Plant for processing used car tires into crumb rubber. Turning tires into crumbs by recycling in a mini-factory Recycling car tires business

There are more than 1.1 billion cars in the world. The number of registered cars in Russia is about 46 million. This means that if trucks are added here, then about 5 billion tires run on the world's roads. The number of tires in the world's landfills is not exactly known. In Russia, by 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 show that tire recycling as a business has a good future.

However, once you decide to run a rubber recycling business, you must choose your recycling method carefully and be aware of all the pitfalls of such a business. Choosing a recycling method, and therefore the direction of your investment, is a very difficult task. Enterprises producing equipment for one or another processing method, naturally, praise their method and carefully hide its shortcomings. In this article, we will try to facilitate the task of choosing a processing method. Remember that there is no perfect method. All have flaws. Here are the main ways to recycle car tires:

• reuse by applying a new tread (in this case, the tires still need to be recycled after reuse);
• combustion for the purpose of obtaining thermal energy;
• heating without air access or with limited air access (pyrolysis);
• grinding to obtain crumb rubber, secondary metal and textile threads;
• burial and use for fortification 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 the application of a new tread on worn tires (“welding”). This is a method to extend the life of tires, not to recycle them. Let's take a closer look at other methods. When evaluating recycling methods, you should have a basic knowledge of the composition of the tire material.

Tire material composition

The main components of tires are cord (metal, textile or mixed), rubber, filler (soot), auxiliary materials (thermal stabilizers, anti-ozonizers, etc.), adhesives (contain polychlorinated hydrocarbons and some other materials in small quantities. Except for metal cord (and this 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 (a vulcanizing agent in rubber and as part of other components), polychlorides (as part of adhesives) and some other components in small quantities.Contrary to popular belief about the presence of arsenic in the composition of tires, it is not there.Heavy metals are also absent (except for a small amount of copper and zinc on the surface of the metal cord). Lead is also not used in modern tires. All these components undergo changes during the processing of tires 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 generate thermal energy

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

Burning one ton of tires gives about the same amount of thermal energy as one ton of thermal coal.

What is the problem? First, tires cannot be burned in conventional thermal power plants. You need special equipment and preparation of raw materials. Secondly, when sulfur is burned, it forms a large number of sulfur dioxide (sulphurous gas). This requires a special cleaning installation. The problem is solved, but the equipment is very expensive. Thirdly, polychlorides at insufficient combustion temperature form one of the most dangerous substances - dioxin. Available international experience shows that such a 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) by the state.

Read also: Equipment for the production of seals and stamps

Tire pyrolysis

The process is heating the material to 400–500 degrees without access to oxygen (air). This produces pyrolysis gas, liquid hydrocarbon fraction, soot and steel cord waste. You can find an excellent product calculation. 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 is the problem? Ask yourself the question, where does sulfur disappear if it contains up to 10% and 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. Another part of the sulfur forms carbon disulfide and other compounds that go into the liquid fraction. And, finally, in the residue, which is bashfully called technical carbon, there are metal sulfides (mainly sodium and calcium). Where did the silicon dioxide disappear - in the remainder. The fate of polychlorides is even more complicated. Some of them pass 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. Having recycled tires in this way, we will create a bunch of new problems. These problems are solved, but require large capital investments, which calls into question the profitability of this method without the help of the state.

Grinding tires in order to obtain crumb rubber

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

With such processing, there are practically no chemical changes (no new toxic waste is formed).

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 new waste. We will show below how to solve this problem. But at the initial stages it is better to deal with the processing of pure steel cord tires. This will significantly reduce capital expenditures. The key issues in building a mini tire recycling plant are the following issues.

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

Let's consider 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 of raw materials (tires) and finished products. The tire recycling line occupies a fairly large area - 150–300 m2. This is best clarified after choosing the equipment. The height of the building (or hangar) is 5–6 meters. The production site should be sufficiently removed from the residential area. Minimum distance 200-500 m. The best place- industrial zone. During the processing of 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.

Tire crumb recycling equipment

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 lines of Russian production and import. When choosing equipment, do not pay too much attention to brands.

Tire recycling line

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

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

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

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

Can you make money recycling tires?

Until the technology of recycling old car tires was developed, unnecessary tires found quite unusual uses for themselves. They were used to fence playgrounds, flower beds, without thinking that you can make a good business on old tires with equipment. The tire could serve as the base 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 breathe new life in debited items.

However, the issue associated with the disposal of that huge amount of old rubber that is thrown into landfills every year is not solved 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, makes it possible to obtain fuel oil or crumb rubber and granulate of various sizes, which has a wide application:

• In the manufacture of new car tires
• For the production of rubber shoes and many types of rubber products
• As additives in production floor covering and composite materials for roofs
• For the manufacture of tiled, rolled and seamless coatings for paths, playgrounds and sports fields
• As a filler in concrete mix, which is used in the construction and repair of pavement.

Fine 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 oil 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 recycling, which is based on tires, it is necessary to draw up a competent business plan. It will help to calculate the profitability of the future enterprise, taking into account upcoming expenses.

Registration

This area is one of those 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 an administrative penalty in the form of large-scale penalties will be imposed on the owner.

To obtain a license, you must provide:

• Relevant statutory documents
• List of works and technological processes to be carried out by the enterprise
• Documents for the ownership or lease of the premises where the processing plant will be located, as well as for the corresponding equipment
• SES conclusion
• Conclusion of ecological expertise
• State duty payment document

Premises for rent

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

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

Purchase of equipment

For the processing process, it is advisable to purchase a ready-made line, which includes equipment that can provide a full cycle of separation and grinding 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: at the reception of waste rubber, you can even make a profit by producing crumb rubber. For example, when tires are handed over by the enterprise. Free material can be obtained from landfills or tire shops.

The tire business is an opportunity to take care of the environment, improve the ecological 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

You can recycle tires if you have the necessary equipment:

1. Electromechanical grinding, when crumb is produced at the output, which is subject to subsequent processing to obtain 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 downtime due to the need for maintenance cutting tool. Knives often become dull and fail when working with steel cord rubber, and it is at least 90% of total raw materials. At the same time, the resulting crumb has a wide scope.

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 a lower cost. It is used as a fuel material. But the recycling process takes place without the cost of updating cutting tools.

Processing problems and their solution

Recycling is still in its early stages of development. It is low-margin as an independent business, however, the problem of pollution of the environment by old tires and the growth of the car fleet, which provides an annual increase in the amount of waste, requires an immediate solution.

The small popularity of recycling tires is associated with the need to obtain a license, resolving issues with environmentalists and firefighters. One of the most effective solutions existing problem may be state subsidies for this type of activity and the opening of complex processing plants, the profitability of which will be provided by other types of raw materials. However, there are many benefits to starting a tire recycling business. For example, the availability of raw materials and the disproportionate environmental benefits.

The SPETSTEHNIKA company will help you start your own business with high profitability and establish a 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 burn them? Firstly, 300 kg of soot and 400 kg of toxic gases will enter the air from each ton. Secondly, after recycling tires, you can get up to 700 kg of useful recyclable materials, plus energy, which are hot goods on the market. You wouldn't burn your own money, would you?

Find out what the SPECTEHNIKA group of companies offers.

Learn more

Prospects for the development of the industry

Our company is engaged in the development and sale of specialized equipment for fast and, most importantly, environmentally friendly tire recycling. The purchase of such plants will be a profitable investment both for a small enterprise with a small start-up capital, and for a large one, where it is decided to launch another production line.

Tire recycling in mini-factories is:

	At least 4 tons of liquid fuel per day, which, according to its characteristics, corresponds to heating oil and can be used to produce thermal energy, as a raw material for diesel fuel and gasoline.
	At least 4.2 tons of carbon black per day, which is used for the manufacture of fuel briquettes, sorbents, as a coloring pigment and as the main component for the production of various rubber products. SPETSTEHNIKA Group of Companies will purchase carbon black from you or assist in its sale.
	Scrap metal. It is used as a high-alloy steel for remelting and manufacturing of metal products.

We offer mini-factories for an environmentally friendly way of tire recycling, which is beneficial in all respects: economical use of water, minimal emissions into the air, free raw material base and support from the state. 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 the worn rubber goes. There are two ways: either the tire is sent to a landfill and thereby pollutes the environment, or it is recycled. It's safe to say that rubber is a dangerous pollutant, so they always try to dispose of it. For this simple reason, there are all the prerequisites for creating your own small plant, where tires will be processed.

What everyone should know

Every year the number of cars on the roads increases by about 5-10%. Based on this, the amount of worn rubber increases by about 1 million tons. In many countries, the issue of recycling is very acute. partly solve this problem You can, if you set up your own small production. You have several business development options. For example, it can be the processing of car tires into fuel oil or crumbs. If you want to get fuel, you will have to spend a little more money, since technological line serious enough. Pay attention also to the fact 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 consider each of them.

Firstly, you do not need to inject a lot of money into the purchase of raw materials. This is due to the fact that worn rubber is thrown away. Local authorities, if they, of course, are worried about the ecology of their city, will deliver everything to you. But that's not all, as the municipality is ready to pay for the fact that your company will process car tires. Agree, getting almost free raw materials, and even making a profit from the fact that you are doing this business, is not bad at all. Of course, everything does not end there, since our main goal is not only to save the environment, but also to receive net profit. Fixed assets 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 fitting points, which are more than enough in big cities. The thing is that service station employees, etc. pay additional funds 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, about 20% of the optimal figure. This means that only a fifth of the worn rubber is disposed of and recycled, the rest goes to landfill. You must understand that 1,000 kilograms of burned tires is 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-fledged rubber can be obtained from mining, which can be used to make fuel and rubber products. It hardly makes sense to talk about the industrial scale of the enterprise, but it is very possible to establish a small tire processing plant.

The complex itself is relatively small, but its size directly depends on production volumes. So, for processing 5 tons per day, you need a room of 18 squares and 10 meters in height. There must be a warehouse on the site where you will store tires, plastic, etc. There must be a site for the preliminary preparation of raw materials (cleaning, cutting rubber). You can not do without a room for storing finished products. In this case, it all depends on what exactly you get. 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, it's much cheaper. Please note that recycling rubber tires is a difficult and dangerous business. Therefore, technology must be carefully observed. Let's talk about this in more detail.

Technological process

In fact, 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. Then you must take them to the warehouse of your enterprise 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 discs or rings. As for the cutting tool, ideally it should be hydraulic shears, 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 tire recycling plant that operates at a given temperature, most often 450 degrees Celsius. Decomposition leads to the fact that we get several semi-finished products, such as gas, metal cord, 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. Can't call it good decision, but the emission resembles the exhaust gases of a truck. As for the remaining mass, it passes through the magnetic separator, speaking in simple words then sifted through a sieve. Metal elements are screened out and sent to the warehouse. Fuel oil is transported by a conveyor to tanks, in which the fuel will be stored until shipment. It should be noted that the plant for the processing of tires, which allows you to get pyrolysis fuel, is quite expensive - about 2 million rubles. Its productivity is about 5 thousand tons of raw materials per day, which is quite a lot.

Production of crumb rubber

And here's one more enough interesting idea, which has not received due distribution to date. The essence of such a business is that you will sell shredded and processed rubber, which can be used for different purposes. In order for you to roughly understand what we are talking about, it is necessary to give 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 building and sports tools, etc. In principle, it is quite easy to find a point of sale.

It is also necessary to take into account the fact that approximately 700-800 thousand tons are emitted on the territory of the Russian Federation every year. worn tires. Approximately 20-25% is disposed of properly, everything else is either simply lying in landfills or burned. So, recycling tires into crumbs can bring 5-8 billion, but this is already industrial scale. If you are going to be doing 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, about 500 kilowatts per ton of finished products. Nevertheless, recycling auto tires in this way will be beneficial. 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 so much equipment, and it is not complicated at all. Nevertheless, the price "bites". The main unit is a tire recycling plant (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 sky. 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 necessary to start production. What else is needed is a few crucibles to unload 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 somewhere around 0.5 tons of steel cord. We should not forget about the solid residue (carbon-containing materials), which is approximately 30% of the total output. It is worth paying your attention to the fact that the processing of old tires in the reactor is carried out continuously. All you have to do is add tires. Combustion is supported by the gas produced inside the furnace. The reactor should be operated 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 get started?

This is one of the main aspects that interests absolutely all beginners. You don't need to spend a lot here. If you are going to purchase used equipment (reactor, shears), you can save up to 20% from total amount. It is worth taking such a step or not, it's up to you. There is no guarantee that a used reactor will not fail after the first heat. In this case, no one will compensate you for the damage. One million rubles should be enough for everything about everything. This includes the cost of a reactor with a capacity of 5 tons / day, as well as shears. 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 apiece. How many pieces you need, think for yourself, but you do not need to be limited to one or two tanks. The fact is that the processing of tires into fuel is a seasonal business.

During the period of a 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 happen for sure, 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 at all that you should completely freeze sales, it is enough to reduce them by 50-75%. You still have to pay employees. Four specialists will cost about 60,000 rubles a month, and tools and overalls - another 50,000. There are also regular monthly costs: electricity, taxes, rent, etc.

About the income of the enterprise

As you can see, tire recycling technology is quite simple. There are no additives to the fuel, complex chemical reactions and other moments. Moreover, as noted above, the raw materials are completely free. Sometimes even collecting tires can make some money, which will pay off the monthly electricity costs. If you live in the outback, then it is unlikely that you will be paid for disposal, but in big cities the situation is completely different. There are many industries that pay good money to recycle rubber. This is due to the fact that many city dumps refuse to accept such waste. For the processing of 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 a good income. Thus, consumers are ready to pay 3,000 rubles for a ton of low-quality carbon. 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 about 350,000-400,000 rubles. Approximately 50% must be paid for electricity, workers, etc. With such an intensity, the tire recycling line will pay off in 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 a mistake.

Problems when starting a business

It happens that it is simply not possible to find a free piece 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 farther the plant is from the city, the greater the cost of delivering raw materials, we should not forget about this. Remember that not everyone wants tires to be recycled under their windows. Feedback from ordinary residents will be negative, even if the reactor is located at a distance of 400 meters from residential areas. For this simple reason, look for a place on the production site. Most likely, you will find it, since quite a few sites are empty. All that is required of you is to negotiate directly with the company, as a rule, this is not so difficult to do. At least, it is much easier than to conclude an agreement with firefighters and a sanitary and epidemiological station.

Do not forget that you need a license to obtain a permit is not difficult, since tires are non-hazardous materials (4th group). 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 delay the purchase for a certain time. Experts say that it is not advisable to open an enterprise for the processing of any one material. Like it 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 kind of production.

A few important details

As noted a little above, you will encounter the fact that the item "contingencies" will appear 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, and 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 considered them, and you probably know what you will be dealing with.

Do not forget that you, as a leader, must not only observe how your employees work, but also perform a number of other equally important tasks. Among these: the constant development and growth of the boundaries of the enterprise, accounting and tax accounting, as well as the adjustment of goals and plans for the near future. In this article, one important point was not mentioned - advertising your product. There are several options here. One of them is to create your own thematic site where you can offer fuel oil, etc. Nobody has canceled ads on poles, stops and stands. Until now, this is a good and effective method to loudly declare yourself. In addition, for a nominal fee, you can rent a billboard and place your advertisement there. By the way, you need to do it wisely. It is important not to overload with unnecessary information, but also to attract the attention of a potential audience.

Conclusion

So we talked with 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 only be happy to get rid of excess garbage, and they will even give you money for the road. Sometimes it makes sense to conclude a full-fledged long-term supply contract. So you can eliminate downtime for your business and increase income. But all these points should be discussed directly with the supplier. Remember that it is much more difficult to find a point of sale for tires than 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 at 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. The cost of electricity per 1 ton of products - 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 changed. In principle, for one knife you need to pay only 30 rubles, which is relatively little. So, a unit with a capacity of 20 tires per hour pays off 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, in principle, and all on this topic. The most difficult thing is to start, and then it will be much easier.

We bring to the attention of buyers a series of mobile installations for the processing of worn tires into crumb "UPSh-M".

The LLC Tekhnoresursy company produces various equipment for the processing of tires, including a series of UPSh-M plants.

Here 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. Modifications are distinguished by the possibility of processing tires according to 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 on the example of the UPSh-2-M model.

The equipment allows processing all types of tires into crumbs.

• Recycled tire seat diameter: R15 to R33
• External (outer) tire diameter up to 2000 mm.
• The weight of recycled tires is up to 600 kg.
• Recycling technology: tire mechanical grinding method 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).
• The cost of electricity for the production of 1 ton of clean crumb rubber is approximately 90 kW. Crumb obtained from the outside of the treads and sidewalls of a tire.
• The cost of electricity for crushing the steel cord layers of the tire is about 130 kW/1 ton.
• Tires are recycled to seat rings with a width of about 50 mm. A thick bead wire runs through them.

Up to 20 kg of clean rubber crumb is removed from each worn truck tire (diameter up to 1200 mm) (depending on the degree of tread wear.) Then the rubber-cord layer is removed and the output is crumb with pieces of cord that requires additional cleaning.
When processing KGSH with a diameter of 1600 to 2000 mm, it is possible to produce pure crumb (50-120 kg of granules) + rubber crumb with inclusions of textile fiber or met. wire 60-150 kg. The throughput for recycling CGT is significantly higher than for smaller standard truck tyres.

Additional options:

• Lifting and landing system for heavy tires, weighing up to 800 kg.
• Tire cutting system into 6 rings. Thanks to this option, the 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: landing rings - 2 pcs; 2 sidewalls; cut treadmill in the center into 2 parts.

This option is relevant if tires are recycled in the partial recycling mode, i.e. grind only the outer shell of clean rubber (from the sidewalls and the treadmill). This option is not required for complete tire recycling.

Main salvage:
BELAZ-type mining CGs, tractor, truck and off-road tires of various sizes with a radial and diagonal cord design that have been decommissioned.

Places of accumulation of worn-out tires:

• on roadsides and unauthorized dumps;
• on the territory of motor transport and other enterprises;
• next to tire shops;
• quarries, landfills, where a large number of KGSH accumulate.

Due to the fact that automobile footwear 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 conjunction with the latest technologies. Tire rubber is practically the strongest and most durable of all types of rubber used, it has many other important qualities (elasticity; resistance to acids and alkalis; bending strength, tensile strength, abrasion resistance, 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 the crumb is a product of tire processing (utilization), 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 of automotive rubber recycling.

The principle of operation of the mobile plant for the processing of automobile tires UPSh-2-M:
1. A tire is rolled up to the machine by the workers.
2. Light tires are loaded into the clamping drum manually (up to 25-35 kg) 2 tires at a time, heavy tires are mounted using a tire lift and landing mechanism.
3. When the tire is put on the clamping drum, the worker spreads the paws of the clamping chuck with the help of hydraulic force 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. An automobile wheel rotates at a certain speed, and a powerful cutting crown rotating at a speed of more than 2000 rpm is brought to it by the operator. A group of knives hidden under a protective metal casing is installed on the crown. The bit advance speed is controlled by the operator, similar to working on a lathe. The higher the speed of the crown approach to the tire, the larger the crumb fraction at the outlet and vice versa (this is a way to adjust the crushed rubber fraction). In the production of small fractions of crumbs, the productivity of the plant is lower than in the production of 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. Then the second stage is the processing of the cord layers of the tire carcass.
7. The larger and heavier the tire, the higher the performance of the mobile unit, and, as a result, the ability to "remove" more clean crumb rubber in more short term(saves time on installing a car tire in a chuck).
8. At the request of the customer, the machine is equipped with an additional option for longitudinal cutting of tires into 6 parts (side rings-2 pieces are cut out, sidewalls-2 pieces + 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 layout of tire residues makes them convenient for further shredding.
As mentioned above, this option is relevant in the "partial processing of tires into granules" 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. Production 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 e-mail. mail, telephone and printed materials sent with the equipment.
6. Warranty period: 12 months.
7. The cost of additional warranty service 24 months: + 7% to the cost of the contract.

Production parameters for UPSh-2-M:
1. Required area - from 25 m2
2. Working shift - 1 person
3. Electricity consumption:

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

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

• Warehouse of raw materials.
• Crumb production sector.
• Finished goods warehouse.

General characteristics and advantages of tire recycling technology on mobile units UPSh-M:
UPSh-2-M replaces the whole complex (line) for the complete processing of tires up to 2000 mm into crumb rubber.
Low installation cost, making it affordable for small business start-ups.
The equipment pays off much faster than multi-stage tire shredding lines - within a few months.
About 90 kW is spent on the production of 1 ton of clean crumbs. This is approximately -300 rubles (depending on the tire size, on the local electricity tariff).
The cost of wear of knives is not more than 2000 rubles per ton of pure crushed rubber without inclusions (depends on the type of tire being processed)
The production is simple, the staff is only one worker.
The crumb is ideal for the production of rubber colored tiles by hot and cold molding, thanks to the crushing technology and the oblong shape of the particles. The shape of the rubber crumb "Christmas tree needle" provides the finished product with high bending and tear strength.
At the output: a) pure rubber granules without inclusions of metal and textiles; b) the rubber is crushed with the inclusion of a cord, requiring additional separation.
Almost any room from 25 m2, where there is 15 kW, is suitable for organizing a workshop.
Production is environmentally friendly - there are no emissions into the ground and atmosphere.
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 recycling of tires, for example, the possibility of processing a wide range of tires to be disposed of by size. Standard equipment can process tires up to 1200 mm in diameter. For example, the UPSh-3500-m model can process tires up to 3500 mm! The cost of recycling of oversized tires and oversized tires is much higher than the cost of recycling a standard car tire up to 1200 mm.

Most of the advantages of the UPSh-M come from the fact that the complete grinding of the tire on the UPSh-M occurs in 1 stage. That is, no additional machines and stages are required, which significantly reduces the cost of the 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 delivery region.
Rubber crumb produced by UPSh-2-M has the following advantages over round and cubic rubber granules:
During hot molding of colored rubber tiles, very strong products are obtained from such crumbs (especially for tearing and breaking). This is possible due to the elongated shape of the particles. The very structure of the particles also contributes to this. The particles adhere to 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 crumb at the output is obtained without inclusions, which is difficult to achieve when processing the entire tire (minimal inclusions of textiles, metal and rubber dust remain).
It is possible to manufacture crumbs of any fraction (see photo below) at the request of the buyer. This is achieved by the fact that by adjusting the supply of the cutter, the crumb is obtained with the required fraction (from dust to large pieces of RD).
Thanks to the sharp blades of the cutter and the effective air cooling system, the crumb does not receive traces of thermal oxidation.
If necessary, the product from such a crumb can be made solid by strong compression of the press.
If necessary, it is possible to obtain on UPSh-2-M from fabric-cord tires, in addition to pure crumbs, granules with the inclusion of a cord. For example, a crumb with a fabric cord today is the main and indispensable filler for sports equipment (for example, professional punching bags). Such crushed rubber can be used as the bottom layer of rubber tiles.

Rubber crumb is the main raw material for the production of many popular goods:
Coatings for children's playgrounds
Gyms and sports fields
rubber anti-slip pavers
Coverings of moorings, pools.
Coatings for car washes, garages
Coating for livestock farms.
Cover under trees to delay evaporation of water, prevent the growth of weeds. It has an attractive aesthetic appearance. Used in landscape design.
Sprayed waterproofing coating of 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 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 with cord inclusion.
Number of workers per shift - 1 person
Form of ownership: individual entrepreneur or LLC, where a simplified taxation system operates - 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 a production facility (25 sq.m) is 10,000 rubles per month.
Average power consumption 9 kW/h.
The energy consumption of the workshop per month is 9 (kW) * 16 (h) * 22 (days) = 3170 kW * 4 rubles / kW = 12,700 rubles.
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 a clean crumb is taken)
2. Calculations:
The energy consumption of the workshop per month is 12,700 rubles.
Wage 2 people per month - 50,000 rubles.
Room rent / month - 10,000 rubles.
Costs for expendable materials(knives, bags) / month - 10,000 rubles.
Other monthly expenses - 5,000 rubles.
Total total costs: 87,700 rubles.

Productivity of a pure crumb / month. - 20 t.
Productivity on a crumb with inclusion of a cord - 10 t.
The cost of 20 tons of pure chips and 10 tons of RD with the inclusion of cord is 87,700 rubles.
Gross profit - (20,000 * 18) + (10,000 * 10) \u003d 360,000 + 100,000 \u003d 460,000 rubles.
Profit minus cost - 460,000- 87,700 \u003d 372,300 rubles.
Profit after taxes and other fees (8%) - 342,500 rubles.

Options for using crumbs with textile inclusions:
lower layers of block rubber products obtained by hot forming.
filler for punching bags and other sports equipment (considered the best filler today)
Crumb with the inclusion of met. cords can be used in the lower layers of rubber tiles.
It can also be cleaned on a magnetic separator. Information on the separator will be sent upon request.
Appearance of the rubber crumb obtained on the 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 units UPSh (for processing the outer shell of the tire into crumbs and the possibility of cutting tires into rings) and the series "UPSh-T" for processing the outer shell of the tire into clean rubber granules of a cubic regular shape.

Comparison table of the capabilities of different sets of equipment for the processing of tires with USB in the kit.

• If the task is to produce crumbs, then you can meet the cost of 570,000 rubles. The output will be crumbs in the shape of a "Christmas needle". It is enough to install UPSh-1200. However, unrecycled tire cords will remain.
• If the task is to produce a cube-shaped regular crumb, then the cost of a set of equipment is from 1,327,000 rubles. However, there will be non-recycled tire parts.
• If it is necessary to process the tire into crumb "Christmas needle" and not have waste (crumb and cord plates at the output), then you will need a kit costing from 1,090,000 rubles.
• If the task is to process a tire into a crumb of the correct cuboid shape, so that the output is crumb and cord chips, then the cost of equipment is 1,732,000 rubles.
• If the task is to process a tire into crumb "Christmas needle" and produce rubber tiles from 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 a regular cube-shaped crumb and produce a rubber tile from the crumb, then the cost of a set of equipment is from 1,827,000 rubles. But there will be leftovers from unrecycled tire parts.
• If the task is to create non-waste production, recycle the tire into crumbs "Christmas needle" and produce rubber tiles from crumbs, then the cost of a set of equipment is from 1,590,000 rubles.
• If the task is to process a tire into crumbs of the correct cuboid shape and produce rubber tiles from crumbs, and establish waste-free production, then the cost of a set of equipment is from 2,232,000 rubles.

If the budget is limited, then you can immediately purchase an inexpensive version of the equipment and eventually buy everything 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 intermediaries.
Prices and configurations may change, so check them with the manager of the company.