Recycling of used tires. Types of machine tools and technology for processing automobile tires. Methods for modifying crumb rubber
Tire recycling is a topical issue of protection environment. Today, 59.6 million people travel on Russian roads. Vehicle. If we take into account that the average tire wear period is 6-7 years, then 34 million of them are replaced annually with new ones. 300-350 thousand tires per region. In Moscow and St. Petersburg many times more.
Meanwhile, statistics claim that only a fifth of car tires. The rest is either burned for recycling or decomposed in landfills. And rubber, as you know, decomposes for about 150 years.
IN European countries ah, for more than 10 years, landfills for the disposal of car tires have been banned.
In this regard, the recycling of automobile tires in Russia has an important environmental significance. Today, there are only 150 mini-factories for the processing of tires in the country. This business has great economic prospects. From used tires with a reasonable approach to their processing, you can get a sought-after secondary product:
Business Benefits
The benefits of a tire recycling business include the following.
1 . As can be seen from the above figures - a large amount of raw materials. Moreover, worn tires will get you for free. Motor transport enterprises are interested in the fastest release from scrap. At the reception old rubber you can earn some extra money (up to 5-6 thousand rubles are paid for the disposal of a ton of tires). The number of cars in the country is growing annually by almost 5%. Therefore, you will not experience a shortage of raw materials.
2 . Premises for doing business need relatively small. For example, for small production, 50 sq. meters. If you have the financial means to deploy a larger business, you need to rent or purchase premises from 300 sq. meters. Keep in mind that for a smaller space, you will have to pay less rent and utilities.
3 . Your products will be in good demand. For example, a crumb is required for the manufacture of coatings for sports and playgrounds, for the construction of which budgetary allocations are allocated. Old tires contain valuable materials: rubber, metal and textiles. Their initial properties during operation basically do not change.
Playground covered with crumb rubber
4 . Only 20% of old tires are recycled. The business is quite new, tough competition does not threaten you. The sooner you enter the market, the more chances you have for further business development. Hurry up to enter the market while the competition is low.
5 . The business is quite simple in terms of technology, it does not require additional costs for various operations for introducing chemical additives into manufactured products. Good profitability of the project. You will pay back the investment in 1.5 years.
6 . Your company will work in the field of ecology. You will be working in a rewarding environment. Municipal and regional authorities are ready to support you if your work brings results.
Tire recycling options
Tire recycling business can be carried out in several ways.
- Crushing, the end product of which will be small rubber crumb. Depending on the size and form of manufacture, it is used as an additive in a variety of mixtures, including for the production of new tires, rubber tiles, sports and playground surfaces. At the same time, they receive additional secondary metal and textile threads.
- Obtaining fuel oil, gasoline, kerosene, gas, carbon black, metal cord by heating to high temperature without access to air (pyrolysis). Technology can hardly be called rational, it is very costly and unprofitable.
- Disposal of used tires by burning. In this case, the released thermal energy can be used for the recycling process. but this method accompanied by the release of a large amount of soot, sulfur and other toxins into the environment.
Crumb rubber production
Processing tires into crumbs using its technology is very simple. The technological process consists of the following stages:
First step. Tire preparation for cutting. Carry out an inspection worn tires in order to remove metal small parts and other foreign elements unsuitable for processing: stones, fragments, bead wire.
Second phase. Cutting tires into small pieces or strips (depending on the type of equipment).
From under the hydraulic shears, where the tires are cut into pieces, the rubber goes to the crusher, and then to the granulator
Third stage. Grinding into crumbs, removal of metal cord and textile elements.
Fourth stage. Sorting rubber crumb into the required fractions.
Fifth stage. Packing the received products and sending it to consumers.
How to start a business
Production for the processing of automobile tires will require the resolution of organizational issues.
Keep in mind that you must have a tire recycling license in order to open a business.
The license applicant must have:
- building or premises on the right of ownership or lease, remote from the residential area not less than 300 meters;
- specialized equipment necessary for recycling old tires;
- if it will be engaged in transportation - a transport equipped accordingly and equipped with special signs.
Employees must be trained and receive certificates for the right to work in the field of waste management.
A conclusion on the compliance of all of the above with the regulatory requirements must be provided by the sanitary and epidemiological supervision body - a division of today's Rospotrebnadzor. The license is issued by the bodies of the Ministry of Natural Resources.
Based on these requirements, you need to register as an individual entrepreneur or legal entity with the tax office.
Pick up the premises and register your rights to it. A room of 50 square meters will be enough to install the equipment. meters. But you need a place to store raw materials and finished products, recreation and catering staff. A garage business is not the best way out.
Uninterrupted power supply, water supply, sewerage, ventilation system are necessary for production.
Means of production
The purchase of equipment should be given the main attention. This is both the largest expense item and the main link on which the success of everything will depend. production process.
At a minimum, the list of equipment looks like this:
- hydraulic shears;
- tape cutter;
- shredder;
- magnetic separator;
- air separator;
- conveyor;
- vibrating sieve.
Tape cutter
You can buy equipment in parts, you can in the complex. For example, it seems to be a very profitable and reasonable business idea to purchase a mini tire recycling plant.
mini plant
For example, the Alpha-tire-recycling/atr 300 automatic tire recycling line can process up to 4,000 tons of tires per year, while producing up to 3,000 tons of crumb rubber. It can successfully and profitably operate in settlements with a population of over 150 thousand people.
The cost of purchasing and installing the line is 10.1 million rubles.
The final product will be:
- rubber crumb 3 fractions: up to 1 mm, 2-3 mm, 4-5 mm;
- metal cord;
- textile cord.
How the ATR-300 line works
On the initial stage the tires are cut into pieces and fed along the conveyor to the initial grinding shredder. Then the whole process proceeds without human intervention. From the primary processing shredder, the tire pieces enter the block, where they are crushed into smaller ones with the metal cord being removed from them at the same time. Scheme further processing tires provides for the passage of the obtained rubber chips through a set of rotary crushers through pneumatic transport.
Location of ATR-300 Tire Recycling Line
The result is the receipt of all three components of processed products with lower energy consumption and lower cost than on semi-automatic lines. In addition, the compactness of the line, due to the absence of belt conveyors, makes it possible to conveniently place machines and more efficiently perform their maintenance. The automated process ensures environmentally friendly production, no harmful emissions and emissions during crushing are observed.
Tire Recycling Line ATR-300
The number of personnel serving the line with a monthly output of 150 tons should include 10 employees with a payroll fund of about 350 thousand rubles.
The business plan for tire recycling should be calculated taking into account the receipt of minimum volumes of finished products.
Number of recycled tires per month: 150 tons.
Crumbs received: 110 t.
Steel cord received: 20 t.
Textiles received: 20 t.
Monthly income
Sale of crumbs (110 tons at an average price of 16 rubles / kg) = 1.76 million rubles.
Sale of steel cord (20 tons at a price of 5.0 thousand rubles / ton) = 100 thousand rubles.
Sale of textiles (20 tons on average at a price of 2.0 thousand rubles / ton) = 40.0 thousand rubles.
Acceptance of used rubber for processing (100 tons at the lowest price of 1,300 rubles / ton) = 130.0 thousand rubles.
Total: minimum income per month = 2.03 million rubles.
Expenses
Staff salary (per month) with insurance payments = 350 thousand rubles.
Purchase of bags for packaging (with a capacity of up to 30 kg) at the rate of 8 rubles / bag = 40.0 thousand rubles. per month.
Payment for electricity (120 kW / t x 4.5 rubles / kW) = 80.0 thousand rubles.
Maintenance of the line, replacement of knives, household expenses = 130.0 thousand rubles.
Rental fee (300 sq. m. x 150 rubles) = 45.0 thousand rubles.
Total expenses: 645 thousand rubles.
Monthly minimum profit: income (2.03 million rubles) - expenses (0.645 million rubles) \u003d 1.385 million rubles.
This indicator can be increased by increasing the volume of processing, prices for sold crumbs, receiving raw materials and other components.
Franchise
One option is to buy a franchise.
A franchise is the right to open a business for a certain fee under the auspices of a brand or simply a more experienced franchisor, using its technologies, work system, and equipment.
What does a tire recycling franchise give? By signing an agreement with the franchisor, you get:
- A set of equipment for processing tires into crumb rubber.
- Equipment for the production of rubber tiles is also possible.
- Inventory, tools and spare parts necessary for work.
- Carrying out by the franchisor the installation of equipment and commissioning.
- Assistance in the repair of equipment.
- Training.
- Customer base of raw material suppliers.
- Quality control of manufactured products.
The franchise fee can be from 3 million rubles. In addition, you will have to pay a certain percentage of your income to the franchisor.
Supply of raw materials
Despite the fact that there are many raw materials for recycling car tires, it is necessary to think over their uninterrupted delivery to the place of production. Your main suppliers are companies that have a significant fleet of vehicles, as well as tire fitting companies, landfills.
It is better to conclude contracts with them for the recycling of old tires on an ongoing basis. You can organize collection points for used tires. Acceptance is made for a fee, the amount of which varies from one thousand to five thousand rubles per ton.
Sales of products
Rubber crumb is a demanded material. It is used as:
- bases for the production of coatings in stadiums;
- material for the construction of children's playgrounds and sports grounds;
- sports equipment fillers;
- the main material in the manufacture of paving slabs. Its share in the tile is 80%.
- filler when creating bituminous roofing, forming
- fiber-reinforced concrete for pouring foundations, production of road surfaces;
- regenerating agent when retreading old tires.
Rubber tiles are widely used not only for flooring in gyms, playgrounds and school yards, but also suburban areas
Manufacturers of rubber products, companies working for the oil industry may also be among the consumers.
What problems may arise
As in any business, a project can turn out great on paper, but in practice, an entrepreneur expects real failures. To minimize the losses from them, the risks should also be calculated in advance and the solution of problematic issues should be considered.
The main problem is disruptions in the supply of raw materials. For some reason, a queue of cars overloaded with old tires does not line up at the gates of your factory. The solution to the problem must be found in the timely conclusion of long-term contracts with motor transport enterprises. One option is to open a mini-factory directly on the territory of a major carrier. It is worth considering a system of points for collecting used tires.
Acceptance of tires for recycling
Frequent equipment failure. This most often happens with used machines or due to human error. It is necessary to establish strict observance of the terms of maintenance of all units of the line, to regularly instruct workers.
Problems with the sale of products. Its solution must be found in long-term agreements with consumers, participation in various tenders for the supply of crumbs for the manufacture of various types of urban sites.
The main indicators of the business plan with calculations, market analysis indicate that the production of automobile tire processing is a profitable and fairly quickly payback enterprise, which also brings great benefits to the environment.
The whole world is committed to a zero waste society, and in some countries, such as Sweden, all garbage is already being recycled. As for Russia, it is very far from the processing of all garbage, but every year more and more such industries appear. One of the waste recycling businesses is the tire recycling business. It is worth noting that the organization, in addition to the main mission of the enterprise - making a profit, will benefit society. It is well known that the term complete decomposition tires are about 150 years old, they are highly flammable and emit harmful substances when burned. People who live near tire dumps are more likely to get sick with various diseases, including cancer. Therefore, today tire recycling is very relevant and necessary for society.
It is worth noting that the tire recycling business initially has significant barriers to entry. Barriers are associated with a large amount of investment at the initial stage, as they require the purchase of special equipment. However, even in Russia there are suppliers who create a whole mini-factory (in other words, a line), with the help of which it is possible to immediately start production.
Competition in the market is quite low, not all cities have at least one such plant, while the need for tire recycling is increasing every year, because the number of motorists is growing. The cost of the raw material itself will be very low, since it is a waste, and many organizations, for example, transport companies, are even ready to pay for disposal (since the release is illegal and subject to a fine). Ordinary citizens do not yet realize that this type of waste is harmful to the environment and must be properly disposed of, so the plant can offer to buy tires from private individuals for a small fee.
In this way, the tire recycling business will have no problems with competitors and raw materials. The plant will quickly begin to operate at full capacity and will receive maximum profit.
Initial investment - 15 480 000 rubles
Monthly profit - 1 300 000 rubles
Payback period - 13 months
Break even - 3 months
Profitability of sales - 65%
2. Description of the business, product or service
The tire recycling plant should be located away from the city, preferably in an industrial area where there is no proximity to residential buildings. According to the law, the distance to local residents must be at least 300 meters. The area of the premises of the plant itself should be about 500 m2, however, everything depends on the parameters of the purchased equipment and the size of the warehouse. The price per square meter for such a room is quite low, while you can get additional benefits when placed in industrial parks, special economic zones etc. For example, placement in the SEZ also gives the right to tax reductions on insurance premiums and profits.
Depending on the line, the plant will receive several types of finished products. In this business plan, we will consider obtaining, after mechanical processing of tires, the following types of products:
- Rubber crumb
- textile cord
- metal cord
Crumb rubber is the main product of car tire recycling. In order for tires to be durable, high-quality components are used in their production: natural and synthetic rubbers, softening oils. Therefore, during the mechanical processing of tires into crumbs, the rubber composition practically does not change. The price of a crumb in the ranks is lower than the price of new rubber, so it is in great demand. Rubber crumb can be of different fractions: up to 1 mm, 1-2 mm, 2-5 mm. The scope of application is quite extensive, for example, for the construction of roads (top layers of asphalt), sports surfaces (such as tennis courts, Treadmill), use as "artificial grass" and more.
The textile cord is a cleaned landing ring and is used in geological exploration, the production of fiber-reinforced concrete, the filling of sports equipment, the production of mixtures for plugging wells during well drilling.
Metal cord is a metal wire or shavings that can be scrapped.
3. Description of the market
The sales market is mainly designed for legal entities, that is, it works on the principle of B2B. The finished product of the tire recycling plant is not a final product, so the buyers will mainly be the same manufacturers. The main activities of such organizations will be:
- construction;
- production of sports equipment;
- pavement manufacturing;
- maintenance of oil companies.
Also, the entire sales market can be divided into a segment of state and commercial enterprises.
State-owned enterprises (for example, municipal unitary enterprises) most often purchase products from recycled tires for the construction of sports facilities or road construction. Typically, such enterprises announce the opening of procurement for their activities and place the start of bidding on the site for government orders. If the conditions are met and the lowest price, you can get an order for a large supply.
Commercial enterprises are purchased for their productions, and then they use their products for retail sales.
A small percentage of buyers is also possible - individuals who buy, for example, crumb rubber for their garden plots.
The advantages and disadvantages of a tire recycling plant are shown in the table:
Strengths of the project: | Weaknesses of the project: |
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Project features: | Project Threats: |
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4. Sales and Marketing
The main sales channels for the tire recycling plant will be:
- Website presence. When searching for a supplier for their production, buyers will look for information on the Internet, so the site should be convenient, have information about the types of products, their characteristics, contacts, and also have a price list with actual prices or contact the sales manager.
- An ad in an Internet service for placing ads, for example, Avito.
- Information on banner structures close up large factories and highways.
- Participation in government tenders for the supply of products.
- calling target audience(companies whose production needs rubber crumb, textile or metal cord) by managers, that is, the use of the "cold sales" method.
5. Production plan
Before starting activities, it is necessary to register a business. Since the business requires large investments, it may be necessary to attract investors or take out loans, so it is best to register in the form of a limited liability company.
The taxation system must be chosen based on the system of taxation of suppliers and buyers. If the majority is common system, then the organization must also choose the general one. If the taxation system is different for everyone, then you can choose a simplified system, with the object of income reduced by the amount of expenses.
Also, for activities that work with dangerous income, a license is required (tires have a fourth hazard class). In order to obtain a license, an organization must provide permits from Rosprirodnadzor, Rospotrebnadzor and the fire inspectorate. To do this, it is necessary to provide a number of documents, purchase fire fighting tools, prepare orders and instructions for personnel training. Also, in order to obtain a license, it is necessary to have a ready area on which the plant and working equipment will be located.
The next step will be preparation directly for work. To do this, it is necessary to hire and train personnel, to study the operation of the equipment. Understand how the equipment works. For instance, technological process obtaining rubber crumb consists of the inspection stage (the surface of the tires should not have foreign objects), cutting into small segments, cutting through a shredder into smaller particles, crushing through an impact crusher, passing through a separation system to remove metal and textile cord and sorting into fractions .
6. Organizational structure
In order for the plant to function, it is necessary to have an administrative (financial) and technical staff. The administrative staff will include the director, sales managers and accountant, while the technical staff will include an engineer, workers and a driver.
The director is a responsible person in the work of the organization, solves strategic and operational tasks, is engaged in the search for suppliers, marketing, work with personnel. His responsibilities also include following a specific production schedule that the organization has set.
Sales managers deal with direct sales via telephone and face-to-face meetings, monitor shipment and discharge required documents(invoices, acts of work performed), are interested in sales growth, since the company's revenue is directly related to their premium part.
The accountant is responsible for accounting and tax reporting, calculation of wages, controls the work of employees in obtaining documents.
The administrative department works in the company's office with a work schedule of 5/2 from 9.00 to 18.00.
The technical staff works directly at the production site in shifts with a schedule of 2/2. An engineer supervises the work of the entire department, who is also responsible for technical issues equipment, monitors the quality of finished products and trains staff - workers.
IN staffing there will be six workers who work in shifts of three. People are hired for this kind of work. higher education and special skills, however experience in production would be an advantage.
The driver works on a floating schedule, depending on whether the car is needed for transportation or not. Requirements for the driver is the presence of rights of category C and E.
The issue of tire recycling in Russia is quite acute. For the natural decomposition of waste of this category, it takes from 120 to 140 years, and the volumes that go to landfills, and often to places of unauthorized waste storage, are simply huge. Meanwhile, crumb rubber is a sought-after raw material for many industries (road surfaces, as a filler, a regenerator for new rubber products ...), which opens up broad prospects for the development of a profitable business.
In contrast to European countries, there are few global tire recycling companies in the domestic market. Accordingly, do not expect high competition. At the same time, the development of the industry is hampered by a high barrier to entry to the market, which is about 20 million rubles, as well as the lack of a centralized public policy regarding waste management. However, the legislation is gradually being improved, which means that those who are ready to combine environmental values and the opportunity to receive a stable income should pay attention to this type of business.
Market situation
World stocks of waste tires are about 80 million tons. Every year this number increases by 10 million tons. And even in countries where work on competent tire recycling has been going on for a long time, they cannot cope with the existing volumes.
As for Russia, only 20% of the total share of the relevant raw materials goes to processing. Moreover, 60% of this amount is distributed among themselves by four large enterprises:
- Volzhsky Regenerate Tire Repair Plant (Volgograd Region);
- Chekhov regeneration plant (Moscow region);
- "KST-ecology" (Smolensk region);
- Tire recycling plant No. 1 (Vladimir region).
One of the reasons for this state of affairs is the fact that most enterprises, both large and small, accept tires for recycling without partial compensation for their cost. Accordingly, it is more profitable for the population to simply take garbage to a landfill than to deliver it for processing at their own expense.
Thus, a novice entrepreneur has three ways to develop his business: follow the “traditions” of free raw materials, determine an economically justified acceptance price, or enter into agreements with landfills, service stations and other “suppliers” who would benefit from the removal of used tires from the territory. In the latter case, you can try to enlist the support of the municipality or environmentalists.
What recyclable materials can be obtained from tires?
The most common recycling technology involves the mechanical grinding of tires in special units. During this process, the following materials are formed:
- rubber crumb with a fraction size of 1 mm, 2-3 mm, 4-5 mm (each of them has its own scope);
- textile cord, suitable, after processing by pyrolysis technology, for the manufacture of fuels and lubricants;
- metal cord intended for remelting.
IN developed countries It's common to rebuild worn tires for their intended use. It provides for the imposition of a new profile on the old frame.
Processing technology
The process of recycling tires into crumbs involves a number of successive stages:
- Quality control of incoming tires. Products are carefully inspected for the presence of spikes and other elements that are not suitable for processing.
- Pre-grinding. Tires are cut into segments 200x200 mm in size.
- Removal of the metal fraction. The raw material is conveyed through the conveyor to the shredder for the next stage of grinding. In parallel, using a magnetic device, the bead wire and other metal elements are removed from the mass.
- Grinding to the final fraction. In the impact crusher, the material is brought to a predetermined fraction value, and is also cleaned from the metal cord.
- Separation. In the separator, the textile cord and the remains of the metal cord are removed from the mass.
- Sorting by fractions. It is carried out by passing the material through a system of vibrating screens.
- Packing and warehousing. The material is packed in bags and sent to the warehouse.
Tire crumb recycling equipment + Video
The universal line contains the following components:
- knife for cutting car tires;
- band conveyer;
- shredders for primary grinding (2 pcs.);
- small cyclones (2 pcs.);
- fan (3 pcs.);
- pneumatic conveyor;
- units for magnetic separation (3 pcs.);
- crusher;
- vibrating screens (2 pcs.);
- large cyclones;
- electrical equipment;
- a vacuum cleaner;
- cord belt conveyor;
- metal carcass.
You can usually buy such a line within 12-15 million rubles. Also, to launch the plant, it is necessary to purchase industrial scales (20 thousand rubles), a unit for packing bags (10 thousand rubles) and the bags themselves (10 thousand rubles), tools and consumables for servicing the installation (30 thousand rubles). .).
Another about 100 thousand rubles. it is necessary to pledge for the delivery of equipment and about 150 thousand rubles. for its installation and commissioning. Wherein fare will depend on the remoteness of the region from the manufacturing plant. The procedure for commissioning, the conditions for warranty and post-warranty service, as well as other points are prescribed in the supply contract. It is optimal when, among other things, the supplier gives an obligation to train your staff to work with the units.
Line example:
Requirements for the arrangement of the workshop and warehouse space
Tire crumb recycling plant must contain directly manufacturing facility with an area of at least 200 m², a platform for storing raw materials in the form of an unheated hangar or just a fenced area, as well as a warehouse for finished products. Sanitary facilities are also required. The office part is equipped depending on preferences and financial opportunities business owner.
The premises can be purchased or rented. Often the first option is unrealistic for a novice entrepreneur, so a lease agreement becomes the best solution. Its cost directly depends on the region, and in Russia it can range from 20 thousand to 100 thousand rubles per month.
Staff
A minimum of 10 people will be required to service the line with a processing capacity of 150 tons of tires per month. At the same time, it is important to have a technologist in the team who is able to control the production process and a person who will be engaged in the current maintenance of the lines. For major damage and Maintenance rationally involve representatives of the equipment manufacturer. For this, as mentioned above, this clause should be written in the contract.
Also for quality work the enterprise will need an accountant, cleaners, security officers and at least one truck driver delivering tires and finished products.
In this situation, the approximate amount of the payroll will be about 400-450 million rubles. However, much here also depends on the size of the average wage in the region.
Obtaining a license
In a number of sources, you can find information about the optional licensing of a business for processing tires into crumbs. However, it is not. The raw materials used belong to the fourth hazard class. Accordingly, according to Russian legislation, acceptance and disposal of such MSW are subject to mandatory licensing.
Before submitting documents, the entrepreneur must complete the following steps:
- Register an enterprise (optimal in this business).
- Prepare production areas, including industrial site and sanitary zone.
- Prepare documents and certificates for equipment.
- Obtain permits from Rospotrebnadzor, Rosprirodnadzor, fire inspection.
The license is issued within 45 days. Its cost is 7,500 rubles. If you want to simplify the process by using the services of intermediaries, the costs will increase several times.
How much does crumb rubber cost?
How much income can be generated by recycling tires into crumbs with a capacity of 150 tons per month?
The average cost of rubber granules on the market is 150 thousand rubles. Accordingly, getting 100 tons of crumbs at the output every month, we have 1.5 million rubles.
Also, during processing, 30 tons of metal and 20 tons of textile cords worth 90 thousand rubles are formed. and 40 thousand rubles, respectively.
Thus, the total dirty income may amount to 1.68 million rubles. Subtracting monthly expenses from this amount, we get net profit. At the same time, the profitability of the enterprise will be influenced by such factors as the location of the enterprise (rental cost, transportation costs), the availability of sales markets, sources of raw materials, marketing policy and others. On average, investments in this type of business pay off within one and a half to two years.
Search for sales markets
When searching for sales markets, it is necessary to carefully analyze the scope of activities of manufacturing enterprises operating in a particular region. Focusing on the all-Russian market and foreign supplies makes sense only for large processing companies, since transportation costs lead to a significant increase in the cost of the material.
Among the main consumers of crumb rubber:
- companies specializing in laying seamless floor coverings (self-leveling floor);
- manufacturers of tiles and floor coverings;
- enterprises involved in road construction (mainly regional centers);
- companies fulfilling state orders in the construction of sports complexes, sidewalks and other facilities.
In small quantities, crumb rubber from tires is gladly purchased by companies manufacturing sculptures for playgrounds, fences, curbs, punching bags, beanbags, bituminous mastics, rubber shoes, insulation, etc.
At the same time, it is not enough to identify potential consumers of rubber crumb - do not hesitate to contact the management of enterprises directly to find out if they are interested in your offer, in what volume they are ready to purchase raw materials and what quality.
How to avoid pitfalls?
The main mistake of entrepreneurs who decide to build a business on the processing of tires into crumbs is the wrong choice of equipment. The fact is that, unlike foreign-made tires, domestic tires contain a mixed or textile diagonal cord. Almost all machines made for the European market are not adapted to work with these materials, so even expensive equipment may be useless.
Output: specify which tires are intended for recycling of certain units.
Another actual problem is the presence of defects in new equipment. Most often this happens with units made in China. To strike a balance between quality and optimal cost will help the analysis of the manufacturer. As a rule, responsible suppliers, along with the manufacture of machine tools, are engaged in the processing of tires and the manufacture of various products from the raw materials obtained. In addition, one should not believe the stories about the ultra-high performance of the equipment - the higher the speed, the greater the risk that the unit will break if a foreign object gets “under the knife”, which is a very common situation.
This is not the whole list of situations that may arise on the way to making a profit. For example, the lack of raw materials often leads to the need to buy tires from the population, which is fraught with an increase in the cost of crumb rubber. Anyway detailed analysis at the initial stage, it will allow you to enter the business gently and quickly recoup your investment.
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 factor 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. With a small investment 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 cost big investments. 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 to find and rent a warehouse with an area of about 100 m 2 and production room the area of which should be an average of 40 m 2, plus a few more small storage rooms. In this case, the production of crumb rubber can start from a production volume of 800 kilograms of the finished product daily (100 kg / hour in 1 work shift).
What you need to process tires into crumb rubber
The minimum complete line for processing tires into crumb rubber includes the following equipment, which can be found on the Internet at prices:
- Bead cutting machine - $ 2,150
- Tape cutter - $ 2,700
- Shredder for shredding rubber - $ 7,650
- Circular sieve - $ 1,000
- Conveyor with magnetic separator - $1,000
- Bead ring processing machine - $2,500
TOTAL: $17,000
Technology for the production of crumb rubber by recycling tires
Video clip, which schematically in the form of 3D animation shows the technological process of tire processing by grinding into rubber crumb:
As you can see in the video, the production process is extremely simple.
If you decide to conduct this activity on a more serious level, an analysis of the sales market in the region where you are going to launch your project will be necessary. Without this work, it is unlikely that the products will generate a profitable income. Will have to include in the business plan the costs of marketing research sales market for finished products in a particular region.
What is the need for this product and in what distribution channels can it be sold? Who else is interested in this industry and what is the competition in the market?
The answers to these questions need to be taken into account and, obviously, to calculate the development opportunities economic activity over the next few years. It is unlikely to accurately foresee the subsequent course of events, but approximate calculations will indicate at least the direction in which it is worth moving. Such determination is better than blind action.
Business plan for the production of crumb rubber with calculations
In the production of crumb rubber, used, old, defective car tires. 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 at minimum wage, and sometimes get dressed to pay for delivery 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.
IN this moment There are two main methods by which crumb rubber is produced:
- mechanical crushing.
- crushing method shock wave.
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 of production space with a ceiling height of 3m. A direct rubber crumb production line will be installed, a 380 volt power supply will be connected and 2 workers will control the operation of the semi-automatic equipment.
The best option during the period of reaching the payback point of the business is to work continuously for a whole week. To do this, three work shifts should be organized. As a result, the staff will consist of eight persons. In addition, you should take care of the places of storage of raw materials and finished products. In this case, the space for storing tires should take out four, and even five times more. In this regard, the surface of the room for raw materials (tires) may require up to 100m 2, and for the storage of finished rubber crumb - 20m 2.
On this basis, the cost of 100 kilograms of products per hour will change and change. 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 of $0.28 per kilogram, we get a gross monthly income 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, average weight tires 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 of 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 has found application in filtering various types of 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 time payback are the next plus in the interests of this type of activity. Consequently, the high demand for the product (as with all building materials), the minimization of risks and the mentioned thresholds for entering the production technology make it attractive from the point of view of investment.
In most developed countries, there is a need to recycle used car tires due to the rapid growth in the number of vehicles. The problem of their disposal has become very acute for the authorities. An excellent solution to this problem is the establishment of a mini-enterprise for the processing of this material. Thanks to this, all environmental and economic issues are resolved as efficiently as possible.
Features of the production process
The establishment of a mini tire recycling enterprise is considered an effective direction entrepreneurial activity, which is able to provide a high income to its owner. However, on an industrial scale, such an industry can be very unprofitable due to high energy consumption. However, the design of a mini-factory is always a profitable business.
As a rule, the rubber crumb manufacturing technology is based on the following steps:
As a result, several types of products are obtained that are fully suitable for their subsequent sale: carbon dioxide, metal cord, fuel oil and rubber crumb itself. A similar method involves grinding tires mechanically. In addition, the so-called pyrolysis method is used in the production process, during which the tires are treated with high temperatures.
Tire recycling equipment
Materials, product range, distribution channels
The raw materials for the manufacture of crumb rubber are old tires that are not suitable for their further use. The main product that is obtained as a result of the processing of tires is small crumbs.
As a rule, this material serves as the basis for the further production of roofing material, technical coatings and other products used in the construction industry.
It is recommended to start looking for sales outlets with organizations that are directly involved in the maintenance or operation of vehicles. The main advantage of this business is that the raw materials for the manufacture of crumb rubber are virtually free. For example, the supply of tires to the plant from a tire shop.
Tire recycling equipment
We offer you to get acquainted with the types of equipment from the Eco Gold Standard company, which today is the leading manufacturer of tire recycling equipment in the Russian and CIS markets. The company produces two types of tire recycling lines: Eco Gold, Eco Gold Euro. Both lines are produced with a capacity of 400, 550, 700, 1400, 4000 kg per hour. However, the composition of the equipment is completely different. Let's take a closer look.
The composition of the equipment of the Eco Gold line Equipment composition of the Eco Gold line:
- machine for cutting and processing tires "Guillotine";
- hydraulic machine "DS-650";
- loading conveyor - 1;
- apparatus for primary grinding Schroeder KG - 2;
- shredding apparatus Schroeder - 3;
- device for primary grinding - 14;
- belt separator - 4;
- collection cyclone - 5;
- Vibrating sieve - 8;
- Magnetic separator - 11;
- industrial electrical equipment - 12;
- Dust cyclone - 10;
- metal structures and gas ducts - 13;
- fans: transport and high pressure — 9;
- impact crusher - 7;
- vibrating sieve and dust cyclone - 6.
Equipment composition of the Eco Gold Euro line:
Exclusively all types of equipment are fully automated, as well as equipped with a high degree protection against unexpected loads, misuse and unstable high voltage.
Features of drawing up a business plan
Production cost and preliminary financial calculations
In order to open a mini rubber crumb factory, an entrepreneur will need to incur certain financial costs, which we propose to sort out further. All data are taken as industry averages.
- Registration process - up to 150 thousand rubles.
- Rent - 180 thousand rubles.
- Repair work and arrangement of the workshop - 150 thousand rubles.
- Purchase of tanks for fuel oil - 80 thousand rubles.
- Production line - about 1,500,000 million rubles.
- Production tools - 200 thousand rubles.
Result: 2,260,000 million rubles.
In addition, in order to ensure a quality production process for the recycling of tires and tires, the plant must pay the following monthly costs:
- Salary to employees - about 120 thousand rubles.
- Electricity and other communication systems - 30 thousand rubles.
- The cost of transportation and advertising campaign - 150 thousand rubles.
Result: 300 thousand rubles.
Revenue part
As a rule, the average price of 1 kg of rubber crumb from tires and tires is about 17 rubles. In parallel with this, one production line produces no more than 2100 tons of products per day. Consequently, the monthly income from the sale of the main product will be approximately 750 thousand rubles.
To the total amount of income should be added the amount from the sale of fuel oil - 375 thousand rubles. The amount of the final revenue will be 1,125,000 million rubles. per month, and net profit before tax will be 645 thousand rubles.
Conclusion
Making rubber crumb from tires is a fairly profitable business. However, immediately before launching the plant, it will be necessary to sort out a whole list of organizational issues, as well as find reliable channels for the sale of finished products. However, this area of activity is not without flaws, but at the same time it is recognized as one of the most profitable and promising.
Video: Recycling tires into crumb rubber