It is just beginning to conquer the construction market, but it already claims to become the number one coating in the near future for the improvement of suburban areas. But what benefits can an entrepreneur take from this trend?

The manufacture of this building material is a new, low-competitive, but promising area of production. The guarantee of business success is the advantages of manufactured products over other types of coatings. Rubber crumb tiles:

safety;
durable (its service life is at least 20 years);
has anti-slip properties.

In addition, it does not crumble and does not crack at low temperatures, and, due to the elasticity of the material, frost is very easily chipped from it.

Production of rubber crumb from tires

The tile is able to pass water through itself, and therefore, with proper installation, there are no puddles on its surface. The range of rubber tiles is wide: it is made in different colors, sizes, can vary in thickness, shape and even the pattern that decorates the surface.

All this allows you to use the coating:

on playgrounds;
in kindergartens;
on sports grounds;
when making country paths;
for arrangement of sites near ponds, fountains, pools;
in garages;
in car services;
in areas where animals are kept.

Potential buyers of products are:

private persons;
building stores;
construction companies;
organizations involved in the improvement of the city.

Stages of production of rubber tiles

Preparation of a mixture, including crushed rubber crumb, coloring pigment and glue in mixers.
Putting the finished mixture into molds.
Pressing and molding in a hydraulic press.
Heat treatment, which gives the products the necessary technical characteristics.
Unloading molds.
Quality control and packaging.
Shipment to the warehouse.

Minimum equipment package to start a business

The best option for starting a crumb rubber tile business is to purchase the entire line of equipment from one supplier, for example, from EcoStep, which is the largest supplier of crumb rubber in Russia, which offers several modifications of mini-factories that differ in productivity and the number of types of products produced. products.

To launch a full-fledged business, the company recommends purchasing an EcoStep mini-factory as standard. It includes the following types of equipment:

The total cost of the equipment set, including VAT and commissioning, is 1,970,000 rubles.

Calculation of the cost price of rubber tiles at EcoStep mini-factory

Although the set of equipment provides for the possibility of manufacturing 14 types of products, the most popular products are EcoStep rubber tiles 500 mm x 500 mm, 40 mm thick.

In the total volume of orders, it occupies 70%, and therefore the calculation of the cost, and in the future, the profitability of production, is best done based on the cost of producing tiles of the specified format.

Product Feature

Name: safety rubber tiles EcoStep 500*500*40 mm.

Material characteristics:

size 500*500*40mm
tile weight - 7 kg.
weight 1m2 - 28 kg.
number of pieces in one m2 - 4 tiles

Parameters of the mini-factory

Work is carried out in 2 shifts.
The duration of the shift is 8 hours.
The productivity of 1 shift is 45 m2.
During the day, the plant produces - 90 m2 of finished products.
The average monthly productivity of the plant when working in 1 shift is 990 m2 of finished products (with 22 working days).
The average monthly productivity of the plant when working in 2 shifts is 2,500 m2 of finished products (with 22 working days).

payroll fund

The site will require 4 people: three workers and a shift supervisor. Their salary will be 17,000 rubles and 20,000 rubles, respectively. Thus, the wage fund when working in 1 shift is 71,000 rubles per month, in 2 shifts - 142,000 rubles per month.

Labor costs per 1 m2 of products is 71000/990 = 71.71 rubles

UST (Unified Social Tax) - 34%, which is 24.38 rubles. in the cost of 1m2 of finished products.

Requirements for production and storage space

To accommodate the EcoStep mini-factory, a heated room with an area of at least 100 m2 with a ceiling height of at least 3 meters is required. To accommodate a warehouse, a room with an area of 100 m2, possibly unheated, is required.

At the rate rent 150 rubles / m2, the cost of renting premises per month will be 30,000 rubles, which is 15.15 rubles. per 1 m2 of finished products.

Consumables costs

Crumb rubber - 16 rubles / kg
Polyurethane binder - 149 rubles / kg
Coloring pigment - 80 rubles / kg.

Cost calculation

Calculation of the cost of materials for the production of 1 m2 of EcoStep 500 x 500 rubber tiles 40 mm thick.

Taking into account other costs for the implementation of activities, it is possible to determine the cost of 1 m2 of rubber tiles.

cost of 1 m2 of rubber tiles EcoStep 500 x 500 40 mm thick.

Business profitability for the production of rubber tiles at the EcoStep mini-factory on the example of the production of EcoStep 500 x 500 tiles with a thickness of 40 mm *

* Please note that all calculations presented in the table are conditional and are given as an example of the potential profitability of this type of activity. The moneymaker factory recommends that you independently calculate the payback of the project before starting any activity.

Price for LPSH line

See Business plan for the production of rubber crumb and rubber products

Video LPSh-300 (option 1)

Installation supervision of all lines is carried out FREE OF CHARGE.

Complete sets and prices of tire recycling equipment

Tire pre-grinding machines

Line LPSh-200 of low productivity for processing tires without textile cord

Complete sets and prices of lines for any types of tires

Option 1. Line LPSh-400 - productivity up to 400 kg / h of input raw materials

Name	price, rub.
Bead cutting machine SOB-01	283 600
	328 400
Tape cutter SLR-01	358 200
Chip cutter SChR-01	399 600
	2 882 000
Vibration separator VS-01 + return conveyor (5-6 meters) + vibrating sieve SV-01	539 000
Magnetic separator SEMAG SM-01 + 2 bucket conveyors (1.5 m and 1.5 m)	286 000
Cyclone with fan + filter	247 500
	379 500
	352 700
electrical equipment	302 500
TOTAL:	6 359 000
Room area	from 120 sq.m.
Room height	4.5 m

Option 2. Line LPSh-600 - productivity up to 600 kg / h of input raw materials

Name	price, rub.
Bead cutting machine SOB-01	283 600
Bead ring processing machine SPBK-01	328 400
Tape cutter SLR-01	358 400
Chip cutter SChR-01	399 600
	2 865 500
Impact crusher SDR-01	715 000
Vibration separator VS-01 + extract + cyclone + filter	390 500
	352 000
Vibration pneumatic complex VPSK-01 + bucket conveyor (3.5-4 m)	380 200
Vibrating sieve SV-01 + bucket conveyor (3 m)	352 800
electrical equipment	322 300
TOTAL:	6 748 100
Room area	from 150 sq.m.
Room height	5 m

Option 3. Line LPSh-800 - productivity from 800 kg / h to 1000 kg / h of input raw materials

Name	price, rub.
Bead cutting machine SOB-01	283 600
Bead ring processing machine SPBK-01	328 400
Tape cutter SLR-01	358 200
Chip cutter SChR-01	399 600
Two-shaft shredder for shredding rubber ShR-01 + direct conveyor (4.5 m) or single-shaft with automation to choose from	2 865 500
Rolling machine SVI-01 + straight conveyor (3-4 m)	3 960 000
Vibrating separator VS-01 + direct return conveyor (6 m)	275 000
Impact crusher SDR-01	715 000
	517 600
Magnetic separator SEMAG SM-01 + 2 bucket conveyors (3.5 m + 3 m)	352 000
vibrating table	352 800
electrical equipment	351 000
TOTAL:	10 758 700
Room area	from 200 sq.m.
Room height	from 5 m.
	953 200
	154 000

Option 4. Line LPSh-1500 - productivity up to 1500 kg / h of input raw materials

Name	price, rub.
Bead cutting machine SOB-01	283 600
	715 600
Tape cutter SLR-01	358 200
Chip cutter SChR-01	399 600
Bead ring processing machine SPBK-01	328 400
Cord squeezer KGSh KV-01	508 200
Conveyors for CGSH, 2 pcs.	387 200
Two-shaft shredder for shredding rubber ShR-01 + direct conveyor (6.5 m) or single-shaft with automation to choose from	2 865 500
	3 960 000
Impact crusher large SDR-01	715 000
Impact crusher small SDR-01	715 000
Vibrating separator VS-01 + return conveyor	420 200
Vibropneumocomplex VPSK-01 + extract + 2 cyclones + filter	517 700
Magnetic separator SEMAG SM-01 + 2 bucket conveyors (3.5 m +3 m)	352 000
Vibrating sieve SV-01 + bucket conveyor (3 m)	352 800
electrical equipment	544 500
Gantry crane, lifting capacity 2 t.	290 400
TOTAL:	13 713 900
Room area	from 250 sq.m.
Room height	from 5 m.
An additional option is a roller cutter for processing the tread part of tires	953 200
Additional option - machine for removing studs	154 000

Option 5. For KGSH - productivity up to 1500 kg / h of input raw materials

Name	price, rub.
Hydraulic scissors for CGSH GN-01	980 000
Cord squeezer KGSh KV-01	913 000
Rubber shredder ШР-01 twin-shaft or single-shaft to choose from + straight conveyor (4.5 m)	5 225 000
Shredder conveyor (6 m) with magnetic roller	319 000
Return conveyor (6.5 m)	158 400
Impact crusher SDR-01 for a fraction of 1-2 mm.	715 000
Impact crusher SDR-01 for a fraction of 2-4 mm.	715 000
Impact crusher SDR-01 for a fraction of 4-6 mm.	715 000
Roller grinding machine SVI-01 + straight conveyor (3-4 m)	3 960 000
Vibrating separator VS-01	275 000
Magnetic separator SEMAG CM-01 + two conveyors	352 000
Vibropneumocomplex VPSK-01 + hood + cyclone + filter	660 000
Vibrating sieve SV-01 + conveyor	352 800
electrical equipment	495 000
TOTAL:	15 835 200
Room area	from 200 sq.m.
Room height	from 5 m.
An additional option is a roller cutter for processing the tread part of tires	953 200
Additional option - machine for removing studs	154 000

Equipment for the production of rubber tiles and rubber coatings

When buying machines separately, the price increases by 15% of the base price.

We restore windrows and rubbing shredders of lines of any manufacturer.

Video LPSh-300 (option 2)

The price of the press and auxiliary equipment

Name	price, rub.
Hydraulic press PG-12 PS with mold heating (simultaneous loading of 10 molds)	753 900
Molds (price for 1 piece):
Tile 500*500 8 mm.	27 000
Tiles 500*500 15 mm.	29 200
Tiles 500*500 15/25 mm. Business for recycling tires into crumb rubber with spacers	36 900
Tiles 500*500 25 mm.	36 900
Tiles 500*500 20 mm. "Bricks"	45 800
Tiles 500*500 30 mm.	36 900
Tiles 500*500 40 mm.	39 900
Tiles 500*500 40 mm. with bushings	39 900
Tiles 500*500 40 mm. "Bricks"	51 700
"Dovetail" 25 mm.	38 000
"Dovetail" 45 mm.	50 200
"Spool of thread" 15 mm.	45 000
"Spool of thread" 25 mm.	49 900
"Spool of thread" 45 mm.	54 800
"Brick" 45 mm.	40 800
"Wave" 45 mm.	64 800
"Border" 45 mm.	46 900
"Puzzles" 25 mm.	57 000
Auxiliary equipment:
Mixer M-600 (4 kW, 2 containers, 50 kg)	68 500
Mixer M-350 (4 kW, vertical loading, 1 container, 70 kg)	45 400

The price includes: 1 year warranty, consulting and training.

Equipment available.

In recent years, the use of rubber crumb and materials made on its basis for decorating sites, organizing paths, and covering roofs of houses has become fashionable. You can also use crumb rubber to create waterproofing for building foundations. In order to use crumb rubber elements on your site, you can contact a company that professionally works with crumb rubber. However, working with this material is not so difficult. If desired, and if you have free time, crumb rubber can be made at home with your own hands.

What is rubber crumb made of?

There are two ways to go about solving this issue. Path number one relies on the transition of rubber to a brittle state at low temperatures. If at home it is possible to cool the source material for preparing crumbs to a temperature of -70 ... -80 degrees Celsius, then it will be possible to obtain crumbs from any type of source materials. However, solving this problem at home is not so easy.

Path number two is the competent selection of source material. As we know, crumbs can be obtained from tires and tubes from car wheels. But tires are very difficult to grind under normal conditions, and it is also difficult to extract the metal cord from them later. For this reason, to obtain crumb rubber at home, it is better to use old worn-out cameras as raw materials. This material can be easily cut with the help of improvised tools available in any home.

How to make crumb rubber at home?

At the initial stage, it is necessary to prepare a sufficient amount of raw materials, i.e.