Installation for processing used car tires into crumb rubber. Automotive tire recycling plant Tire and tire recycling equipment

The issue of recycling tires in Russia has been brewing for a long time.

There is really a lot of waste material; it is thrown into landfills, in places that are not at all intended for this.

It would seem that an ideal environment is being created for business in the rubber processing sector. However, there are many nuances to this topic, which we will try to shed light on in this material.

Any old material can be “breathed” into a second life and used effectively in any industry.

Let's take a closer look at what useful benefits old car tires can provide.

Mechanical recycling

In case of mechanical recycling of tires the output is the following material:

1. Tire crumbs of different fractions, which are used for the manufacture of new products.
2. Textile cord that can be recycled by pyrolysis to produce fuel.
3. Metal cord, which is also melted down.

Learn more about electrical mechanical method and its varieties are possible.

There are three fractions of crumbs:

• 1 mm;
• 2-3 mm;
• 4-5 mm.

Each type has its own consumer, but the selling price of crumb rubber is approximately the same.

In China, European countries and the USA, the technology of reusing tires for their intended purpose is also used by overlaying a new profile on an old tire.

A development plan in this direction was developed at the state level back in the days of the USSR, but failed after its collapse.

Pyrolysis method

There is also a pyrolysis method for recycling old rubber.

Pyrolysis is a change in the formula and properties of the starting material with the splitting of its components.

Speaking in simple language, rubber and rubber included in tires, separated from the court. Final products pyrolysis - quite suitable fuels and lubricants.

In a number of countries, the use of this method is prohibited by law due to harmful emissions into the atmosphere. However, this issue is now being reconsidered and may begin to gain momentum in the future.

The method of pyrolysis processing of tires and rubber goods is described in more detail here.

Business organization

When considering recycling used tires as a business, it is worth weighing all the pros and possible cons.

Let's focus on the mechanical method, and use the example of one of the production lines to consider detailed business plan recycling of car tires.

Let’s take the proposed ALFA TIRE RECYCLING 500 platform as a model – electromechanical production line for processing tires of different diameters, including truck tires.

Cost of equipment

Starting capital to purchase the necessary equipment:

Below is a table with the name of the equipment within the ATR 500 tire recycling line:

You can learn a little more about this line by watching the video:

It is worth paying attention to the following points:

• prices for individual equipment items must be clarified with the seller (supplier);
• all obligations for warranty repairs and the conditions for their provision are specified in the supply contracts.

The cost of delivering equipment throughout Russia can fluctuate upward depending on the remoteness of the region.

More detailed description this line.

You can also ask prices for equipment from other suppliers, for example, this one.

Requirements for production premises and warehouses

Space will be needed for:

• placement of equipment;
• storage of raw materials;
• storage of the finished product.

To install the line you will need: minimum 200 square meters.

An outdoor unheated hangar or a fenced-in area for unloading recyclables is suitable for storing old tires.

Purchasing the necessary premises can be an overwhelming burden for a new entrepreneur.

You can use the offered rental options, the cost, depending on the region, can range from 20,000 to 100,000 rubles/month.

Staff

Let's consider the number of service personnel and the monthly payroll.

For uninterrupted operation production line with a finished product output capacity (crumb rubber) of 150 tons/month. required staff of about 10 people.

Approximate monthly salary fund - RUB 350,000.

These calculations are presented in the form of an average plan and may differ depending on the region of Russia.

Other expenses

Production will be accompanied by other monthly expenses:

1. Purchase of packaging bags (containers) for finished products. The price of a 30 kg bag will be 8 rubles, based on the monthly consumption we get the amount of 4,000 rubles.
2. Communication – 10,000 rub.
3. Unforeseen expenses - 10,000 rubles.
4. Average data on energy consumption of a production line, designed for the production of finished products of 150 tons/month. equal to about 100,000 rubles/month.
5. Maintenance – 50,000 rub.
6. A separate expense item should be considered the replacement of cutting elements (knives) - 35,000 rubles.
7. Garbage truck services – RUB 20,000.

Adding rental and salary costs to these figures, we end up with monthly cost part - about 620,000 rubles.

License for acceptance and disposal

Contrary to information on most websites, tire recycling as a business requires a license.

Tires have fourth hazard class. According to the legislation of the Russian Federation, the reception and disposal of this type of waste requires obtaining a license.

Before submitting documents, an entrepreneur must have:

• production area;
• industrial site with a sanitary zone;
• equipment;
• permits from Rosprirodnadzop, Rospotrebnadzor, fire inspection.

The license cost is 7500 rubles, the deadline for its registration is 45 working days. When using the services of intermediaries, be prepared to pay many times more.

Profitability calculations

Project profitability and revenue generation plan:

1. Finished products in the form of rubber granules, average price 15 rubles/kg. 100 tons = 1,500,000 rub.
2. Metal cord 30 tons at a price of 3,000 rubles/ton = 90,000 rubles.
3. Textiles based on the resulting material being 20 tons and the average market price of 2,000 rubles/ton = 40,000 rubles.

We receive monthly revenue of 1,680,000 rubles. Through simple deductions for expenses and maintenance, we get a net profit of 1,001,000 rubles.

The presented business plan has average calculations and does not take into account some factors:

• location;
• territorial affiliation;
• availability of a sales market in a particular region.

It cannot be accepted as a formula, but even despite this, the benefit is obvious.

At favorable conditions The payback for the production of crumbs from old tires will occur 1.5-2 years after the launch of the line.

Underwater rocks

When we talk about “favorable conditions” we mean:

• no problems with the supply of raw materials;
• properly working equipment High Quality and declared performance;
• well-established sales at reasonable prices.

In reality, not everything goes smoothly. Let's consider a few nuances:

1. Wrong choice of equipment. Our tires differ from foreign ones in that they have a mixed or textile diagonal cord. Most imported machines, which are produced for the domestic market, and not specifically for the Russian Federation, are not capable of processing such products. So, in the absence of experience, you can purchase equipment that will be useless or ineffective in Russian realities.
2. Purchase of defective/faulty units. Again, a common problem when ordering from abroad, especially from China. Faults begin to appear en masse in the first months of active operation; constant breakdowns will cost money for repairs and lead to line downtime.
3. Increased performance. Sometimes the manufacturer can greatly embellish these parameters, especially for sellers from China. Having bought high performance at a much lower cost, there is a high probability of getting equipment that does not work efficiently. As a result, the stated payback period of 1-2 years will turn into 5, or even 10 years.

Problems may arise in other areas, for example, in obtaining raw materials. It may not be enough or it may be expensive.

Enterprises have to collect tires and transport them to production facilities on their own. Many people buy tires from the population. All this leads to the fact that the cost of tire crumbs increases significantly.

Demand for crumb

Here is a list of the main areas of need for crumb rubber:

1. Seamless floor coverings. Enterprises engaged in laying such coatings are distributed throughout the Russian Federation and are constantly in need of high-quality raw materials.
2. Production of tiles and roll coverings. There are large and small industries that are in need of medium grade crumb rubber.
3. Road surfaces. The main consumer is the Moscow Region, but there are prospects for development in other regions. For asphalt, fine crumbs and rubber dust are used.
4. Government orders for the construction of sports facilities, running track surfaces, and sidewalks.

• gravestones;
• figures for playgrounds;
• rubber curbs, bollards;
• various items in which crumbs act as a filler (bean bags, punching bags, etc.);
• rubber shoes;
• MBR (bitumen mastics), where crumbs are needed as a filler;
• rubber insulation;
• other RTI.

Be that as it may, before opening production you need to find out which enterprises are located in or near your region in order to identify demand for crumb rubber.

Tire recycling

Recycling car tires is a labor-intensive and time-consuming process. Their disposal requires the availability of appropriate equipment. A tire recycling plant will allow you to get rid of old rubber by grinding it, and the machine will help you obtain fuel from car tires.

The price of such equipment may be high, but despite the difficulties of installing it, this technology is progressive and effective. Recycling tires makes it possible to get rid of very difficult material that is not subject to natural decomposition, but is very common as a recyclable material.

Used tires are only partially recycled - 20% of required quantity, that is, this niche is still free. The problem of recycling tires is quite serious, so you need to approach the choice of equipment with all responsibility. Tire processing equipment is often stationary and takes up specific place, but does not require special knowledge from the operator, since the machine itself remembers the sequence of actions. And still recycling tires have important economic and ecological significance, so don't underestimate the importance of rubber tire recycling equipment.

Features of tire recycling

For efficient processing For such complex material as tires, special plants or mini-plants are needed. When recycling such products, a variety of products can be obtained: liquid fuel, carbon black, steel cord, etc., the cost of which is beneficial to the consumer. Tire recycling plants also provide crumb rubber, which is a collection of shredded rubber particles.

It is worn tires that are the main raw material for the production of crumb rubber. The price of a tire recycling line is not that high compared to the results that can only be obtained by using it. Even a mini rubber recycling plant will bring good results.

The main thing is to choose the right equipment for setting up the plant, otherwise there is a high risk of failure. Crumb rubber production lines make it possible to obtain from industrial rubber waste something that is in demand, which means it will bring income and benefit, and a business can be built on this. There are very few tire recycling plants, despite the fact that old tires make up the majority of difficult-to-recycle waste suitable for reuse. So tire recycling is important from several points of view.

An industrial business idea for launching a mini-factory for the production of crumb rubber by processing car tires is attractive due to its excellent ratio of large volume money turnover and short payback periods. And most importantly, recycling is the production of money from garbage. We present to your attention a business plan for the production of crumb rubber with calculations and analysis of possibilities. For example, it is worth paying attention to the additional income from extracting metal from tire cords, which contain as much as 7%. What other useful secrets does it keep? this production, let's look at it in more detail.

Mini-plant for processing tires into crumbs

How to correctly calculate the rate and volume of production of crumb rubber from recycled car tires? The answer to this question is not so simple. The production of crumb rubber depends on many nuances. There are two key factors that formed the basis for the attractiveness of this activity from an investment point of view. They will help answer this question.

Factor No. 1: Entry threshold into industrial small business

First of all, you should correctly assess your financial reserves that you own (your own savings and possible loans). It is worth noting that this type of industry is possible with different amounts of investment, which means this business scales well. With small investments in the initial phase, the income may be minimal, taking into account regular expenses for electricity, transportation costs, employee salaries, 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, investing too little increases risks significantly. You can start production on a large scale through the construction of a specialized enterprise large areas, for example, several hundred square meters, which will be worth a large investment. Do optimal choice investment strategies in favor of the golden mean between these boundaries.

Factor #2: Production Capacity for Small Businesses

In case you have about $17,000 of money, the question of choice should not be an obstacle. For this money you can purchase a production line for processing tires into crumbs with a minimum configuration and a productivity 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 m2 and production room the area of ​​which should be on average 40 m2, plus several small storage rooms. In this case, the production of rubber crumbs can begin from a production volume of 800 kilograms of the finished product daily (100 kg/hour in 1 work shift).

What is needed to process tires into crumb rubber?

A minimally equipped line for processing tires into crumb rubber includes the following equipment, which can be found on the Internet at prices:

1. Bead cutting machine – $2,150
2. Tape cutting machine – $2,700
3. Rubber shredder – $7,650
4. Circular sieve – $1,000
5. Conveyor with magnetic separator – $1,000
6. Machine for processing bead rings – $2,500

TOTAL: $17,000

Technology for the production of crumb rubber by recycling tires

A video clip that schematically shows in the form of 3D animation the technological process of recycling tires by grinding them into rubber crumbs:

As you can see in the video, the production process is extremely simple.

If you decide to conduct this activity at a more serious level, an analysis of the sales market in the region in which you are going to launch your project will be necessary. Without this work, it is unlikely that the products will generate profitable income. You will have to include in your business plan the costs of marketing market research for finished products in a specific 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, development opportunities must be calculated economic activity over the next few years. It is unlikely to accurately predict the subsequent course of events, but rough calculations will at least indicate the direction in which to move. Such determination is better than acting blindly.

Business plan for the production of crumb rubber with calculations

Used, old, and defective car tires were used in the production of crumb rubber. For obvious reasons, one should not even talk about the search for raw materials and their price. Old tires can be found in large quantities. You can buy them for a minimum payment, and sometimes you can 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:

1. Mechanical crushing.
2. Crushing by shock wave method.

Shock wave crushing of rubber into crumbs is a relatively new method for processing tires. The most popular is mechanical crushing.

The production of crumb rubber using a shock wave requires a special approach. In particular, you need equipment in which the products will be stored, such as refrigerated pantries, which are quite expensive. There is a noticeable advantage in installing equipment for the production of crumb rubber from car tires using the shock wave method in smaller production areas. You can save on monthly rent. At the same time the cost electrical energy will be less than with an analog installation. But still, such equipment is fully justified for large and medium production volumes, since it is very expensive.

The production of crumb rubber can begin with a small production volume and at relatively low cost. 40 square meters of production area with a ceiling height of 3m is enough. A direct line for the production of crumb rubber will be installed, a power supply of 380 volts will be connected, and 2 workers will control the operation of semi-automatic equipment.

The best option when reaching the breakeven point of a business is continuous work for a whole week. To do this, three work shifts should be organized. As a result, the staff will consist of eight people. In addition, you should take care of the storage areas for raw materials and finished products. In this case, the space for storing tires should be four or even five times larger. In this regard, the surface of the room for raw materials (tires) may require up to 100 m 2, and for storing finished crumb rubber - 20 m 2.

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

1. Purchase of tires at a price of $40 per 1 ton – $960 (24 tons of raw materials per month are required).
2. The cost of renting a warehouse will be about $400-$600 per month.
3. Salaries of workers servicing the production line cost $300-$700 per month;

A good idea is to allow customers to recycle tires for money. Having your own receiving point will help not only reduce transportation costs for the delivery of raw materials, but also immediately receive preliminary additional income, which is described below.

If a production line produces 100 kilograms per hour, working without interruptions, then in a month the amount of finished products produces 24 tons of crumb rubber (100 kg * 8 hours * 30 days = 24,000).

Taking into account the average retail price of crumb rubber of $0.28 per kilogram, we get a gross monthly income of $6,720 (0.28*24,000).

It is also worth noting that during production, metal remains in the waste (wire in tire tires). Its volume is about 7%.

Interesting fact! According to the Goodyear Tire and Rubber Company, average weight tires about 22 pounds (up to 10 kg). Moreover, it contains 0.68 kg of steel cord (it serves as a reinforcing material for the rubber structure in tires).

On the one hand, this industrial waste, and with positive side– this is a significant additional profit: 0.7 kg of metal wire and tire cord. And that’s 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 in profit from selling metal wire from cord. It’s worth thinking about how to organize your recycling of car tires for money.

This amount of benefit is sometimes a more economically justified income received in the process of implementing this activity.

Tire processing products

Where is the crumb rubber from tire recycling used? This unique and durable building material is indispensable in the following industries:

1. Production of paving slabs from rubber crumbs.
2. When covering roads, asphalt and concrete fences on roads with the addition of crumbs.
3. In the production of safety coatings for sports, playgrounds and gyms.
4. In landscape design.
5. Production of hydrophobic materials.
6. Granules are used in the construction industry for the production of rubber sheets, palettes, roofing materials and the like.
7. Crumb rubber granules are also used in the production of rubber mats for pedestrians.
8. Rubber crumbs have found application in filtration different types liquids, creating thermal insulation for industrial premises.

In order to minimize the risk, the scope of production of crumb rubber can be expanded. Thus, 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 industry's big expectations is the production of crumb rubber. Our industry of this type is not particularly developed today.

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. Bottom line, if there is the right approach to selling this product, the sales channels can be easily adjusted. This type of production does not require special skills, it is technologically simple.

Depending on the amount invested in the product, the payback time can last from six months to two years. Relatively short time payback is the next plus in the interests of this type of activity. Consequently, the high demand for the product (like all building materials), minimizing risks and the mentioned entry thresholds into production technology makes it attractive from an investment point of view.

Removal, processing and disposal of waste from hazard classes 1 to 5

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Tire recycling, as a business, allows you to solve two problems at the same time - environmental and economic, since the crumbs obtained as a result of recycling old rubber will be used for production needs, and the amount of hazardous waste at landfills will be reduced. The fact is that car tires wear out over time and become unsuitable for further use. They are replaced with new ones, and old rubber is sent to landfills, where it can lie for decades, polluting the environment.

Is it possible to make money recycling tires?

Until the technology for recycling old tires was developed, unwanted tires found rather unusual uses. They were used to fence playgrounds and flower beds, without thinking that with old tires, if you have the equipment, you can make a good business. The tire could serve as the basis of a country bench or a flower bed, and even the foundation for a light summer building. They are still used today as interesting landscape decorations, thanks to craftsmen who are trying to inspire new life into things written off.

However, the issue related to the disposal of the huge amount of old rubber that is annually thrown into landfills is not resolved in this way. Unfortunately, this is due to the lack of competent collection in our country and the lack of a business environment with necessary equipment. Recycling as a business, depending on the technologies and equipment used, makes it possible to obtain fuel oil or rubber crumbs and granules of various sizes, which are widely used:

• In the production of new car tires
• For the production of rubber shoes and many types of rubber products
• As additives in the production of flooring and roofing composites
• For the production of tile, roll and seamless coverings for paths, playgrounds and sports grounds
• As a filler for concrete mixture, which is used in the construction and repair of road surfaces.

Small crumb particles up to 2 mm in size are used for the manufacture of special sorbents necessary for cleaning the surface of soil and water from petroleum products. This raw material is used once. After application, the absorbent is burned as a fuel mixture, or becomes part of the road surface.

Business plan

Before the beginning entrepreneurial activity for processing, the basis of which is tires, it is necessary to draw up a competent business plan. It will help calculate the profitability of the future enterprise, taking into account upcoming expenses.

Registration

This area is one of those types of activities for which it is necessary not only to open an individual entrepreneur or LLC, but also to obtain a license. This document issues federal Service on supervision in the field of environmental management. In the absence of a license, the company’s activities will be considered illegal, and the owner will be subject to administrative penalties in the form of large fines.

To obtain a license you must provide:

• Relevant statutory documents
• List of works and technological processes that the enterprise will carry out
• Documents for ownership or lease of the premises where it will be located processing plant, as well as related equipment
• Conclusion of the SES
• Conclusion of environmental assessment
• Document confirming payment of state duty

Renting premises

If processing is planned on a medium to large industrial scale, it is necessary to find a room of appropriate size. In the processing workshop, it is necessary to rationally install all the equipment; this will require an area of ​​500 square meters. m.

Warehouse facilities will also be needed to store raw material and processed crumbs, as well as other finished products. Recycling rubber tires is a hazardous production, therefore the complex should be located away from residential areas, in a specially designated industrial zone.

Equipment purchase

For the processing process, it is advisable to purchase a ready-made line, which includes equipment capable of providing a full cycle of separation and crushing into crumbs. With a limited budget for initial stage you can get by with one shredder and subsequently expand the enterprise with new equipment.

Procurement of raw materials

The tire recycling business is most often carried out on the basis of free raw materials. And even more than that: by receiving waste rubber you can even make a profit by producing crumb rubber. For example, when a company rents out tires. Free stuff can be obtained from landfills or tire shops.

The tire business is an opportunity to show concern for environment, improve environmental situation and obtain inexpensive raw materials for the production of necessary goods and infrastructure. For example, crumb rubber is used to make the basis for playgrounds and public transport stops.

Processing technologies

Tires can be recycled if you have the necessary equipment:

1. Electromechanical grinding, when the output produces crumbs, which are subject to subsequent processing to produce rubber products.
2. As a result of pyrolysis or thermal destruction to produce fuel oil.

Each method has its own advantages and disadvantages. Recycling of old tires as a result of electromechanical shredding is accompanied by frequent equipment downtime due to the need to maintain the cutting tool. Knives often become dull and fail when working with metal cord rubber, and it makes up at least 90% of the total amount of raw materials. At the same time, the resulting crumb has a wide range of applications.

If the technology involves changing the chemical structure of rubber, then the resulting raw material is not suitable for re-production and is characterized by lower cost. It is used as a fuel material. But the processing process takes place without the cost of updating cutting tools.

Recycling problems and their solutions

Processing is still in its early stages of development. It is low-profitable as an independent business, however, the problem of environmental pollution from old, worn-out tires and the growth of the car fleet, which ensures an annual increase in the amount of waste, requires an immediate solution.

The low popularity of recycling car tires is due to the need to obtain a license and resolve issues with environmentalists and firefighters. One of the most effective solutions existing problem State subsidies for this type of activity and the opening of complex processing plants, the profitability of which will be ensured by other types of raw materials, may become possible. However, there are many advantages to opening a tire recycling organization. For example, the availability of source material and disproportionate benefits to the environment.