Installation for processing used car tires into crumb rubber. Turning tires into crumbs through processing at a mini-factory Recycling of car tires business

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 different 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.

Question about recycling and disposal car tires is acute all over 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 coastline, installation of 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 burned, sulfur forms a large number 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.

Read also: Equipment for the production of seals and stamps

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 and the resulting textile material from crumb rubber - it is practically 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 expenditures. 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 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– 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

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 simultaneously - environmental and economic, since the crumbs obtained as a result of recycling old rubber will be used in 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 the necessary equipment. Refining as a business, depending on the technologies and equipment used, allows you to obtain fuel oil or crumb rubber and granules of various sizes, which have wide applications:

• In the production of new car tires
• For the production of rubber shoes and many types of rubber products
• As additives in production flooring and composite materials for roofs
• 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 is issued by the Federal Service for Supervision of Natural Resources. 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 the processing plant will be located, as well as for the corresponding 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 material can be obtained from landfills or tire shops.

The tire business is an opportunity to show concern for the environment, improve the 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 for maintenance cutting tool. Knives often become dull and fail when working with metal cord rubber, and it makes up at least 90% of total number starting 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.

The SPECTEHNIKA company will help you start your own business with high profitability and establish profitable production, the main resource for which will be free tires, the number of which is only increasing every year.

Why can't they just be burned? Firstly, each ton will release 300 kg of soot and 400 kg of toxic gases into the air. Secondly, after recycling tires, you can get up to 700 kg of useful recyclable materials, plus energy, which are a hot commodity on the market. You wouldn't burn your own money, would you?

Find out what the SPETSTEKHNIKA group of companies offers.

Find out more

Industry development prospects

Our company develops and sells specialized equipment for fast and, most importantly, environmentally friendly tire recycling. The purchase of such plants will be a profitable investment for both a small enterprise with a small start-up capital and a large one that has decided to launch another production line.

Tire recycling at mini-factories is:

	At least 4 tons of liquid fuel per day, which in its characteristics corresponds to heating oil and can be used to produce thermal energy, as a raw material for obtaining diesel fuel and gasoline.
	At least 4.2 tons of carbon black per day, which is used for the production of fuel briquettes, sorbents, as a coloring pigment and as the main component for the production of all kinds of rubber products. GC "SPETSTEKHNIKA" will purchase carbon black from you or provide assistance in its sale.
	Scrap metal. Used as a high-alloy steel for remelting and manufacturing metal products.

We offer mini-plants for an environmentally friendly way of processing tires, which is beneficial in all respects: economical use of water, minimal emissions into the air, free raw materials and government support. Call right now so as not to miss the opportunity to make a profit of 1,369,000 rubles per month.

Each of us knows that vehicle can't 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. Partially solved this problem It is possible if you set 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 technological line 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 receive net profit. Fixed 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. You can't call it good decision, but the emission resembles exhaust gases from a truck. As for the remaining mass, it passes through a magnetic separator, so to speak in simple words, then 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's another one is enough interesting idea, which 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 are thrown away every year on the territory of the Russian Federation. worn tires. Approximately 20-25% is disposed of properly, the rest either just lies in landfills or is burned. So, processing tires into crumbs can bring 5-8 billion, but this is already 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, under 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 go ahead 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% 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 complex fuel additives here. chemical reactions and other points. 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.

We offer our customers a series of mobile installations for processing worn tires into crumbs "UPSH-M".

The Tekhnoresursy LLC company produces various equipment for processing tires, including a series of UPSH-M installations.

From us you can buy inexpensive mobile equipment for processing all types of car tires into crumbs of the UPSH-M series.

The UPSH-M series includes seven models. The modifications differ in the ability to process tires along the outer diameter.
For example, the UPSh-1200-M model processes tires up to 1200 mm, and the UPSh-3500-M model shreds large tires up to 3500 mm in outer diameter.
Below is a description of the operation of the installations using the example of the “UPSh-2-M” model.

The equipment allows you to process all types of tires into crumbs.

• The diameter of the seat ring of recycled tires: from R15 to R33
• External (outer) diameter of tires up to 2000 mm.
• The weight of processed tires is up to 600 kg.
• Recycling technology: method of mechanical shredding of tires at ambient temperature.
• Machine dimensions: (L/W/H): 2200*2000*3000 mm.
• Machine weight: no more than 1500 kg.
• Cutting group: 10 cutters.
• Service life of cutters: 180-350 tires (depending on the condition of the tire and its size).
• Average productivity of the machine: 6-20 tires/hour or up to 120 kg of crumb rubber (depending on the type of tires).
• Electricity consumption for the production of 1 ton of pure rubber crumb is approximately 90 kW. Crumbs obtained from the outside of the treads and sidewalls of a tire.
• Electricity consumption for crushing the steel cord layers of a tire is about 130 kW/1 ton.
• Tires are processed down to seat rings approximately 50 mm wide. A thick bead wire runs through them.

From each worn-out truck tire (up to 1200 mm in diameter) up to 20 kg of clean rubber crumb is removed (depending on the degree of tread wear.) Next, the rubber-cord layer is removed and the output is crumb with pieces of cord, which requires additional cleaning.
When processing rubber rubber with a diameter of 1600 to 2000 mm, it is possible to produce pure crumb (50-120 kg of granules) + crumb rubber with inclusions of textile fiber or met. wire 60-150 kg. The productivity when processing CGT tires is significantly higher than when processing standard smaller truck tires.

Additional options:

• System for lifting and landing heavy tires weighing up to 800 kg.
• Tire cutting system into 6 ring parts. Thanks to this option, UPSH-2 can replace the BB-500 machine. That is, cut a large tire with a diameter of up to 2000 mm into 6 rings: seat rings - 2 pcs; 2 sidewalls; cut treadmill in the center into 2 parts.

This option is relevant if you recycle tires in the partial recycling mode, i.e. Grind only the outer shell of clean rubber (from the sidewalls and treadmill). If tires are completely recycled, this option is not needed.

Main salvage materials:
Out-of-service quarry tires of the BELAZ type, tractor, truck and off-road tires of various sizes with radial and diagonal cord construction.

Places where worn tires accumulate:

• on roadsides and unauthorized landfills;
• on the territory of motor transport and other enterprises;
• next to tire shops;
• quarries, landfills where large amounts of carbon dioxide accumulate.

Due to the fact that automobile shoes must experience long-term destructive loads during operation, expensive high-quality components (natural, synthetic rubbers, oils, reagents, fillers, etc.) are used in the production of new tires in combination with the latest technologies. Tire rubber is practically the strongest and most durable of all types of rubber used, and has many other important qualities (elasticity; resistance to acids and alkalis; bending strength, tensile strength, abrasion, resistance to cyclic loads, temperature changes, etc.).

At mechanical processing tires into crumbs - granulate, the physical and chemical composition of tires practically does not change. Due to the fact that crumb is a product of processing (disposal) of tires, the market price for it is 3-5 times lower than for primary rubber raw materials. Therefore, the crumb is an inexpensive, high-quality product for recycling automobile rubber.

Operating principle of the mobile tire recycling plant UPSH-2-M:
1. A worker rolls a tire to the machine.
2. Light tires are installed in the clamping drum manually (up to 25-35 kg) 2 tires at a time, heavy tires are installed using a tire lifting and landing mechanism.
3. When the tire is put on the clamping drum, the worker, using hydraulic force, spreads the chuck's paws and the tire is securely fixed in the drum.
4. After installing the tire, the worker turns on the rotation drive of the chuck, and the fixed tire begins to rotate. Since the wheels have different outer diameters, there are 3 rotation speeds.
5. The car wheel rotates at a certain speed, and the operator brings a powerful cutting bit rotating at a speed of more than 2000 rpm to it. A group of knives is installed on the crown, hidden under a protective metal casing. The speed of the bit advance is controlled by the operator, similar to working on a lathe. The higher the speed at which the bit is brought to the tire, the larger the crumb fraction at the output and vice versa (this is a way to adjust the crushed rubber fraction). When producing small fractions of crumbs, the productivity of the installation is lower than when producing large granules.
6. In this way, first, clean rubber crumb is cut off from the tire, and the tire is processed until the cord appears. Next, the second stage is the processing of the cord layers of the tire carcass.
7. The larger and heavier the tire, the higher the productivity of the mobile installation, and, as a result, the ability to “remove” more clean rubber crumbs for less time. short term(saves time on installing the tire into the chuck).
8. The machine, at the customer’s request, is equipped with an additional option for longitudinal cutting of tires into 6 parts (2 bead rings are cut, 2 sidewalls are cut + the frame is cut into 2 parts in the center of the treadmill). This is convenient for the layout of tires, which reduces their volume and makes rubber a more transportable material. The arrangement of tire residues makes them convenient for further grinding.
As mentioned above, this option is relevant in the “partial processing of tires into granulate” mode.

The sale of mobile tire recycling plants includes the following steps:
1. Concluding an agreement and issuing an invoice for an advance payment of 50%.
2. Manufacturing of equipment from 35 to 65 days (depending on the model and configuration).
3. Payment by the buyer of the remaining 50% and sending the equipment to the buyer’s address through a transport company.
4. Receipt of equipment by the buyer in his city at the warehouse of the transport company.
5. Personnel training, consulting, information support, exchange of experience is carried out by email. mail, telephone and printed materials sent with the equipment.
6. Warranty period: 12 months.
7. Cost of additional warranty service for 24 months: +7% to the contract price.

Production parameters for UPSH-2-M:
1. Required area – from 25 m2
2. Work shift – 1 person
3. Electricity consumption:

• Installed power is no more than 15 kW.
• Average consumption – no more than 10 kW/hour (due to the fact that the equipment operates cyclically, not at full load after starting the engines)

4. A 20-40 foot metal container or a suitable non-damp room is suitable for a warehouse of finished products.
One 20/40 foot container contains 15/30,000 kg of crushed rubber.
Production is conventionally divided into three zones:

• Raw materials warehouse.
• Crumb production sector.
• Finished goods warehouse.

General characteristics and advantages of tire recycling technology using mobile installations UPSH-M:
UPSH-2-M replaces an entire complex (line) for the complete processing of tires up to 2000 mm into rubber crumb.
Low installation cost, making it affordable for budding small businesses.
The equipment pays for itself much faster than multi-stage tire shredding lines - within several months.
It takes about 90 kW to produce 1 ton of clean crumbs. This is approximately -300 rubles (depending on the tire size and the local electricity tariff).
Costs for wear of knives no more than 2000 rubles per ton of pure crushed rubber without inclusions (depending on the type of tire being processed)
Production is simple, with only one worker.
The crumbs are ideal for the production of colored rubber tiles by hot and cold molding, thanks to the grinding technology and the oblong shape of the particles. The “Christmas tree needle” shape of the rubber crumb provides the finished product with high bending and tearing strength.
The output: a) clean rubber granules without metal and textile inclusions; b) the rubber is crushed with the inclusion of cord, requiring additional separation.
Almost any room from 25 m2 with 15 kW is suitable for organizing a workshop.
The production is environmentally friendly - there are no emissions into the soil or atmosphere.
The production is not harmful to personnel in terms of dust, vibration and noise levels.
Due to the fact that UPSh-2-M has the ability to process large tires, a number of advantages are achieved compared to the operation of a standard expensive equipment multi-stage tire recycling, for example, the ability to process a wide range of tires that need to be recycled by size. Standard equipment can process tires with a diameter of up to 1200 mm. For example, the UPSH-3500-m model can process tires up to 3500 mm! The cost of recycling CV tires and oversized tires is significantly higher than the cost of recycling a standard car tire up to 1200 mm.

Most of the advantages of UPSH-M come from the fact that complete shredding of a tire on UPSH-M occurs in 1 stage. That is, no additional machines or stages are required, which significantly reduces the cost of produced commercial granulate.

The cost of 1 ton of crushed rubber on the Russian market is approximately 15-30 thousand rubles. depending on the type of granules, quality, fraction, seasonality and region of delivery.
Rubber crumbs produced by UPSH-2-M have the following advantages over round and cubic rubber granules:
When hot molding colored rubber tiles, such crumbs produce very strong products (especially for tearing and fracture). This is possible due to the elongated shape of the particles. This is also facilitated by the particle structure itself. The particles adhere over a larger surface and overlap each other, which is less pronounced when cross-linking round and cubic rubber granules.
The tread of any car tire contains only pure rubber. Neither metal nor textile cord passes through this part. The output crumb is free of inclusions, which is difficult to achieve when processing the entire tire (minimal inclusions of textiles, metal and rubber dust remain).
It is possible to produce crumbs of any fraction (see photo below) according to the buyer’s requirements. This is achieved by the fact that by adjusting the supply of the cutter, the crumbs are obtained into the required fraction (from dust to large pieces of RD).
Thanks to the sharp cutter blades and an effective air cooling system, the crumbs do not receive traces of thermal oxidation.
If necessary, a product made from such crumbs can be made hard by strong compression of the press.
If necessary, in addition to pure crumbs, UPSH-2-M can be used to produce granules containing cord from fabric cord tires. For example, crumbs with fabric cord today are the main and irreplaceable filler for sports equipment (for example, professional punching bags). Such crushed rubber can be used as the bottom layer of rubber tile coverings.

Crumb rubber is the main raw material for the production of many popular products:
Coverings for children's playgrounds
Gyms and sports grounds
Rubber anti-slip paving stones
Coverings of piers, swimming pools.
Coverings for car washes, garages
Covering for livestock farms.
Covering under trees to delay water evaporation and prevent weed growth. Has an attractive aesthetic appearance. Used in landscape design.
Sprayed waterproofing coating for walls and foundations.
Filler for sports equipment (punching bags, mats)
Filler in bitumen-rubber mixtures (for the production of high-quality new generation asphalt, rubber mastics and roofing materials).

Economic calculations for crumb production

1. Data:
For simplicity of calculations, we will take one tire size 14.00-24.
We work 8 hours per shift, 2 shifts per day, 22 days per month.
Productivity per month: - 20 tons of pure rubber crumb: 10 tons of crumb including cord.
Number of workers per shift - 1 person
Form of ownership: individual entrepreneur or LLC, where a simplified taxation system applies - 6% of total revenue.
The cost of electricity is 4 rubles/kW (each region has its own tariff)
Monthly deductions for salary (2 workers, when working in 2 shifts) - 50,000 rubles.
The cost of renting an industrial premises (25 sq.m.) is 10,000 rubles/month.
Average energy consumption is 9 kW/hour.
Energy consumption of the workshop for a month is 9 (kW) * 16 (h) * 22 (day) = 3170 kW * 4 rub./kW = 12,700 rub.
Other monthly expenses (office, household) – 5,000 rubles.
The cost of selling 1 ton of crumbs on the market is 18,000 rubles. (the minimum price for pure crumbs is taken)
2. Calculations:
Energy consumption of the workshop per month is 12,700 rubles.
Wage 2 people per month - 50,000 rubles.
Rent of premises/month - 10,000 rubles.
Costs for Consumables(knives, bags)/month - 10,000 rub.
Other monthly expenses - 5,000 rubles.
Total total costs: RUB 87,700.

Productivity of clean crumbs/month. - 20 t.
Crumb production with cord included -10 t.
The cost of 20 tons of clean crumbs and 10 tons of RD including cord is RUB 87,700.
Gross profit – (20,000*18) + (10,000* 10)= 360,000 + 100,000= 460,000 rub.
Profit minus cost – 460,000-87,700 = 372,300 rubles.
Profit minus taxes and other fees (8%) - RUB 342,500.

Options for using crumbs with textile inclusions:
bottom layers of block rubber products produced by hot molding.
filler for punching bags and other sports equipment (considered the best filler today)
A crumb containing meth. cord can be used in the bottom layers of rubber tiles.
It can also be cleaned using a magnetic separator. We will send information on the separator upon request.
Appearance of crumb rubber produced on UPSH-2-M.

In addition to the UPSH-2-M model, we can offer other modifications of this type of equipment:
UPSH-1200-M, for complete recycling of tires up to 1200 mm.
UPSH-1-M, for complete recycling of tires up to 1600 mm.
UPSH-3-M, for complete recycling of tires up to 2200 mm.
UPSH-4-M, for complete recycling of tires up to 2700 mm.
UPSH-5-M, for complete recycling of tires up to 3000 mm.
UPSH-3500-M, for complete recycling of tires up to 3500 mm.

There are others special modifications mobile installations UPSH (for processing the outer casing of a tire into crumbs and the ability to cut tires into rings) and the UPSH-T series for processing the outer casing of a tire into clean rubber granules of cubic regular shape.

A table comparing the capabilities of different sets of equipment for processing tires with UPSh included.

• If the task is to produce crumbs, then you can meet the cost from 570,000 rubles. The output will be a “Christmas needle” shaped crumb. It is enough to install UPSH-1200. However, there will be some unprocessed tire cords left.
• If the task is to produce cube-shaped crumbs of the correct shape, then the cost of a set of equipment starts from 1,327,000 rubles. However, there will still be parts of tires that are not recycled.
• If you need to process a tire into “Christmas tree needle” crumbs and have no waste (the output is crumbs and cord plates), then you will need a kit costing from RUB 1,090,000.
• If the task is to process a tire into crumbs of the correct cubic shape, so that the output is crumbs and cord plates-chips, then the cost of the equipment is 1,732,000 rubles.
• If the task is to process a tire into “Christmas tree needle” crumbs and produce rubber tiles from the crumbs, then the cost is from 1,185,000 rubles. But there will be remnants of unrecycled tire parts.
• If the task is to process a tire into crumbs of a regular cubic shape and from the crumbs to produce rubber tiles, then the cost of a set of equipment starts from 1,827,000 rubles. But there will be remnants of unrecycled tire parts.
• If the task is to create waste-free production, process a tire into “Christmas tree needle” crumbs and produce rubber tiles from the crumbs, then the cost of a set of equipment starts from RUB 1,590,000.
• If the task is to process a tire into crumbs of the correct cuboid shape and produce rubber tiles from the crumbs, and establish waste-free production, then the cost of a set of equipment starts from 2,232,000 rubles.

If your budget is limited, then you can purchase an inexpensive version of equipment right away and buy more over time. necessary equipment, for example, a kit for the production of colored rubber tiles for 500,000 rubles.
Russian-made equipment is simple, reliable and inexpensive. We produce all these equipment options ourselves, so you have the opportunity not to overpay to intermediaries.
Prices and configurations may change, so check them with the company manager.