Production of rubber paving slabs (March 2022)

Among the newest building materials that have recently appeared on the Russian market, rubber tiles can be distinguished. Although this is a rare, but quite promising product. In this article we will look at the technology of its production and the equipment that will be needed for the production of rubber tiles.

Rubber paving slabs

To understand what material an entrepreneur will be dealing with, let's look at several of its characteristics. Firstly, the service life that manufacturers promise is on average 20 years. Secondly, this coating has anti-slip properties, which expands the possibilities of its application. Thirdly, the rubber tile has sufficient elasticity to prevent the formation of an ice crust on it.

How much money do you need to start a business?

Starting investments are from 2 million rubles, this is how much the equipment, its delivery and setup will cost. Rented premises will cost 30 thousand rubles. per month. Remuneration for workers in 2 shifts - 170 thousand rubles. in 22 working days.

Costs of consumables.

For 1 sq.m. rubber tiles 40 cm thick and 50 by 50 cm in size. Rubber crumbs - 25-26 kg, coloring pigment - 350 grams, glue (polyurethane) - 2.45 kg. Price for 1 kg: glue - about 148-150 rubles, crumbs - 15 rubles, and pigment - 80 rubles. As a result, the cost of consumables is about 780 rubles. Plus manufacturing costs - approximately 120 rubles. Therefore, the cost of producing 1 sq.m. tiles will cost nine hundred rubles.

Registration of business in the organizational and legal field

To register a business, you need to decide on the organizational and legal form. Will it be an individual entrepreneur or LLC. You should also choose a tax payment system:

general (if you do not submit an application to switch to another tax regime, you will automatically switch to OSNO);
patent;
simplified.

Usually they choose a patent or a simplified version.

Documentation

To open an individual entrepreneur you will need the following documents:

application for registration of individual entrepreneurs;
copy of the passport;
receipt of payment of state duty (800 rubles).

You can open an individual entrepreneur within a few working days by submitting an application to the tax office in your region.

To open an LLC you will need more documents:

application for registration of LLC;
founder's decision;
LLC charter;
receipt of payment of state duty (RUB 4,000);
a letter of guarantee for the provision of a legal address or the consent of the owner when registering at the home address.

You will also need an authorized capital of 10,000 rubles. Typically, an LLC is registered when a large enterprise or company with several founders is launched. It is easier for an LLC to enter into contracts with legal entities than for an individual entrepreneur. In addition, an LLC is not liable for debts with the property of its founders.

Selecting OKVED

When registering a business, the economic activity code is indicated. The following are suitable for the production of rubber tiles:

OKVED code 22 – production of rubber products;

OKVED code 22.19 – production of other rubber products.

After registering an individual entrepreneur or LLC, it is also necessary to register with the pension fund and social insurance fund. You also need to open a company or individual bank account.

Obtaining the necessary permits and certificates

The next step is to obtain permits from:

local administration;
fire inspection;
Sanitary and epidemiological stations.

To do this, the premises must comply with all fire safety and sanitary and epidemiological standards. You must have a lease agreement and a waste removal and disposal agreement.

Any polymer coating must be certified for fire safety.

During the inspection, authorities authorized by the Ministry of Emergency Situations will check combustion toxicity, speed of ignition and flame spread, etc., and issue a certificate. Additionally, you can undergo voluntary certification for compliance with GOSTs. This will help ensure customer loyalty and promote sales growth.

What equipment is needed for tile production?

To open a workshop you will need the following equipment:

mixers or raw mixers (at least 2 pieces);
volcanic press;
pressing molds;
drying chamber.

Rubber crumbs and other components of the working mixture are loaded into the mixer. This equipment has low-speed blades that can thoroughly mix everything. Typically, the glue and solid components of the crumb are mixed separately, which is why at least two pieces of equipment are needed.

Hot pressing equipment

Press molds must be placed on molding tables. There they are filled with a mixture for rubber tiles. The molds are then placed in special carts and placed under pressure. After this, the carts are moved to the drying chamber. The temperature is low, only 60 degrees, but high humidity is maintained to provide a sauna effect. Under such conditions, chemical processes occur that ensure a tight connection of particles of crumbs, glue and coloring matter. The crumb increases in volume, voids appear, which are completely filled with the binder composition.

Cold pressing

The productivity of the entire production line is determined precisely by the dimensions of the drying chamber. Its minimum volume, which ensures profitable production, is 200 sq.m. Depending on the size, other equipment is selected - carts and molds.

Sales market

At the initial stage, it is very important to find sales markets in order to provide the company with constant orders. It is better to look for such customers among the following clients:

construction companies that maintain housing stock;
companies responsible for the improvement of parks and recreation areas;
HOA;
management companies;
administrations of cities and districts;
companies involved in the sale and installation of playgrounds;
companies responsible for installing outdoor sports equipment;
landscape designers.

You can identify a circle of clients and send them commercial offers or leave requests on wholesale trading platforms. This way you can reach customers from other regions. After contacting managers of construction companies, they usually practice “cold calls”, in which they describe the benefits of cooperation with you and offer to hold a meeting/conclude a contract.

Raw materials and technology for the production of rubber paving slabs

The raw materials used are another advantage of the rubber tile production technology. Crushed rubber is used as it - the result of recycling car tires. The material of tires has all the advantages that should be inherent in paving slabs:

Wear resistance and strength;
Elasticity and at the same time the ability to maintain shape;
Resistant to alkaline and acidic environments.

Like any secondary raw material, the cost of crumb rubber is very affordable. 1 kg of material does not exceed 30 rubles. The price of crumbs may be lower, it depends on the processing technology, size and color.

The production of tiles from rubber crumbs can be established in two ways: hot and cold pressing. The equipment for them is largely similar. The first method is not widely used, as it has a number of side effects. With the increase in production efficiency, the quality of products began to deteriorate noticeably: wear resistance decreased, and an unpleasant odor appeared in the finished product. The cold pressing method of crumb rubber does not produce such side effects. The technology consists of the following stages: mixing raw materials, pressing at normal ambient temperature, drying in special chambers for 4-6 hours.

Risks

This production has not only advantages. There are also a number of risks. This is due to the lack of specialists who know the technology of creating products. In this case, you can do it in two ways - find a technologist or train employees in this activity yourself. But then you need to be a professional yourself.

Seasonality plays an important role. Rubber tiles are used outdoors and in car service centers, garages, animal facilities, as well as areas near swimming pools and gyms. It is advisable to open a business in late winter and early spring. In the fall, the products will also be in demand as street improvements take place.

The enterprise will function normally only if there is always the required amount of raw materials. For average production, a stock of 100 tons is needed. The risk is equipment breakdown, so you need to be especially careful when purchasing it.

If you calculate all costs, then the market price of the product will be equal to 1350 rubles per 1 sq.m. The daily profit will be about 16.5 thousand rubles, and 350 thousand per month. The payback period reaches 145 working days if the profitability is 40%.

The production of rubber tiles is a popular industry. If you approach business organization wisely, you can make it profitable in a short time. The main thing is to have everything necessary to produce quality products.

Production Features

The production of multi-colored and black paving slabs from rubber crumbs has different costs. When dyes are added to the composition, the amount of adhesive solution increases significantly, so colored products are more expensive. The selling price of rubber paving slabs also depends on the cost of raw materials. Large chips, as a rule, cost less, but they are less easy to paint. In order to minimize costs, the production of rubber paving tiles was established using a two-layer technology. The lower part is a layer of a larger fraction of raw materials, and the upper part is made of fine crumbs, which are easier to paint and apply designs.

Business relevance

The finished product will definitely find its consumer due to the wide range of areas in which it can be used.
Covering for a country house, garden plot, industrial facilities and various public buildings. The products will be equally in demand for both private buyers and wholesalers. It is enough to produce the coating material and sell it to a hardware store, which will further sell the rubber tiles. As you know, demand creates supply, and there are a lot of customers who want to purchase tiles. But it should be borne in mind that in order to produce products, it is necessary to take care of supply issues in advance.

For the supply of finished material in small quantities, advertising in local print media, as well as newspapers that are published in places where cottage villages exist, is very suitable.

Company organizational plan

Registration of a manufacturing enterprise

You can work as an individual entrepreneur or LLC. The required OKVED code is 25.13

The next step is tax registration and concluding agreements with local utility services. You should also obtain permission from the fire authorities.

Room

A workshop for the production of rubber tiles can be located in an industrial zone on the outskirts of a populated area - this way the business owner will save on rent. There should be no residential buildings in the immediate vicinity of the workshop building.

To accommodate the equipment, an area of at least 80 square meters will be required. m, the ceiling height must be at least 3 m, access to power supply lines of the required power is important. A powerful ventilation system is required, since the fumes generated during the production process are very toxic.

With properly organized eye and respiratory protection, the released fumes will not cause harm to employees.

The premises should be divided into zones: administrative, production and storage. In the latter, separate areas must be allocated for storing raw materials and finished products. For work in winter, it is important to have heating. There should be access roads convenient for trucks near the building.

Equipment

To equip the workshop you will need:

industrial mixer;
pressing machine;
molding table and molds;
heating cabinet

Don’t forget about the necessary office and workshop furniture - you will need several tables and chairs, cabinets, and shelving. You also need scales and some working tools.

Where to get raw materials?

Finding a supplier of rubber raw materials is not difficult - such recyclable materials are not in short supply today. It is produced mainly from used car tires. It is mistakenly believed that, in order to save money, you can produce crumbs yourself - by collecting old tires and recycling (grinding) them. However, doing this manually is problematic - special equipment is required. In addition, for further use, this material must be devulcanized by treating it with special chemicals.

The choice of high-quality glue in this case is more important than the choice of rubber, because it is the binder that will bear the entire load from the effects of mechanical and atmospheric factors. Almost any recycled rubber on the market has the same properties, but the adhesive composition varies. It would be a good idea to buy a product from several manufacturers to check the quality of each and choose the best option.

The list of consumables should include coloring pigments: the option of coloring the crumbs yourself is more economically profitable than purchasing multi-colored raw materials.

Staff

To maintain the operation of one automated belt, three operators per shift are required. Subsequently, their number can be increased to 4–5 employees. Most often, such enterprises start with a one- or two-shift operating mode. Over time, when the business owner forms an established sales scheme for products, you can switch to working in 3 shifts.

Two guards will guard the workshop during non-working hours; it is advisable to entrust tax and financial accounting to a visiting accountant. We also need an administrator and a sales manager. At first, these responsibilities can be combined by the business owner himself. It would be useful to hire a chemical technologist on staff, but this specialist can also be a freelance consultant. We also need 1-2 loaders, a cleaner and a delivery driver.

Before we begin

Rubber tiles are just beginning to conquer the Russian building materials market. Competition is minimal, prospects are very optimistic. But potential consumers do not know enough about this material. Your initial task is to find potential wholesale buyers in your locality and region. To do this, you should draw up a competent business plan, a commercial proposal with a clear list of advantages and prices of new tiles, and conclude at least several preliminary agreements with construction companies and stores. When starting the release of an innovative and poorly known product, it is recommended not to study, but to create demand.

Where is it used?

Application of rubber tiles:

Playgrounds;
Treadmills and more;
Parking;
Flooring of administrative buildings;
As part of landscape design.

Business relevance

The products will be equally in demand for both private buyers and wholesalers. It is enough to produce the coating material and sell it to a hardware store, which will further sell the rubber tiles. As you know, demand creates supply, and there are a lot of customers who want to purchase tiles. But it should be borne in mind that in order to produce products, it is necessary to take care of supply issues in advance.

For the supply of finished material in small quantities, advertising in local print media, as well as newspapers that are published in places where cottage villages exist, is very suitable.

Documents and licenses

It is better to hire a specialized law firm to prepare a package of documents. Choosing a registration form and type of taxation is not particularly difficult. You can register as an individual entrepreneur and work on a simplified system. If you want to sell rubber tiles to legal entities, develop your production and attract investors, form an LLC.

Difficulties begin in the process of product certification. It is necessary to go through the process of confirming compliance with the technology, assessing the quality of compliance with the declared standards of raw materials and equipment. Without the help of an experienced lawyer, these procedures are delayed and lead to unnecessary financial losses.

Features and Benefits

This relatively new material is rapidly gaining high positions among the variety of different types of coatings, both in cities and in suburban areas. Rubber tiles are made from waste obtained during the mechanical destruction of tires, the problem of disposal of which is acute in Russia.

Tire crumbs retain all the original qualities of rubber: molecular structure and elastomeric properties. This allows it to be successfully used for the production of a large number of useful products, among which this tile has become the most popular.

Its useful consumer qualities:

durability - service life is up to 15 years;
anti-slip effect - protects against accidental injuries;
aesthetics - it is possible to add color pigments;
frost resistance - does not crumble even in 40-degree frosts;
biostability - not destroyed by fungus, does not mold;
strength - the ability to withstand high loads.

Rubber tiles have so many advantages that the growing popularity of this building material does not surprise anyone. The only drawback is the relatively high cost compared to concrete and other types of covering paths and areas.

Currently, in our country only about 20% of used tires are processed into crumbs. Every year the number of plants for their recycling increases, therefore, raw materials will become cheaper. This industry is only at the beginning of its development, and, accordingly, the production of rubber tiles and coatings is not only profitable, but also a very promising business.

Technological process

Crushing rubber, obtaining crumbs.
Rubber fraction, polymer glue, dyes and modifying additives are added to the mixer.
The mixture is mixed and loaded into special molds.
Pressing raw material into tiles of the desired thickness and shape.
Baking is the finishing process. There are two ways: “when cold,” the molds are sent to thermal cabinets. There, the raw materials are processed at low temperatures. “Hot” vulcanization requires high temperatures.

During hot processing, pressure is applied to the tile at a temperature of 140C. The procedure takes 15 minutes. Cold processing lasts 4 hours or more, and the temperature is only 80 C.

Car tires as raw materials for recycling

More and more countries have recently been paying attention to the problems of using waste in production, including used tires, which are one of the largest volumes of polymer waste. Tires that are already out of service cause great harm to the ecological environment, since the places where they accumulate only contribute to the habitat of a number of rodents and insects

Rubber is highly resistant to external factors and there is no point in burning such a valuable material in the household. The process of recycling tires by burning pollutes the environment for a long time. As you know, rubber, when burned, releases toxic and harmful components that have a destructive effect on the environment.

Tires that are already out of service cause great harm to the ecological environment, since the places where they accumulate only contribute to the habitat of a number of rodents and insects. Rubber is highly resistant to external factors and there is no point in burning such a valuable material in the household. The process of recycling tires by burning pollutes the environment for a long time. As you know, rubber, when burned, releases toxic and harmful components that have a destructive effect on the environment.

It is much more rational to grind tires into small fractions and use them as raw materials for the production of useful and durable building materials. In modern life there are many areas where crumb rubber is used - it has proven itself well and is becoming increasingly popular. The demand for this product is growing from year to year. Crumbs are used in many industries, for example:

used in the construction of highways and rail linings;
when improving areas around municipal and commercial facilities;
in the construction of children's and sports facilities, as well as for many other suitable needs.

Another problem with the use of used tires is the economic factor, since the cost of household needs is constantly increasing. In addition, after the elimination of waste tire dumps, significant areas of land occupied by them will be freed up for their intended use.

Location

Look for production or warehouse premises in the suburbs, industrial areas or a short distance from large cities. Convenient transportation and rental costs are important.

The area of the premises is selected depending on the planned production volumes and equipment. A mini-factory requires a workshop area of 100 m², a minimum ceiling height of 3 meters. The room must be heated, connected to a 380 V power supply and water supply.

It is necessary to allocate separate areas for storage of raw materials and finished rubber tiles. Heating is not necessary for these rooms; each area is at least 100 m². Also, separate premises for staff and office are needed.

Find out in advance the requirements of the fire department and SES. Be sure to take into account the recommendations of these services when searching and renovating a premises.

Crushing methods

There are two main methods used in production:

mechanical crushing;
shock wave crushing.

Mechanical crushing involves grinding the material using special cutters. The low cost of equipment and simple technological process make this method popular and often used.

The metal seating ring is removed;
The rubber tire is cut into strips 5-7 cm wide;
The remaining seat rings are removed;
The rubber is crushed to obtain crumbs with a fraction of 5 mm;
Finally, the resulting crumbs are sorted into fractions.

Shock wave crushing and grinding requires the use of special equipment. In a specially equipped chamber, the rubber is subjected to shock wave treatment. The entire process is automated and requires the participation of one operator.

Tips for beginners

Before starting your own business, you should collect all the necessary documents and obtain a certificate for your products. It is also recommended to find a trusted supplier of equipment and raw materials in advance. In this case, you can hope for warranty service for the equipment, which will avoid long downtime. It is necessary to outline in advance possible markets for the finished material. You should also rent a territory of sufficient area for production and storage of products. After this, you can start purchasing equipment and raw materials, finding personnel and starting work.

Tile molds

You can make molds for rubber tiles yourself. But this activity will take a lot of your time and money, so it is better to purchase ready-made products or order their production according to a sketch.

Before use, do not forget to treat the mold with soapy water or silicone so that the solution does not stick to it. Non-metallic molds, after removing the finished rubber, are treated with an acid solution to eliminate dust.