Buy equipment for the production of polymer-sand tiles. Production of polymer sand tiles: a simple business for beginners. Production of polymer sand tiles

In the construction market, there are a lot of materials characterized by a variety of properties. And many of them can become a source of high income for an enterprising person. We include here the production of polymer sand tiles. And the main advantage of the organized business will be not only the great demand for products on the market, but also the fact that it can be manufactured on relatively inexpensive mobile equipment. Polymer-sand tile is a building and finishing material made on the basis of sand and polymers. He owns several positive qualities, for which he won the trust of customers - strength, frost resistance, durability.

Our business valuation:

Starting investments - from 1,000,000 rubles.

Market saturation is low.

The complexity of starting a business is 5/10.

It is not difficult to open the production of polymer-sand tiles - neither huge investments nor hiring highly qualified personnel. What should an entrepreneur take into account here?

The process of obtaining products

Commonly available and inexpensive components are used as raw materials for the manufacture of finished tiles. You can get them in every region of the country.

Technological scheme for the production of polymer sand tiles

These include:

cleaned sand,
polymers,
pigments.

To reduce the cost of purchasing all the necessary components, you can purchase secondary raw materials - it costs much less.

As for the exact recipe, everything is strictly individual here - each manufacturer works with its own composition. You can develop a recipe yourself, or you can invite an experienced technologist for advice.

The technology for the production of polymer sand tiles is extremely simple and does not require any specific skills and knowledge from the entrepreneur (if he decides to do all the work himself).

Making polymer sand tiles with your own hands is carried out as follows:

Preparation of all components and mixing them.
Melting of raw materials.
Pressing products.
Storage finished products.

Business prospects.

Purchase of equipment for the production of products

The next thing an entrepreneur will need to do is to buy equipment for the production of polymer sand tiles. And even home production will require certain machines.

Line for the production of polymer sand tiles

The technical equipment includes the following items of equipment:

Dispenser - from 30,000 rubles.
Concrete mixer - from 40,000 rubles.
Melting and heating machine - from 350,000 rubles.
Press - from 150,000 rubles.
Molds - from 1500 rubles / piece.

The final price of equipment for polymer sand tiles will depend on the power of the machines, their configuration and degree of automation. The minimum cost of a production line for a mini-workshop and its commissioning is ≈800,000 rubles. And this figure can be much higher if we talk about a more powerful enterprise.

Sales of finished products and shop profitability

The sale of polymer sand tiles, with well-established distribution channels, should bring the entrepreneur a high profit. And given the demand for products, there is no doubt that many customers will be interested in purchasing quality tiles from a direct supplier. It is used for paving roads, interior and exterior cladding.

Products can be sold:

construction shops and warehouses,
developers,
repair companies,
private buyers.

Despite the fact that wholesalers will bring the bulk of the profits, you should not discount private buyers. To do this, a small pavilion can be organized in the workshop, where manufactured products will be exhibited to customers.

Production of polymer sand paving slabs, as practice shows, will begin to pay for itself quickly enough. The launch of a small workshop will require an investment of at least 1,000,000 rubles. This will include the following expenses:

purchase of the most basic equipment,
preparation for the work of the premises (conducting light, water and sewerage),
providing a raw material base for the release of the first batch of goods,
company registration.

To calculate the profitability of the planned enterprise, let's take as an example a low-power line with a capacity of up to 50 m 2 of finished tiles per 8-hour shift. It turns out that more than 1000 m 2 of products can be received monthly. Polymer-sand tiles for basement today cost 250-500 rubles / m 2 on the wholesale market. This means that if you immediately sell all the products produced, the entrepreneur can receive revenue in the amount of 500,000 rubles. And these are excellent profitability indicators for a workshop in the small business segment.

To calculate net income and total revenue, subtract variable costs:

Polymer sand equipment makes it possible to produce new types of materials with unique properties and consumer qualities, which favorably distinguishes them from the classic types of products made from concrete and plastic building materials.

Products for the garden

Tile garden polymer-sand
Polymer sand garden fences
Polymer sand board

pavement products

Polymer-sand paving stone
Paving slabs polymer-sand
Polymer sand curbs
Polymer sand channels for water drainage
Manholes sewer polymer-sand
Manholes country polymer sand

Roofing materials

Polymer sand tiles
accessories for roofing

Facing materials

Socle polymer-sand tile
Sand polymer board
Wood-polymer board (WPC)

Polymer sand composite is an artificially created material not found in nature. and combining qualities unusual for other materials: high strength and reliability, durability, low weight, attractive appearance and ease of installation.

Production technology

The composition of the composite mixture for the manufacture of polymer-sand products includes a filler (sand), a polymer and a dye. Instead of sand, waste from mining and processing plants, screenings of rocks can be used.

At the first stage of production, polymer waste (plastics, plastic) is crushed, or in the case of polyethylene, agglomeration is carried out to obtain a polymer from recycled materials.

At the second stage, uniform mixing of the main components is carried out: filler + polymer + dye. The color of the future product will depend on the choice of pigment.

At the third stage, a thoroughly mixed dry mixture is placed in a melting unit (APN) and subjected to heat treatment, as a result of which the polymer envelops each particle of the filler.

During subsequent molding and solidification of the polymer sand mass forms a homogeneous monolithic structure with high strength. The finished material is stacked on pallets and sent for storage.

Basic equipment

Melting and heating unit (APN)

APN is designed for mixing and heating the components of the polymer-sand composite (sand, polymer, pigment) and obtaining a homogeneous mass of tight dough consistency.

A pre-prepared, evenly mixed mixture of polymer components is fed into the heated working chamber of the APN through the receiving hopper, and is pushed deep into the chamber by an auger. The rotating auger ensures the mixing of the composite mixture and its advancement inside the working chamber passing through the heating zones.

Forming press

The press is used for molding products. The resulting mass in the extruder is placed in a mold installed on the working table of the press, the molding of the product occurs under pressure while cooling the mold, which can significantly increase productivity, ready product it is automatically removed from the mold by the lower pushers and is ready for palletizing without additional aging (unlike cement products).

Press forms

The molds are installed on the molding press and allow the production of a wide range of products.

Crusher

The purpose of the crusher is the preparation of polymer from recycled materials (crushing to a homogeneous fraction) for further use, the proposed crushers are universal, since they can process both hard and soft film materials (agglomeration is not required), depending on the intensity of production, crushers can have different capacities, cans, bottles, canisters and other polymer waste can be processed.

Polymer-sand equipment can be used in the production of composite materials with various formulations, for the manufacture of a wide range of products based on them (polymer-sand, polymer-glass, polymer-rubber, polymer-faience, etc.). 100% composed of secondary constituents by mass.

A number of unique technical solutions were used in the design of the equipment, which made it possible to achieve high indicators of quality and reliability of products manufactured on it.

The advantages of the equipment include the possibility of using difficult-to-recycle types of plastics in the production: layered plastics, packaging materials made of cross-linked polyethylene, plastic materials with a foil layer, trimmings of polyester needle-punched pile thermally bonded fabric, etc. Such waste is transported to landfills for disposal or are burned.

With the help of the proposed polymer equipment, you can create a complete production cycle - from the preparation of raw materials to the finished product at a bargain price. This allows the production of a wide range of products.

Polymer-sand tiles appeared on the Russian building materials market quite recently, but have already managed to establish themselves as a material worthy of becoming a full-fledged replacement for traditional cement tiles. The demand for such tiles is growing, and those businessmen who are not afraid to work in innovation sphere, there is a great opportunity to show your entrepreneurial talent, of course, having assessed all possible risks before doing so.

The appearance of this building material was initially due to the desire of technologists to find the coating that can solve the two main problems of cement tiles: low frost resistance and durability. And, admittedly, they succeeded: polymer sand tiles have many advantages. She is:

durable: according to manufacturers, its service life is about 30 years
sustainable to negative influences external environment. Polymer sand tiles are not afraid of frost, moisture, direct sunlight, exposure to acid-containing liquids and oils. It is resistant to high mechanical loads and is not at all prone to point splitting.
decorative: can have any shape, any surface: matte, glossy, structured. It is made in a wide range of colors, and more importantly, does not lose its decorative effect over time.
Does not emit toxic fumes under the scorching sun
Easy to clean
Easy to repair and easily withstand repeated use

Polymer sand tiles can be used:

when ennobling garden plots;
for the arrangement of adjacent territories;
in places of mass attendance: courtyards of summer cafes, parks, trade and exhibition pavilions);
in garages and covered parking lots;
in workshops;
for covering operated flat roofs;
for plinth cladding.

All of the above is about demand of this product among buyers and, as a result, the large capacity of the market, and taking into account the simple manufacturing technology and relatively low costs for starting a business, all this makes the production of polymer sand tiles quite relevant to start.

The implementation of the finished tile can be carried out:

directly to consumers of products: individuals, construction teams and organizations, organizations whose activities are aimed at improving the city;
through the wholesale network: wholesale warehouses, bases.
through retail network: building supermarkets, specialized stores, markets.

Raw material for the production of polymer sand tiles are:

sand without clay inclusions, the fraction of which does not exceed 3 mm;
polymers: primary and secondary - the latter option is more attractive from an economic point of view,
pigments, both mineral and organic.

Main stages of production

Crushing or agglomeration of raw materials. This stage may be absent if the manufacturer purchases polymer chips.
Mixing raw materials in a concrete mixer.
Melting the mixture in the extruder (APN).
Forming a product with a press.
Shipment of finished products to the warehouse.

When calculating economic efficiency production of polymer sand tiles, the following parameters were taken as a basis: work is carried out in 2 shifts, the duration of each of which is 12 hours. The productivity of the mold is 5.83 m 2 of finished products per hour, respectively, the entire line produces 140 m 2 of finished products per day.

Finished product characteristics

Tile size - 330 x 330 x 35 mm;
The number of pieces of the product in 1 m 2 - 9 tiles;
Tile weight - 4 kg;
Weight 1 m 2 - 36 kg.

Initial cost of starting a business

	Naming of expenditures		Price without VAT, rub.	Depreciation per year, rub.
	Naming of expenditures		Price without VAT, rub.
	Commissioning works


	General purpose scales MK-15.2-AV20

Visit the list of equipment for polymer sand tiles in a special section.

Requirements for production premises and rental costs

The cost of rent in terms of 1 m 2 of finished polymer sand tiles will be 2.38 rubles.

Labor costs

		Number of employees	Wage, rub.	Total, rub.

	APN operator
	Ancillary worker on the batch
TOTAL per month

The cost of materials for the manufacture of 1 m 2 of finished products

Thus, the costs for the manufacture of 1 m 2 of polymer sand tiles will be 136.58 rubles.

Electricity consumption for 1 work shift

Equipment		Power, kW/h	Quantity, pcs.	Total consumption	Consumption for 1 shift, h	Total, kWh/shift

	Press D2430 modernized
	Concrete mixer SBR-500
	Scales of general purpose MK-15.2-AB20
	Lighting

The average cost of electricity in Russia is 4.03 rubles. for 1 kW / h, from which it follows that the manufacture of 1 m 2 of paving slabs will entail electricity costs in the amount of 7.8 rubles.

Current costs of the workshop for 1 month of work

Naming of expenditures		per month, rub.		per 1 m2, rub.
Naming of expenditures
	Electricity
	Salary


	Depreciation

The final calculation of the profitability of the business for the production of polymer sand tiles


Cost of 1 m 2, rub.
Overhead costs, rub.
Including overhead
Market price of 1 m 2, rub.
Profit before tax per 1m 2, rub.
Income tax (20%), rub.
Profit from 1 m 2, rub.
Profit per day total, rub.
Profitability, %
Payback period, days

* The calculations presented in the section are conditional and provide only a general understanding of the profitability of this type of activity based on the expert opinion of the author of the material. To determine the exact amount of profitability, you must independently make a feasibility study, based on the specific numbers of your region and the size of the business you are planning.

Polymer-sand products are products made using waste polymers (polyethylene bags and PET bottles).

Is it profitable to engage in this production and how quickly will it pay off?

The main forms of polymer-sand products are facing and paving slabs, curbstones, tiles and occasionally manholes.

Polymer-sand products have a number of useful properties:

high impact resistance (compared to cement-sand products) - they do not break during installation and during transportation;

durability - their service life exceeds 100 years;

lightness - polymer-sand products are two times lighter than cement-sand analogues;

cheapness;

not spreading flame and electricity;

resistance to environmental influences - they withstand temperature drops from -60 to +200 degrees, are resistant to ultraviolet radiation, absorb sound well, and this is their advantage over metal roofs. Polymer-sand tile does not absorb moisture, washes well, does not accumulate snow, and retains its original color for up to 30 years.

In Europe, these are ANDERA polymer-sand tiles, which have received recognition at various exhibitions and the approval of the Swedish Consumer Association (SVK).

The production technology of polymer-sand materials is very simple. They are made up of polymer sand and dye. The ratio for tiles is 24/75/1, for paving slabs - 5/94/1.

For work, you will need soft (bags, plastic wrap) and hard (polystyrene, polypropylene, PET bottles) polymers. Their ratio is 50/50. Do not use rubber and refractory polymers - polycarbonate, fluoroplastic.

Raw materials for business can be found in a regular landfill or recycling centers. You can buy sorted and cleaned waste, but it will cost much more, and there is no great need for this, because paper and food waste burn out and will not have any effect on product quality.

1 ton of untreated waste on average in Russia - 3 thousand rubles.

Sand is used as a filler for finished products. The moisture content of the sand should not exceed 10%, and the clay content should not exceed 20%. Permissible fraction - up to 3 mm.

1 ton of sifted dry sand costs an average of 300 rubles in Russia.

The third component is Bayerferrox dye (Bayer). Its average cost is 90 rubles/kg. If you work without dye, then the finished product will have a gray color (curb stone, paving slabs).

Main stages technological process:

Crushing of polymeric waste. We use the device - polymer crusher PT 2003.00.000 (capacity 900 kg/h).

The resulting mass is placed in an extrusion machine (Extrusion machine PT 2004.00.000 with a capacity of 85 kg / h), where the polymers are heated and mixed. The finished mass cools down and the slightly hardened conglomerate is again placed in a crusher to obtain an already fine homogeneous fraction up to 10 mm.

The resulting polymer mass, prepared sand and dye are mixed and poured into a melting and heating unit (APN PT 2002.00.000 with a capacity of 250 kg / hour). This stage is the most important, mixing, heating the mass and enveloping each particle of sand with a polymer takes place here. This is achieved by a peculiar design of the shaft, the blades of which advance the mass at different speeds in three heating zones, and this leads to high-quality mixing of the mass.

The resulting mass of the consistency of a tight dumpling dough is placed in a molding press, where the mass is put into molds, and under pressure (250 tons) it is cooled. To obtain paving slabs, the mass is cooled evenly. To obtain a tile, to give it a shine, the lower part of the mold is cooled faster than the upper one.

The average productivity of such a production line is 100 square meters. m per day (two working shifts of 8 hours).

For production, you will need a room with an area of 150 square meters. m with forced ventilation. Ceiling height - 4 m. Renting such a room will cost you an average of 15 thousand rubles per month.

Since the products and equipment are original and non-standard, certificates and licenses for production are not required.

Calculations for 100 m2 of products:

polymer 520 kg x 3 r / kg = 1560 rubles

sand 1580 kg x 0.3 r / kg = 474 rubles

dye 12.5 kg x 100 r / kg = 1250 rubles

electricity 25 kW x 16 hours x 1.8 r / kWh = 720 rubles

salary - 8 people for 8000 rubles. = 64000 rubles per month: 30 = 2133 rubles

water supply - 100 rubles per day

room rental - 15000: 30 = 500 rubles per day

transportation costs - 300 rubles per day (calculated individually).

The total cost of 100 m2 of finished products will be 7037 rubles.

The cost of finished products for different manufacturers is 250-400 rubles per 1 sq. m. To prove yourself and enter the market, you need to take the lower price - 250 rubles per 1 sq.m. Therefore, 100 sq.m. we will sell for 25 thousand rubles. Net income minus cost - 17963 rubles. per day.

The average cost of a production line of polymer-sand materials (for different manufacturers) is 900,000 rubles + 100,000 for transportation.

Therefore, the payback of the line with an average workload and work in two shifts is 1,000,000:17963 = 55 working days (3 calendar months).

However, by purchasing a set of drawings for the production of equipment, the payback period can be significantly reduced. For example, we purchase a complete set of drawings with all modifications of units for the production of the entire line here: www.polimercherepisa.narod.ru

Next, place an order for the manufacture of all equipment according to the purchased drawings at any tool company or machine-building plant in your city. The production time of the entire line depends on the capacity of the plant and, as a rule, does not exceed 2 months, and at the same time, its production will cost us no more than 200 thousand rubles.

Let's calculate the payback: (200,000 + 20,000 for the drawings): 17963 = 12.2 work. day.

That is, the payback period when choosing this method of obtaining equipment will decrease by almost five times.

Thus, it is extremely profitable to produce polymer-sand materials and starting a business is quite simple. In addition, the production of polymer-sand products is effective solution plastic waste problems.

Good luck in building your business!

Based on the article by Serik Ainurov for the project www.polimercherepisa.narod.ru

In the early 90s of the last century, the European construction market appeared innovative material- polymer-sand tiles. Composite roofing, compared to conventional ceramics, is characterized by increased strength and impact resistance, low specific gravity, and a wide range of colors. An additional plus is democratic price explained by the availability of raw materials. It is necessary to organize the flow of secondary waste, find a room, purchase machines and arrange them in accordance with the technological scheme.

Production technology and necessary equipment

The raw materials for molding are quartz sand, pre-recycled plastic waste and dyes, which also play the role of a binder in the mixture.

1. Polymer component. It is a combination of an agglomerate obtained during the melting of conventional polyethylene and a solid part (polystyrene, polypropylene, ABS plastic). Thanks to soft polyethylene, the future roof will not be afraid of frost and will acquire gloss, and the “hard” product will provide heat resistance under the influence of sunlight.

No need to carefully sort, wash and dry waste. It is enough just to launch 40-50% soft and 60-50% hard plastics - approximately in this ratio they go to landfills. It is advisable to immediately separate refractory polycarbonates, fluoroplastics, rubber, small scrap metal, foil. Paper and fusible inclusions burn out during the remelting of raw materials.

2. Sand (filler) must be coarse (3 mm), dry, without clay and dust particles. There are no special requirements for the origin and color of the bulk material.

3. A variety of pigments make it possible to obtain polymer tiles of any desired shade at the output. To prevent the roof from fading ahead of time, you should look for a reliable brand of paint.

It is important that the production is carried out in compliance with the correct proportions of all components: polymer material - 24%, sand - 75%, dye - 1%.

The production of tiles occurs in stages:

Drying sand. It is poured into the loading hopper, then it enters the feeder, which delivers it in doses to the conveyor, and then into the chamber, where gases or air heated by the burner are supplied. Ready sand enters the unloading chamber.
Shredding of plastic waste. In order for the polymer component of various sizes to become homogeneous, it is passed through a crushing machine.
Mixing. For this operation, extrusion equipment is used, into which crushed solid polymer product is loaded, as well as polyethylene and polypropylene films. A high temperature is created inside the extruder machine, at which the components are mixed and fused to form a viscous pasty mass. Balls up to 10 cm in diameter are formed from it and immersed in water to cool. Then they are removed from the liquid and kept in air for complete cooling and setting.
Re-grinding. The cooled balls are again passed through the crusher.
Preparation of polymer-sand mixture. This production is harmful, it should be isolated from the harvesting area. In the room where the machine will work, powerful ventilation is installed to remove harmful gaseous waste.

Crushed polymer semi-finished product, dry sand and pigments are loaded into a thermal mixer. The finished mass, heated to 180 ° C, is squeezed out of the chamber when the damper is opened. The operator cuts off with a knife a portion weighing approximately 2 kg - this is how much is spent on the manufacture of one polymer tile.

After weighing, the cake is placed into the mold with the help of a scoop and sent under the press. The last stage has its own nuances.

In order to obtain glossy products, the press equipment is set up for uneven cooling of the mold. Its upper half has a temperature of 80 o, and the lower half - only 45 o. The bottom must be cooled as quickly as possible so that the shingles are formed in 30-50 seconds. Under such conditions, the polymer composition rises and fills the pores between the grains of sand on the surface.
To prevent unevenly cooled products from “driving”, they are placed on the table and pressed down with a load. If this condition is not met, the roof will be uneven.
The production of the matt variety requires uniform rapid cooling of the upper and lower molds.

Overview of popular machine models

The manufacture of polymer-sand tiles is within the power of small entrepreneurs. In this case, it makes sense to buy affordable compact units (you can use them) and place them in a suitable room. Equipment is selected according to the following criteria:

Dryer. For this purpose, drum sets of various capacities are mainly used. When the chamber rotates, the sand is poured and dries faster (the process is accelerated if there are blades on the inside of the drum for mixing the bulk product).
Shredder of polymeric waste. It is advisable to buy a crusher that can grind any plastic raw materials: cans, canisters, film, basins.
extruder. It is chosen depending on the projected output. The maximum productivity reaches 1000 kg/h.
Press for molding. The machine must have a force of approximately 100 tons. If it is planned to manufacture not only polymer-sand tiles, but also paving slabs, curbs, it is advisable to choose a table with adjustable dimensions.

Sometimes, in order to reduce costs, used equipment is purchased, but it is better not to save on it. Only high-quality molds made of alloy steels with subsequent heat treatment are able to work out 5 million molding cycles and ensure the production of conditioned products.

As an example, we give several models of machines for operations included in the technological cycle.

1. Drum type dryer SBP.

It is used for any bulk materials, it runs on natural gas or diesel fuel. An electric drive is rigidly fixed on the frame, which transmits rotation to the drum tires. At the time of unloading, the sand is heated to +80 o, so you can additionally purchase a cooler.

The equipment of the SBP series is characterized by a wide range of performance characteristics:

dimensions - from 3000x950 to 13500x2200 mm;
drum capacity - from 2.12 to 51.3 m3;
burner power - from 100 to 16000 kW;
productivity - from 1.25 to 50 t / h;
electric drive power - 5-15 kW.

2. Impact crusher IPR (polymer grinder).

The machine is assembled from such units: bed, rotor, body, hopper, electric drive. The housing and the electric motor with a belt drive are fixed on the frame. In the body part, a cutting device (rotor) with knives attached to the side disks rotates on bearings. Waste is placed in the loading neck manually or automatically. The dimensions of the finished fraction depend on the dimensions of the grid cells fixed at the bottom of the grinder.

The crusher features a rigid structure, no dust, minimal noise and high efficiency. The machine has the following technical data:

rotor diameter - 250-500 mm;
rotor speed - 450-1100 rpm;
engine power - 7.5-45 kW;
weight - 500-2700 kg.

3. Extruder EG-300.

Serves for melting of different-fraction soft and hard plastic. The machine consists of a metal case with a loading hopper, an electric drive (engine and gearbox), electric tape heaters, a temperature controller, an unloading window.

Specifications:

productivity - not less than 300 kg / h;
power source - 3-phase AC network with a voltage of 380 V;
electric motor power - 2.2 kW;
total power consumption - 11.2 kW;
dimensions - 3600x1200x400 mm.

4. Thermo screw machine APN.

The melting and heating unit operates on the principle of continuous operation. Serves for mixing crushed polymers with sand filler and dye, as well as preparing hot mass for feeding into the press. The amount of the working mixture in it is maintained at the same level, adding the following portions as it is unloaded. In order for polymer-sand tiles to turn out to be of high quality, the grains of sand must be completely covered with a polymer shell.

The APN consists of a frame, a body-pipe, a bunker, a damper, an auger, a drive (motor, a chain coupling and a reducer), heaters, a damper, a fence, and two temperature control sensors. The body is insulated with heat-insulating material, dimensions - 520x3200x1230 mm.

5. Hydraulic molding press PASH-1.

The machine for pressing polymer-sand tiles creates a force of up to 100 tons. The equipment is equipped with a gear hydraulic pump NSh-10, a three-phase electric motor with a power of 5.5 kW, dimensions - 1000x500x2000 mm.

Full cycle lines

If you plan to produce large volumes of products, it is better to purchase a set of installations that fully support the entire process. It is produced in Russia, and the cost is very acceptable.

1. Polimerstroy 18 (Izhevsk).

The company supplies high-quality machines from China, and also practices the manufacture of its own developments. The latter include extruders, melting and heating equipment (up to 600 kg / h), presses with a force of 100-400 tons. Grinding polymer scrap (hard, soft, film) is offered on crushers of domestic and Chinese production. Their power is not more than 300 W, the resulting fraction is 5-8 mm.

2. Monolith (Chrysostom).

The complex includes: