Tire shredder. We make crumb rubber with our own hands using a homemade crusher

Each of us knows that a vehicle cannot do without tires. However, not everyone thinks about where worn-out tires go. There are two ways: either the tire is sent to a landfill and thereby pollutes the environment, or it is recycled. It is safe to say that rubber is a dangerous pollutant, which is why they always try to recycle it. For this simple reason, there are all the prerequisites for creating your own small plant, where tire processing will be carried out.

What everyone should know

Every year the number of cars on the roads increases by about 5-10%. Based on this, the volume of worn rubber increases by approximately 1 million tons. In many countries, the issue of recycling is very acute. This problem can be partly solved by setting up your own small production. You have several options for business development. For example, this could be the processing of car tires into fuel oil or crumbs. If you want to receive fuel, you will have to spend a little more money, since the production line is quite serious. Please also note that you can work not only with tires, but also with plastic products, which will slightly increase the profitability of the enterprise. This business has several undeniable advantages, now we will look at each of them.

Firstly, you do not need to invest a lot of money in purchasing raw materials. This is due to the fact that worn tires are thrown away. Local authorities, if, of course, they are concerned about the ecology of their city, will deliver everything to you themselves. But that’s not all, since the municipality is ready to pay for your company to process car tires. Agree, getting practically free raw materials, and even making a profit from doing this business, is not at all bad. Of course, it doesn’t end there, since our main goal is not only to save the environment, but also to make a net profit. The main funds will come from the sale of the same fuel oil, which is an extremely popular type of fuel in agriculture. By the way, you can also get free raw materials at tire service points, which are more than abundant in big cities. The thing is that service station employees, etc., pay additional money for the removal of old tires and their disposal.

Recycling rubber tires: pros and cons

It is impossible not to say a few words about the fact that this niche has not yet been fully filled. The number of entrepreneurs in this area is relatively small, approximately 20% of the optimal figure. This means that only a fifth of worn-out rubber is disposed of and recycled, the rest is sent to a landfill. You must understand that 1,000 kilograms of burned tires means 450 kg of various toxic gases, as well as 250-270 kilograms of soot. But if the same amount of rubber is properly disposed of, then about 700 kilograms of full rubber can be obtained from the waste, which can be used to make fuel and rubber products. Here it hardly makes sense to talk about the industrial scale of the enterprise, but it is very possible to set up a small tire processing plant.

The complex itself is relatively small, but its size directly depends on production volumes. So, to process 5 tons per day, you need a room of 18 square meters and 10 meters in height. There should be a warehouse on the site where you will store tires, plastic, etc. There must be an area for preliminary preparation of raw materials (cleaning, cutting rubber). You can’t do without a storage room for finished products. In this case, it all depends on what exactly you are getting. It could be fuel and so on. For example, for fuel oil you will need to purchase several large-capacity tanks. They don’t have to be new; it’s even better to buy used ones, it’s much cheaper. Please note that recycling rubber tires is difficult and dangerous. Therefore, technology must be carefully followed. Let's talk more about this.

Technological process

In essence, there is nothing complicated here, but it is necessary to control the process at all stages of production. At the very beginning you have to start collecting tires. Next, you must take them to your company’s warehouse for further processing. In order not to damage the scissors, which, by the way, are not cheap, it is necessary to inspect all raw materials for the presence of metal objects, such as disks or rings. As for the cutting tool, ideally it should be hydraulic scissors, but this is not at all necessary, we will talk about this a little later. Next, the crushed rubber is sent to the reactor - a special installation for processing tires, which operates at a given temperature, most often 450 degrees Celsius. Decomposition leads to the fact that we obtain several semi-finished products, for example gas, steel cord, and fuel fraction.

The same gas is used to support combustion in the furnace as a by-product fuel. Its waste is released into the environment. This cannot be called a good solution, but the emissions resemble exhaust gases from a truck. As for the remaining mass, it passes through a magnetic separator; in simple words, it is sifted through a sieve. Metal elements are screened out and sent to the warehouse. Fuel oil is transported by conveyor to tanks, in which the fuel will be stored until dispatch. It should be noted that the tire processing plant, which produces pyrolysis fuel, is quite expensive - approximately 2 million rubles. Its productivity is about 5 thousand tons of raw materials per day, which is quite a lot.

Making crumb rubber

Here is another rather interesting idea that has not received proper distribution to date. The essence of such a business is that you will sell crushed and processed rubber, which can be used for various purposes. In order for you to roughly understand what we are talking about, it is necessary to provide general indicators in numbers. Thus, a ton of crumb rubber on the Russian market will cost no more than 20,000 rubles. As for the main consumers, these are construction companies, manufacturers of rubber products, roofing materials, coatings for construction and sports tools, etc. In principle, it is quite easy to find a sales point.

It is also necessary to take into account the fact that approximately 700-800 thousand tons of worn tires are thrown away every year on the territory of the Russian Federation. Approximately 20-25% is disposed of properly, the rest either just lies in landfills or is burned. So, processing tires into crumbs can bring in 5-8 billion, but this is already on an industrial scale. If you will be engaged in this kind of recycling at your plant, then you will need a mechanical crusher. will have to be changed very often, which leads to high costs. Another disadvantage of this idea is that a lot of electricity is consumed, approximately 500 kilowatts per ton of finished product. Nevertheless, recycling tires in this way will be profitable. But only if you receive appropriate support from the state.

Tire recycling equipment

Separately, we need to talk about what our production line will consist of. In principle, there is not much equipment, and it is not complicated at all. However, the price is steep. The main unit is a tire processing unit (reactor), 10 meters high, 3.5 meters wide, 5 m long. This unit must be installed only in an open area, that is, in the open air. You, as a future entrepreneur, must understand that you will have to pay quite a lot of money for electricity. The reactor itself consumes about 6 kW per hour. In addition, there are also scissors - 7-8 kW/h. In principle, this is practically all the equipment that is needed to start production. What else is needed is several crucibles for unloading the resulting material.

As noted above, the reactor has a capacity of about 5 tons per day. But of this mass, approximately 40% will be liquid fuel. The fact is that as a result of decomposition you will get gas (about a ton) and about 0.5 tons of steel cord. We must not forget about the solid residue (carbon-containing materials), this is approximately 30% of the total output. It is worth drawing your attention to the fact that the processing of old tires in the reactor is carried out in a continuous mode. All you have to do is add tires. Combustion is supported by gas produced inside the firebox. The reactor must be maintained by two specially trained specialists. In principle, training courses can be completed fairly quickly. Now let's move on and look at a few more important points.

How much money do you need to start?

This is one of the main aspects that interests absolutely all beginners. There is no need to spend a lot of money here. If you are going to purchase used equipment (reactor, scissors), you can save up to 20% of the total amount. Whether to take such a step or not is up to you to decide. There is no guarantee that a used reactor will not fail after the first melting. In this case, no one will compensate you for the damage. One million rubles should be enough for you to do everything. This includes the cost of a reactor with a capacity of 5 tons/day, as well as scissors. In addition, you will need to purchase several tanks (60 tons). If these are used containers, then you will have to pay about 25,000 rubles per unit. Decide for yourself how many pieces you need, but you don’t need to limit yourself to one or two tanks. The fact is that processing tires into fuel is a seasonal business.

During a period of decline in fuel prices, it is better not to sell it, but only to accumulate it. When the period of increase comes, and this will definitely happen, you can get a good income by selling all the fuel oil at once. This tactic works and is considered quite effective. But this does not mean that you should completely freeze sales; it is enough to reduce them by 50-75%. You still need to pay your employees. Four specialists will cost approximately 60,000 rubles per month, and tools and workwear will cost another 50 thousand. There are also regular monthly costs: electricity, taxes, rent, etc.

About enterprise income

As you may have noticed, the technology for recycling tires is quite simple. There are no fuel additives, complex chemical reactions or other issues. Moreover, as noted above, the raw materials are completely free. Sometimes you can even earn some money by collecting tires, which will cover your monthly electricity costs. If you live in the outback, then you are unlikely to be paid for recycling, but in big cities the situation is completely different. There are many industrial enterprises that pay good money for recycling rubber. This is due to the fact that many city landfills refuse to accept such waste. For recycling a ton of tires you can get a different amount, from 2 to 5 thousand rubles.

It is safe to say that even recycling tires at home will bring good income. Thus, for a ton of low-quality carbon, consumers are willing to pay 3 thousand rubles. Scrap metal is accepted at the rate of 4 thousand rubles per ton, and fuel oil - 3-4 thousand rubles per ton, depending on the period. By simple calculations, you can come to the conclusion that in a month you will earn approximately 350,000-400,000 rubles. Approximately 50% must be paid for electricity, paid to workers, etc. With such intensity, the tire recycling line will pay for itself within six months, which is quite fast. As you can see, the idea is very interesting and promising, but not everything is so simple. In such a business, as, in fact, in any other, there are a lot of pitfalls. Let's see how not to make mistakes.

Problems when starting a business

It happens that you simply cannot find a free plot of land. This is due to the fact that it is necessary to maintain a safe distance to residential buildings, which is 300 meters. The further the plant is from the city, the higher the cost of delivering raw materials, do not forget about this. Remember also that not everyone wants tires to be recycled outside their windows. Feedback from ordinary residents will be negative, even if the reactor is located 400 meters from residential areas. For this simple reason, look for a location on a production site. Chances are you'll find one, as quite a few of the sites are empty. All you need to do is negotiate directly with the company; as a rule, this is not so difficult to do. At least, it’s much easier than concluding an agreement with firefighters and the sanitary and epidemiological station.

Do not forget that you need a license. It is not difficult to obtain a permit, since tires are classified as non-hazardous materials (group 4). But the catch is that your production officially pollutes the atmosphere. Most likely, you will be asked (forcibly) to buy a treatment plant. Its price is usually several times higher than the entire plant. But there are several ways that will help you postpone the purchase for a certain time. Experts say that it is not advisable to open a plant for processing any one material. Whether this is true or not, decide for yourself. In any case, you can always expand your workshop and melt glass, plastic or metal there. According to statistics, 75% of entrepreneurs encounter environmentalists who are wary of this type of production.

A few important details

As noted a little above, you will encounter a “contingency” clause in your business plan. This is due to the fact that it will be necessary to resolve issues with environmentalists and firefighters. For example, to store fuel oil in new tanks, only a protective shield is needed, but used tanks require additional protection. There are special lines for fuel and gas, fire safety instructions for personnel, and much more. In any case, you need to have a reserve in your budget of several hundred thousand rubles. This will save you a lot of trouble. The expense items are quite large, but we have already covered them, and you probably know what you will be dealing with.

Don't forget that you, as a manager, must not only monitor how your employees work, but also perform a number of other equally important tasks. Among these: constant development and growth of the boundaries of the enterprise, accounting and tax accounting, as well as adjustment of goals and plans for the near future. This article did not mention one important point - advertising your product. There are several options here. One of them is to create your own thematic website where you can offer fuel oil, etc. No one has canceled the advertisements on poles, stops and stands. Until now, this is a good and effective method to loudly declare oneself. In addition, for a nominal fee you can rent a billboard and place your advertisement there. By the way, you need to do this wisely. It is important not to overload with unnecessary information, but also to attract the attention of a potential audience.

Conclusion

So we talked to you about what tire recycling is and how to open such a business. As you can see, everything is quite simple, but there are a lot of important points. Sometimes it happens that it is difficult to find a supplier, or the latter refuses to just give away old tires and demands money for them. In principle, you can find another, more acceptable enterprise, where they will be happy to get rid of excess garbage, and they will even give you money for the trip. Sometimes it makes sense to enter into a full-fledged long-term supply agreement. This way you can eliminate downtime in your business and increase your income. But all these points must be discussed directly with the supplier. Remember that it is much more difficult to find a point of sale for tires than to find a businessman who is ready to buy this garbage. This is due to the fact that in some cities there are no tire recycling reactors at all.

If you get good fuel oil, then aim for city or private boiler houses. There you will be happy to purchase fuel, which is vital for heating water. If you are going to get crumb rubber, then you will need a machine that costs about 500,000 rubles. Electricity consumption per 1 ton of product is 90 kW. The disadvantage of this approach is that a group of knives (40 pieces) wears out after processing hundreds of tires, so they often need to be replaced. In principle, you only need to pay 30 rubles for one knife, which is relatively little. Thus, a unit with a productivity of 20 tires per hour pays for itself in about six months. The results are the same as in the production of fuel oil. But in the first case, there are fewer problems with environmentalists and firefighters, since we are not dealing with either waste into the atmosphere or liquid fuel. Well, that’s basically all on this topic. The most difficult thing is to start, and then it will be much easier.

Of the total amount of used tires, only 20% is recycled, despite the fact that a ton of tires contains approximately 70% of rubber suitable for recycling into fuel, products or building materials. When this amount of tires is burned, 460 kg of harmful gases and 280 kg of soot are released into the atmosphere! Equipment for tire processing pays for itself in 6 to 12 months; there are never any problems with raw materials and sales of finished products.

Types of tire processing

There are two recycling technologies, during which car tires are made:

• powder, granules, crumb rubber, chips;
• liquid fuel.

To produce the first four types of raw materials, the same type of machines and equipment are used. The process involves grinding and separating raw materials. The entire cycle takes place without the use of chemical reagents and the release of harmful products into the atmosphere.

When processing into liquid fuel, pyrolysis is used - thermal decomposition of rubber with the release of gas. Some of the gas is released into nature, so such equipment must be equipped with cleaning stations.

Crumb production line

The tire recycling line operates in semi-automatic mode. This prefabricated equipment occupies approximately 200 square meters. meters. The productivity of a small workshop per hour is 200 - 1000 kg of finished crumbs, up to 200 kg of metal per shift, up to 1000 kg of textile wool per shift. To service the machines, 3–4 unskilled workers are needed. The line recycles used tires, releasing metal and textile inclusions.

Not all tire recycling equipment contains stud and cotton textile separators. This should be taken into account when selecting machines.

In addition to the area for equipment, it is necessary to prepare a warehouse for raw materials and finished products. The basis of the line are roller-type shredders. Most mini-plants are designed to process tires up to 120 cm in diameter; modernization to 170 cm is possible. Not only tires can be processed, but also any rubber waste (gas masks, conveyor belts). The output is:

• crumb rubber;
• crushed steel;
• textile wool.

Rubber yield ranges from 60 to 80% of the total tire weight. The properties of crumb rubber may vary depending on the quality of the scrap.

Averages:

• pure rubber content 99.9%;
• metal content up to 0.1%;
• textile content up to 0.2%;
• division into factions;
• black color;
• does not oxidize under the influence of temperature.

The machines produce crumb rubber with particle sizes from 0.8 to 3 mm. The amount of crumbs of various fractions depends on the degree of wear and hardness of the original product. Using a vibrating separator, you can clearly separate the crumbs into fractions.

Diameters can be adjusted by adjusting crushers and replacing screens. The smaller the particles, the longer it takes to produce them. To produce rubber dust, an additional wiper is installed, which produces particles less than 0.1 mm.

Processing technology

1. A seat ring is cut out of the tire, the metal is squeezed out, and rubber remains.
2. The tire is spirally divided into strips 3–5 cm wide.
3. A second metal ring stands out.
4. The tape is cut into thin and short pieces.
5. The workpieces are crushed on rollers into crumbs and dust.
6. Rubber, metal, and cotton wool are released on the separators.
7. Finished products are sent to the warehouse.

Tire shredding equipment

The production process is divided into two stages, taking place in different areas:

• preliminary;
• abrasion.

The preliminary stage takes place on machines:

• landing ring selector;
• tire separator into lanes;
• lane separator;
• ring squeezer.

Equipment for the main stage:

• chief eraser;
• coarse vibrating sieve;
• magnetic filter;
• air separator;
• belt conveyors;
• thin vibrating sieve.

The grinding machine is the main equipment in the workshop for recycling car tires. A hard concrete or asphalt floor covering is required to place the machines.

Selling crumbs

The final product of tire processing is used:

• in the production of various types of fuel: pyrolysis gas, fuel oil, gasoline;
• in the construction of highways: the production of special slabs for areas of special danger, brake modules, fences for car parks, soundproofing panels, crossings over railway and tram rails, bitumen-based mastics, sports and play surfaces;
• in the manufacture of shoe blanks, floor coverings;
• in the production of rubber products, roofing coverings;
• for preparations for the adsorption of oil and its derivatives from water and land.

Fuel production line

The second type of device processes tires into liquid fuel. The machine occupies about 18 square meters. meters at a height of 10 m. Tires are cleaned of metal rings and disks, crushed and transported to the reactor receiving tank.

The reactor maintains a temperature of about 460 degrees, at which the rubber decomposes into liquid fuel, gas, carbonaceous matter and metal wire. Part of the gas is used to operate the reactor itself; the excess is released into the atmosphere. Their quantity is small and therefore does not harm the environment.

Liquid fuel is poured into containers and sent to a warehouse for further sale. The carbon-containing substance is cooled, quenched, and metal is released from it. All processed products are ready for sale.

Such equipment processes up to 5000 kg of tires per day, producing:

• liquid fuel - about 2000 kg;
• metal - 500 kg;
• carbon-containing substance (solid residue) - about 1500 kg;
• gas - 1000 kg.

The equipment is installed outdoors, on a concrete or asphalt area. The continuously operating workshop is serviced by 2 workers per shift. On average, the machine consumes 14 kW per hour. Gas obtained from tire recycling is used as fuel.

The first video talks about the process of recycling car tires, the second demonstrates the processing of tires into crumbs, the third shows a homemade pyrolysis plant for producing fuel from tires:

Enterprises involved in the production of rubber elements, tires, tubes and other similar products often use rubber shredders.

They allow you to recycle tires, tubes and other elements made of rubber. The material remains flexible and elastic, retaining its molecular formula

How to choose the right crusher

You should choose this type of equipment based on the following parameters:

• build quality;
• high-strength knife metal that can withstand constant heavy loads;
• overall dimensions of the device;
• dimensions of the receiving neck;
• engine power.;
• maximum amount of processed material per hour.

Taking into account all the above points, you can choose a crumb rubber shredder for your specific tasks. Engine power should not be neglected. By overloading it with constant actions, it will not cope with the required volume of material that needs to be processed and will experience regular failures and breakdowns. In addition, our company offers tire recycling lines.

Before tires go into the shredding container, they must be cut. Rubber tire parts instantly turn into crumbs, significantly saving you time and money on more expensive equipment.

High-quality work of the shredder will give you undamaged, flexible and elastic crumb rubber. Parts and elements of high quality and strength are produced from recycled materials.

One of the environmental problems is the disposal of used tires. Improper disposal of rubber causes irreparable harm to the environment and human health. Recycling recyclables using a tire shredder can help solve this issue.

You can purchase the required model remotely using Internet resources. The application is completed quickly and easily, and delivery is carried out in the shortest possible time.

Process Benefits of Using a Tire Shredder

• Rubber shredder shows high performance in the presence of impurities

  The unit is capable of processing small and large recyclable materials

  The final product is in demand in the national economy

  The unit meets the requirements of the European standard

  The product is competitive on the market

Why is it worth buying equipment from us?

Purchasing an innovative original shredder at prices below market prices;

You are guaranteed: free consultation, friendly attitude and individual approach to each order;

When purchasing a product, customers are provided with a manufacturer’s warranty and the possibility of after-sales service;

Contacting the company guarantees the selection of a tire shredder in accordance with the specified requirements;

Delivery and payment of goods is beneficial for both parties to the transaction.

How to place an order?

To place an order, you must visit the company's official website to fill out an online application. It specifies information with the client’s personal data, type of equipment, power, price criteria and other requirements. The answer will be provided via a manager's call. We are waiting for your applications.

Order a specialist consultation for free!

Fill out a simple form and we will call you back.

Waste disposal is one of the pressing problems of our time - however, few businessmen are able to see the prospects for activity in this direction. The paradox is that every year thousands of tons of raw materials are lost in city landfills and landfills, while being an almost free resource for creating a successful and profitable business.

An example of such a business is the processing of tires into crumbs: the price of the equipment and the requirements for production space make it possible to quickly develop an enterprise in fairly modest conditions, and the income measured in millions leaves no room for doubt about the feasibility of the investment.

Considering that existing domestic factories are not able to recycle more than 20–25% of the volume of used tires that end up in landfills annually, it can be assumed that in this free niche, a newly created business will not experience difficulties in finding raw materials. This will allow the entrepreneur to pay more attention to organizing sales and creating related production that allows him to receive additional income.

What can you get from recycling?

When considering, it should be taken into account that the recycling of old tires involves two possible directions: pyrolysis processing and grinding into crumbs. The differences between them are in the equipment used, energy intensity, the amount of start-up capital and methods of selling finished products.

In pyrolysis plants, the raw material is heated to 450–500°C and breaks down into:

1. Synthetic liquid fuel, which is used in boilers and heating installations. With further distillation, hydrocarbon fractions can be obtained from it - gasoline, diesel fuel, fuel oil and resins;
2. Carbon black, which is used as an adsorbent, a filler in the production of rubber products, a dye in the paint and varnish industry and a base for bitumen mastics;
3. Gas used for re-combustion in a pyrolysis plant.

Tires are made from high-quality rubber, which, after mechanical grinding, fully retains such properties as elasticity, strength, and resistance to chemical attack. When processing car tires into crumbs, the main products are various fractions - from 0.25 to 5 mm, widely used for the manufacture of:

• Rubber tiles, coverings for stadiums, gyms and playgrounds;
• Sports equipment (as a filler);
• Soles for shoes, rubber boots;
• Wear-resistant road surface;
• Speed ​​bumps, bump stops, railroad crossings;
• Bumpers, mats, mudguards and other automotive rubber products;
• Linings for railway sleepers.

The steel component of the tire is also separated from the rubber and used as a reinforcing additive for concrete in the construction of buildings and roads, or as a raw material for melting.

Thus, the processing of worn tires into crumbs, as well as pyrolysis recycling, are practically waste-free processes that make it possible to obtain products that are quite in demand in industry.

Processing technology

Currently, three main technologies for processing tires into crumbs are used:

• Cryogenic grinding after treatment with liquid nitrogen. Despite its effectiveness, this method requires huge costs - about 30–40 million rubles;
• Mechanical abrasion and deformation in a confined space;
• Cutting tires into pieces and then grinding them using crushers and mills.

In the latter case, equipment for processing tires into crumbs is the most affordable for small businesses, since it can be located on an area of ​​300–450 m² with a total investment of 4–7 million rubles.

The technological process includes:

1. Preliminary inspection of raw materials and removal of foreign matter;
2. Removing the seat ring from one side;
3. Cutting the tire into strips 4–5 cm wide;
4. Removing the second ring;
5. Cutting the tape into “chips” measuring 20–40 mm;
6. Grinding of fragments using a shredder and rollers;
7. Separation of textile and steel cord;
8. Sorting crumbs into fractions;
9. Packaging and shipping.

Equipment for processing tires into crumbs

Sources of raw materials

Organizing a continuous supply of raw materials is one of the most important tasks in this business: processing tires into crumb rubber will be profitable if the equipment is fully loaded for at least one eight-hour shift per day. Even a small workshop can process 200–500 kg of rubber per hour - such an enterprise will require a daily supply of at least three to four tons of old tires. To ensure such volumes, you will have to establish contacts with all possible sources:

• Motor transport enterprises, bus and trolleybus fleets;
• Landfills for urban and industrial waste;
• Tire workshops and car services.

According to the law, legal entities must pay for waste disposal (including old tires) in the amount of 2000–2500 rubles per ton. Therefore, the offer to recycle tires at a lower price will be commercially profitable for them.

In addition, the population also experiences problems with recycling tires: by organizing a stationary collection point, you can buy them at a mutually beneficial price and constantly supply the plant for processing tires into crumbs with raw materials.

Sales organization

Crumb rubber, textiles and metal cord cannot be classified as goods in demand among retail buyers. Therefore, a business plan for processing tires into crumbs should include organizing sales through contacts with wholesale buyers or direct deliveries to construction and processing industries.

You can find interested clients using the Internet, participation in specialized exhibitions, sending commercial offers and personal negotiations. At the same time, it is important to correlate the customer’s needs with the capabilities of its own production - not every company is ready to buy tens of tons of crumb rubber every month.

Advantages and disadvantages of business

Recycling tires into crumbs is a business that is of interest to entrepreneurs and investors, not only because of its environmental benefits, but also because of its acceptable level of profitability, quick payback, and also:

• Continuously replenished sources of raw materials, available practically free of charge or at a symbolic price;
• Simplicity of technology - servicing a line for processing tires into crumb rubber does not require special qualifications or special knowledge;
• A large number of industries that use tire processing products;
• Opportunities for obtaining comprehensive government support for an enterprise carrying out socially and environmentally beneficial waste disposal activities.

Disadvantages of business include significant capital investments, as well as difficulties that arise when finding regular suppliers and buyers. Therefore, it is advisable to establish the necessary contacts for work before purchasing machines for processing tires into crumbs.

Enterprise registration

When an enterprise is officially registered, there are no legal subtleties - since 2012, tire recycling activities are not subject to licensing. Of course, to open a business, you need permits from the fire and sanitary services, as well as contracts for the supply of electricity and waste removal. However, when choosing a form of ownership, some economic factors should be taken into account:

• Individual entrepreneurship presupposes the availability of sufficient start-up capital or the possibility of receiving government assistance in the form of grants, partial compensation for the cost of equipment, preferential loans and reimbursement of payments under equipment leasing agreements;
• If the launch of a mini plant for processing tires into crumb requires the involvement of partners, co-owners or private investors, then it would be advisable to register a limited liability company.

Search for premises

A suitable production facility should include not only the space required to install a tire crumb processing line, but also an area for stockpiling raw materials, as well as space for storing finished products. A workshop with an area of ​​350–500 m² and a ceiling height of 5 meters, located on the outskirts or outside the city in an industrial zone and with good access roads for heavy vehicles, would be acceptable.

The second necessary condition is the presence of a connection to utility networks: water supply and power lines with a capacity of at least 120–150 kW.

Third, the distance between the enterprise and residential buildings. Due to the noisy production, the sanitary standard here is taken to be 300 m.

You can find such premises on the territory of former and operating enterprises, bases, and warehouse complexes. Rental prices here will be reasonable, and the lack of renovation requirements will lead to additional savings.

Equipment selection

The average cost of equipment for processing tires into crumbs is determined both by its capacity and the country of production. The advantage of domestic lines over Chinese ones is the availability of services for setting up, starting up, maintaining and repairing machines. However, even at the initial level, processing 100–200 kg of raw materials per hour requires costs of 1.5–2 million rubles. Unfortunately, such lines are often functionally limited (for example, there is no magnetic separator or cyclone), so to launch a full-fledged enterprise, it is advisable to consider complexes with a capacity of up to 300–500 kg/h, consisting of:

• Bead cutting machine;
• Machine for removing seat rings;
• Machine for cutting tires into strips;
• Machine for cutting tape into “chips”;
• Roller machine, mill;
• Vibrating table and vibrating screens;
• Magnetic separator for metal removal;
• Cyclone for removing textiles;
• Electrical switching equipment;
• Conveyor set.

The total price of machines for processing tires into crumbs to produce such capacity is 5.5–5.7 million rubles. However, the needs of the enterprise sometimes require the purchase of additional equipment:

• Large tire cutter;
• Storage bins;
• Libra;
• Machines for sewing polypropylene bags.

Taking into account hand tools, a tire recycling workshop can be equipped for 6–6.2 million rubles. However, despite the impressiveness of this amount, investments in production pay off quite quickly.

Staff

The process of processing tires into crumbs with your own hands is technologically simple, and therefore does not require the constant presence of highly qualified personnel (with the exception of repair and maintenance of the line - sharpening knives, replacing conveyor belts or electric motors). Such production can be serviced by 3–4 people. In addition to them, you should hire:

• Accountant (possible on a part-time basis);
• Receiver of raw materials (storekeeper);
• Sales Manager;
• Driver with cargo vehicles.

General spending plan

Considering the high cost of equipment for processing tires into crumb rubber, entrepreneurs can turn to the state or private investors for help. To do this, you need to develop a detailed business plan that takes into account all the associated costs:

Initial investment in business

Monthly expenses

Revenues and profitability

The main advantage of processing used tires into crumb rubber is the minimum price of raw materials. Most often it is zero, but in some cases enterprises even pay extra for waste disposal.

The line with a capacity of 400 kg/h allows you to process up to 80 tons of rubber per month, producing 55 tons of crumbs, 15 tons of metal cord and 10 tons of textiles. When determining income, we can assume that the price of crumb rubber of different fractions is approximately the same: 16–17 rubles per kilogram. The market value of a kilogram of textiles is 2 rubles, and of metal cord is 2.5 rubles.

Enterprise income

Thus, the average return on investment in a business when the enterprise is fully loaded is 8.5–9 months. The minimum volume of raw materials that needs to be processed to recoup current costs is 170 kilograms per hour.

Production risks

Like any business, recycling old tires comes with known risks. Some of them are reduced by timely maintenance of machines, others are unforeseen circumstances:

• Interruptions in the supply of raw materials;
• Breakdown and subsequent downtime of equipment;
• Failures in sales organization;
• Damage to products due to non-compliance with storage conditions;
• Falling product prices.

Organizational risks should be minimized by duplicating supply and sales channels, searching for new buyers not only in Russia but also abroad, as well as by expanding the scope of activity. For example, products from processing tires into crumbs at home can be pressed into tiles and painted, thus producing a practical and safe coating for tennis courts, sports and playgrounds.

Video on the topic

There are more than 1.1 billion passenger cars in the world. The number of registered cars in Russia is about 46 million. This means that if we add trucks, then there are about 5 billion tires running on the roads of the world. The number of tires in landfills around the world is unknown. In Russia, according to various estimates, from 30 to 45 million tires are thrown away per year. There is no need to talk about the harm that such waste causes to the environment.

The issue of recycling and disposal of car tires is acute throughout the world.

There is not a single country in which this problem is considered solved. In our country, according to various sources, from 8 to 12% of old tires and conveyor belts are recycled. These figures indicate that tire recycling as a business has good prospects.

However, having decided to run a rubber processing business, you must carefully choose the processing method and imagine all the pitfalls of such a business. Choosing a processing method, and therefore the direction of your investment, is a very complex task. Enterprises that produce equipment for one or another processing method naturally praise their method and carefully hide its shortcomings. In this article we will try to make the task of choosing a processing method easier. Remember that there is no perfect method. Everyone has flaws. Here are the main ways to recycle car tires:

• reuse by applying a new tread (in this case, after reuse, the tire still needs to be recycled);
• combustion to produce thermal energy;
• heating without air access or with limited air access (pyrolysis);
• grinding to produce crumb rubber, recycled metal and textile threads;
• burial and use for strengthening the coastline, installing fences, etc. This method is prohibited in most countries, including Russia. We will not consider it.

We do not consider in this article applying new tread to worn tires (“welding”). This is a method of extending the life of tires rather than recycling them. But let's look at other methods in more detail. When evaluating recycling options, you should have a basic knowledge of the tire material composition.

Tire material composition

The main components of tires are cord (metal, textile or mixed), rubber, filler (soot), auxiliary materials (thermal stabilizers, anti-ozonators, etc.), adhesives (contain polychlorinated hydrocarbons and some other materials in small quantities. If we do not consider metal cord (which is a steel wire coated with brass - an alloy of copper and zinc), then the composition of the tires includes: hydrocarbons (rubber, etc.), carbon (soot), silicon dioxide, sulfur (vulcanizing agent in rubber and other components), polychlorides (in adhesives) and some other components in small quantities. Contrary to popular belief about the presence of arsenic in tires, it is not there. Heavy metals are also absent (except for a small amount of copper and zinc on the surface of the steel cord). Lead is also not used in modern tires. All these components undergo changes during tire processing and form new substances, many of which are more dangerous than the original ones. Now let's look at the advantages and disadvantages of various tire recycling methods.

Burning tires to produce thermal energy

The method seems attractive. Therefore, it is worth talking about it in more detail.

Burning one ton of tires produces approximately the same amount of thermal energy as one ton of thermal coal.

What is the problem? Firstly, tires cannot be burned in conventional thermal power plants. You need special equipment and preparation of raw materials. Secondly, when sulfur is burned, it produces large amounts of sulfur dioxide (sulfur dioxide). This requires a special cleaning installation. The problem is being solved, but the equipment is very expensive. Thirdly, polychlorides at insufficient combustion temperatures form one of the most dangerous substances - dioxin. Available international experience indicates that this method has the right to life only when processing very large quantities (more than 100 tons) per day, requires huge capital investments and is profitable only in the case of subsidies (financial support) from the state.

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Tire pyrolysis

The process involves heating the material to 400–500 degrees without access to oxygen (air). This produces pyrolysis gas, a liquid hydrocarbon fraction, soot and steel cord waste. You can find excellent product costing. For example, from 1 ton of tires you can get 500 kg of liquid hydrocarbon fraction (fuel and even gasoline!), 200 kg of gas (used to heat the reactor and save fuel), 200 kg of carbon black and 100 kg of metal. What's the problem? Ask yourself a question: where does sulfur disappear if it contains up to 10% silicon dioxide? Very simple. Most of the sulfur turns into hydrogen sulfide (the strongest poison, a substance of hazard class 1), which is contained in pyrolysis gases. The other part of the sulfur forms carbon disulfide and other compounds, which go into the liquid fraction. And finally, the residue, which is bashfully called carbon black, contains metal sulfides (mainly sodium and calcium). Where did the silicon dioxide disappear - into the residue. The fate of polychlorides is even more complex. Some of them go into the residue, some form hydrogen chloride (not a gift!), and some form dioxins, which can be found in all products. This “carbon black” will not be used by any responsible consumer. You can't bury it either. By recycling tires in this way, we will create a bunch of new problems. These problems can be solved, but require large capital investments, which calls into question the profitability of this method without government assistance.

Grinding tires to obtain rubber crumbs

The essence of the method is very simple. Tires are shredded. In this case, three products are formed - metal, crumb rubber (we will consider the directions of its use below) and textile cord waste.

With such processing, virtually no chemical changes occur (no new toxic waste is generated).

This is the main advantage of the method. What are the problems? It is very difficult to separate textile threads from crumb rubber and the textile material thus obtained is practically a new waste. We will further show how this problem can be solved. But at the initial stages it is better to start processing purely steel-cord tires. This will significantly reduce capital costs. The key problems when constructing a mini-tire recycling plant are the following problems.

1. Choosing a location for production. Construction or use of existing structures.
2. Selection, purchase and installation of equipment.
3. Obtaining a processing license.
4. Formation of reliable channels for obtaining raw materials and marketing finished products.

Let's look at everything in order.

Production site and buildings

Even a mini-tire recycling plant requires a fairly large site. Most of the production site will be occupied by a warehouse for raw materials (tires) and finished products. The tire recycling line occupies a fairly large area - 150–300 m2. It is better to clarify this after choosing the equipment. The height of the building (or hangar) is 5–6 meters. The production site must be sufficiently remote from residential buildings. Minimum distance 200-500 m. The best place is an industrial zone. When recycling tires, the material heats up quite strongly and releases volatile substances with a specific odor. Local ventilation is required. It is necessary to provide special absorption cartridges as part of the ventilation equipment. They are produced industrially.

Equipment for processing tires into crumbs

For processing tires into crumbs, the price of equipment is not prohibitive. However, the cost of a set of equipment of 10–15 million rubles should be considered minimal. The choice of equipment for processing tires into crumbs is quite wide. There are Russian-made and imported lines. When choosing equipment, don’t pay too much attention to brands.

Tire recycling line

If possible, visit an existing production facility and listen to all about the problems of this production. When purchasing equipment, it is better to focus on complete lines, but some components can be used or purchased separately. Here is the minimum list of equipment:

• shredders (shredder, hydraulic shears, tape cutter);
• separators (air and magnetic);
• conveyors;
• vibrating screens