Recycling of car tires. Tire recycling: how to open a business and get a stable income. Factories in Russia

Reforms in the field of environmental protection, which began to be implemented in last years, are gradually becoming tougher.

What should resource users expect? A complete ban on the disposal of waste tires and car tires is being introduced.

This position of legislators should stimulate industry development recycling waste, opening new production facilities for their modification.

Deserves close attention. Low cost, easy way tire recycling requires the use of special equipment.

Let's take a closer look at the popular types of machines and the production lines formed from them, the characteristics of these units and how much they cost.

The technology for producing crumb rubber from waste tires is a process of sequentially grinding raw materials into small pieces and then grinding them into a fine fraction.

Manufacturers offer big choice machines for the production of crumb rubber, prices depend on the performance of the equipment.

Single shaft shredders

The operating principle of a single-shaft plant is based on grinding raw materials sequentially lowering and rising low-speed cutting shaft.

The operation of a rubber shredder is as follows:

1. Tires are fed into the shredder chamber for loading raw materials, where under the action of a hydraulic press they are fed to rotating knives.
2. The press moves from top to bottom, returning to its original position after reaching the maximum degree of pressure on the shaft.
3. The crushed raw materials are pressed through special sieves placed under the shaft.

Fastening double-sided knives with screws allows them to be reused after one of the edges wears out. This design feature allows increase standard service life tire crushers.

Among the advantages of single-shaft rubber crumb crushers are:

• simple design;
• ease of use;
• possibility of individual use and inclusion in the production line;
• processing of thick raw materials.

An example of such equipment is a single-shaft machine for processing rubber and tires into crumbs from Netmus; the price of the presented equipment varies in the range 120,000 - 2,800,000 rub..

Twin shaft rubber shredders

Twin-shaft machines for crushing tires into crumbs are designed for cutting raw materials into pieces no larger than 5x5 cm. The shredder blades can process tires of both passenger cars and heavy-duty vehicles.

Principle of operation machine is as follows:

1. A tire is fed into the raw material receiving chamber. The size of the window allows you to load the entire product; the only requirement is to first remove the cord.
2. The tire shredder shafts rotate in opposite directions. Hooks placed on the rotors grab the raw material and tear it into pieces.
3. The crushed raw materials are sifted through a sieve, which is a rotating drum. Particles larger than the sifter mesh size are thrown into the loading chamber for reprocessing.
4. After sorting into fractions, the finished material falls onto a conveyor belt and is fed for packaging.

Benefits of use two-shaft machine for the production of crumb rubber:

• the ability to process large-sized raw materials;
• no need to sharpen knife blades when reinstalling them.

Productivity of rubber processing machine directly depends on given dimensions final products. Thus, when producing tapes and pieces measuring 5x5 cm, the output of 1 machine will be 2 tons/hour and more, with more thorough grinding - up to 2 tons/hour.

The personnel servicing the machines does not require any special skills in their work.

The number of auxiliary workers to work in 1 shift is 1-2 people: 1 person for loading raw materials, 1 person for receiving finished products.

Twin-shaft machines for crushing tires are supplied by the Russian company TechnoService LLC.

Tire shredding plant

Let's look at tire shredding plants using the example of UPShK equipment from the Tekhnoresursy company.

The installation is a rotating crown with 25 knives installed on it, connected to a tire clamped in a special chuck.

Manufacturing process as follows:

1. Feeding the tire to the clamping drum.
2. Installation and fixation of the tire in the drum manually, or using the installation lifting mechanism.
3. Turn on the drive and start rotating the drum. The installation control system provides 3 rotor speeds. It is advisable to choose them depending on the outer diameter of the tire.
4. Approaching the cutting bit rotating in reverse side in relation to the drum. The speed of movement of the crown is set by the service personnel and depends on the desired size of the finished product fraction - the slower the movement, the finer the crumb rubber obtained.

The rubber is removed from the tire starting from the outer layer until reaching the cord layers.

Textile cord can be crushed together with rubber; metal cord is the limit beyond which the use of the installation is prohibited.

Advantages of using the machine:

• successfully replaces an entire tire shredding line;
• competitive price;
• ease of transportation;
• quick installation;
• instant connection to the power supply system;
• the ability to recycle tires of various sizes;
• short payback period.

The installation is serviced by one worker. The production technology itself is very simple and does not require additional training.

In a month, one installation is capable of producing 34 tons of clean rubber crumb.

Prices for such equipment for processing rubber into crumbs start from 770,000 rub..

Lines

An integrated approach to solving the problem tire processing is provided by lines for grinding waste tires into crumbs.

The equipment packages offered by different manufacturers differ little from each other:

• device for removing the bead ring;
• guillotine for shredding tires into strips;
• machine for squeezing metal cord;
• rollers for making crumb rubber;
• magnetic and air separators;
• vibrating sieve

Technology tire processing is as follows:

1. Separation of tires by weight and diameter, cleaning from large contaminants.
2. Place the tire in a vice to separate the bead ring from the rubber.
3. Cutting the resulting rubber into strips about 4 cm wide.
4. Dividing strips into small pieces.
5. Grinding the workpieces into crumbs and then feeding the product onto the conveyor.
6. Purification of products in the separation chamber. Using the magnetic fields created by the installation, metal cord particles are separated from total mass crumbs. In the air cleaning chamber, due to the generated vortex flows, the final separation of foreign impurities from rubber particles occurs.
7. Sorting the resulting products into size fractions.

The finished crumbs are packaged and can be sent for implementation. Larger particles are returned to the conveyor and re-crushed.

Line productivity is from 500 kg of raw materials per hour.

To maintain the line, 2-3 people will be required per 1 shift, and no special training in how to operate the equipment is required.

On the market of production equipment, tire processing lines are represented by manufacturers different countries. Let's look at the distinctive features of individual brands of equipment.

Tire processing line from the Novokuznetsk company ALPHA SPK “ATR-250” declared by the manufacturer as fully automatic. Human participation is required only if there is a need to shred extra-large tires. Equipment price starts from 5,000,000 rub.. You can study the supplier’s offer in more detail on the website.

Factories

Mini-factories for the production of crumbs from rubber tires are the best option for those who want to process raw materials on a large scale.

Such production will have not only a personal, economic effect, but also a social one.

New jobs will be created and social tension will decrease.

Benefits of use mini-factories for the production of crumb rubber:

• low energy consumption, and therefore the cost of produced crumbs;
• compactness;
• ease of maintenance;
• excellent quality of raw material grinding, allowing production to be set up in one cycle;
• environmental friendliness.

Compact rubber grinding plants "ATR-300" from ALPHA SPK capable of producing up to 350 kg of crumbs from tires. The equipment crushes rubber tires mechanical crusher.

The crumbs produced using this technology are of high quality, which means they are of great value to the end consumers of the product.

The mini-plant is equipped with the following equipment:

• tire crusher;
• double-sided bead ring puller;
• knives for cutting tires into noodles;
• conveyer belt;
• impact crusher;
• magnetic separator;
• vibrating screens

Mini plant works like this:

1. Visual inspection of raw materials for the presence of impurities that can damage the equipment.
2. Grinding large pieces of raw materials using hand tools. Small tires are fed into the loading chamber entirely.
3. Shredding rubber using shredder equipment into smaller fractions. At this stage, the raw materials are purified from metal impurities.
4. Feeding raw materials into a compartment with a rotating blade element to grind raw materials to the desired size. Cleaning metal cord particles from particles is an additional option launched by the system at this stage of rubber processing.
5. The raw material enters the separation compartment, where the final cleaning of the crumb rubber from impurities occurs.
6. Passing the finished product through the cells of a vibrating sieve for sorting into fractions.

The price of such a mini-plant is RUB 9,800,000. The productivity of the mini-plant when producing crumbs of three fractions is up to 350 kg per 1 working hour. 3-4 people are enough to service the equipment. About the need to carry out special training for service personnel the equipment manufacturer does not explicitly state. All questions you may have can be asked on the website.

Pay attention to tire recycling plants from EcoStep.

The line of equipment includes models designed for both beginning entrepreneurs and more experienced tire processors.

The advantage of the equipment declared by the manufacturer is: European quality and reliability.

Processing plants car tires models KPSh from the company Doza-gran They process tires into 3 fractions, including rubber dust.

On the company’s website you can calculate the required equipment performance depending on your needs and ultimate goals.

Cost of equipment - from RUB 8,300,000.

Another manufacturer of equipment for tire processing is the company Europlit.

The NEO line equipment it presents allows you to independently configure the desired parameters of the final product.

Comparative characteristics and prices

Equipment brand	Characteristic		Price	Link to the manufacturer's (supplier) website
Mini plant "ATR-300"	Energy consumption, kW/h	80-120	9.8 million rubles.	alfaspk.ru
		500
	Product output, kg/hour.	350
	Generation of by-products (additional income)	Yes
		120
	LxWxH workshop, m.	20x4.5x4.2
	Number of workers, people	3-4
Plant Bio-KPSh	Volume of raw materials processed, t/year	720-3000	From 8.3 million rubles.	dozagran.com
	Product output, t/year.	650-2700
	Power consumption, kW/h	180-430
Line NEO-300	Product output, kg/hour.	300	Upon additional request	eplit.ru
	Power consumption, kW/h	55
	Number of workers, people	3
	LxWxH workshop, m.	33x6x3
	Obtaining by-products (additional income)	Yes
Line NEO-500	Product output, kg/hour.	500	According to buyer's request
	Power consumption, kW/h	90
	Number of workers, people	3
	LxWxH workshop, m.	41x6x4
	Additional products	Yes
Line NEO-1000	Product output, kg/hour.	1000	Notified upon buyer's request
	Electricity consumption, kW/h	180
	Number of workers, people	5
	LxWxH workshop, m.	43.75x8x4
	Additional products	Yes
ECO STEP 500	Energy consumption, kW/h	100		eco-step.ru
	Product output, kg/hour.	350
	Volume of raw materials processed, kg/hour.	500
	Number of workers, people	4
	Maximum diameter of recycled tires, see.	150
	LxWxH workshop, m.	30x10x5
ECO STEP 700	Power consumption, kW/h	100	Available upon buyer's request	eco-step.ru
	Product output, kg/hour.	350
	Volume of raw materials processed, kg/hour.	500
	Number of workers, people	4
	Maximum diameter of recycled tires, see.	150
	LxWxH workshop, m.	30x10x5
Line LT400	Volume of raw materials processed, kg/hour.	250	52 thousand dollars	best-china.ru
Line LT450	Volume of raw materials processed, kg/hour.	500	59 thousand dollars
Line LT560	Volume of raw materials processed, kg/hour.	1000	74 thousand dollars
Line LPS-300	Volume of raw materials processed, kg/hour.	500		uas.ru
	Crumb output, kg/hour.	300
	Maximum inner diameter of tires, cm.	150
	Power consumption, kW	From 100
	Number of workers, people	2-3
	Possibility of receiving additional income	Yes
	Room size, m 2	200
LPS-200	Room size, m 2	40	1.853 million rubles.	uas.ru
		Up to 200
LPSh-400	Room size, m 2	From 120	5.781 million rubles.
	Volume of processed raw materials, kg/hour	Up to 400
LPSh-600	Room size, m 2	From 150	6.135 million rubles.
	Volume of processed raw materials, kg/hour	Up to 600
LPS-800	Room size, m 2	From 200	RUR 8,800 million
	Volume of processed raw materials, kg/hour	800-1000
LPS-1500	Room size, m 2	From 250	11.105 million rubles.
	Volume of processed raw materials, kg/hour	Up to 1500
KGSh-1500	Room size, m 2	From 200	14.156 million rubles.
	Volume of processed raw materials, kg/hour	Up to 1500
"ATR-250"	Power consumption, kW/hour	80-100	5.6 million rubles.	alfaspk.ru
	Room size, m 2	80
	Volume of processed raw materials, kg/hour	Up to 300
	Crumb volume, kg/hour	Up to 250
	Number of workers, people	3-4
UPSHK-1200	Power consumption, kW/hour	5	0.77 million rub.	stanki-ru.ru
	Installation size, LxWxH, m	1.8x1.2x2
	Volume of processed raw materials, kg/hour	35-52,5
	Number of workers, people	1
UPSHK-2000	Power consumption, kW/hour	8	0.87 million rub.
	Installation size, LxWxH, m	2.5x1.7x3.2
	Volume of processed raw materials, kg/hour	87,5
	Number of workers, people	1
UPSHK-2200	Power consumption, kW/hour	8	1.12 million rubles.
	Installation size, LxWxH, m	2.8x1.8x3.4
	Volume of processed raw materials, kg/hour	100
	Number of workers, people	1
UPSHK-2700	Power consumption, kW/hour	11	2.25 million rubles.
	Installation size, LxWxH, m	3.0x2.0x3.4
	Volume of processed raw materials, kg/hour	112,5
	Number of workers, people	1
Single shaft machine Model 800		400-600	1.285 million rubles.	darex.pro
	Receiving chamber size, cm.	147.5x80
	Total number of knives	49
	Power consumption, kW	22-37
		Up to 4
Single shaft machine Model 1000	Equipment productivity, kg/hour	600-800	1.41 million rubles.
	Receiving chamber size, cm.	147.5x100
	Total number of knives	68
	Power consumption, kW	37-45
	Finished product size, cm.	Up to 4
Single shaft machine Model 1300	Equipment productivity, kg/hour	700-900	1.845 million rubles.
	Receiving chamber size, cm.	147.5x130
	Total number of knives	91
	Power consumption, kW	45-55
	Finished product size, cm.	Up to 4
Single shaft machine Model 1800	Equipment productivity, kg/hour	1400-1800	2.75 million rubles.
	Receiving chamber size, cm.	147.5x180
	Total number of knives	130
	Power consumption, kW	75-90
	Finished product size, cm.	Up to 4
Tire crusher No. 1	Equipment productivity, kg/hour	2000	Available upon buyer's request	texservis.com
	Finished product size, cm.	Noodles -5, chips - 5x5
	Receiving chamber size, cm.	120
	Total number of knives	22
	Dimensions of the machine (LxWxH), see.	630.3x280x366.7
Tire crusher No. 2	Equipment productivity, kg/hour	Until 2000	Available upon buyer's request
	Finished product fraction, see	Noodles -4, chips - 4x4
	Receiving chamber size, cm.	75x22x6
	Power consumption, kW	58
	Dimensions of the machine (LxWxH), see.	282x230x258
Single shaft shredder 3E WT 2260	Total number of knives	34	RUB 0.998 million	pragmat.ru
	Rated power, kW	18,5
	Productivity, kg/hour	200-300
	Machine dimensions (LxWxH), m.	1.774x1.359x1575
Double-roll crusher DDR-300	Power consumption, kW	60	Available upon buyer's request	tet-ua.com
	Productivity, kg/hour	300
	Reception window size, cm.	60x70
	Maximum tire diameter, cm.	600
Double-roll crusher DDR-500	Power consumption, kW	60	Available upon buyer's request
	Productivity, kg/hour	500
	Limit of the raw material acceptance chamber, see.	75x80
	Maximum tire diameter, cm.	750
Double-roll crusher DDR-750	Power consumption, kW	90	Available upon buyer's request
	Productivity, kg/hour	750
	Window size for storing tires, see	82x100
	Maximum tire diameter, cm.	870
Double-roll crusher DDR-1000	Power consumption, kW	90	Available upon buyer's request
	Productivity, kg/hour	1000
	Receiving chamber size, cm.	85x130
	Maximum tire diameter, cm.	1200

conclusions

Tire recycling equipment is a real godsend for those who want to set up a recycling business.

Affordable price, simple installation and maintenance, wide scope of use of the resulting products - reasons to consider this type of production as a priority for beginning entrepreneurs, as well as for established businessmen to master an additional type of activity.

In contact with

No one will deny that the number of motorists has increased significantly over recent decades. The abundance of cars on Russian roads, the increase in the level of mobility - this is happening thanks to the uninterrupted operation of the global automobile industry. However, increasing living standards also comes with increasing problems. One of them stands in front of modern humanity Particularly acute is the problem of recycling used tires, not only in our country, but also in all developed countries of the world, which have significant environmental and economic significance.

The focus of this article is on processing technologies. We will talk about which methods are currently popular in the world, which technologies are more effective and what are their main differences.

World situation

This problem is relevant for every industrialized country, since it is directly related to the environmental situation. In addition, current economic realities indicate the need to use secondary resources for maximum efficiency.

Every year in the world, according to data provided by the UN, more than 25 million tons of waste are generated in the form of used car tires, of which approximately 15 million tons, i.e. over 60%, are simply sent to landfills.

IN European countries Every year over 2.5 million tons of tires go out of use, with the recycling rate reaching 90%. The bulk of collected end-of-life tires destroyed by burning for energy extraction, it is approximately 40%. A slightly smaller scale is processed to a crumb state - this is a little more than 30%. Also, just over 20% of tires can be retreaded or taken away for recycling or disposal.

It should be noted that the pan-European market is actively moving towards increasing the share of automated recycling methods: if in 1992 only 5% of collected tires were crushed into crumbs, then after only 16 years in 2008 the percentage was already 34. Moreover, The scale of tire burning is rapidly growing, especially since special environmentally friendly equipment has been developed that has high efficiency.

According to the foreign magazine EUROPEAN RUBBER, the EU Council has prepared recommendations for member states on voluntary initiatives to develop technologies for the recycling and use of used tires.

One of the fundamental goals of such initiatives are:

• increasing the recycling rate from thirty percent to one hundred;
• lowering the level of their burial from fifty percent to 0.

In addition, a significant challenge in recycling tires is the extraction of high-quality secondary raw materials and their reuse to reduce the consumption of natural resources.

In Russia, the annual scale of tire depreciation exceeds 1.1 million tons per year. Over the previous 5 years, this figure has increased by almost 25%. The actual volume of tire recycling in our country is less than 10%.

The most popular methods of tire recycling in Russia are crushing and pyrolysis. At the beginning of 2000, a significant volume of collected tires was incinerated, and currently these two technologies occupy approximately equal shares with a slight predominance of the mechanical method.

It should be noted that pyrolysis technologies are prohibited in some Western countries, since they are recognized as environmentally unsafe.

Recycling approaches

At the moment, two fundamentally different ways have emerged to solve the problem of recycling worn-out tires:

1. electromechanical grinding using cutting equipment (in an elastic state or with cooling) with further processing of crumb rubber into reclaimed material or rubber products;
2. processing by changing the chemical structure of rubber using rubber pyrolysis or thermal destruction to obtain liquid decomposition products similar to petroleum products, suitable for producing anti-corrosion mastics, flammable lubricants, etc.

Electromechanical grinding

The main disadvantages of the method:

1. low coefficient of “pure” operating time of technological lines (not higher than 60%) and downtime associated with equipment repairs and time costs for replacing cutting elements. Downtime and failure of lines to operate are especially significant when shredding steel cord tires, and they make up over 90 percent of the tire range;
2. rapid wear of the cutting compound, short service life of equipment, low productivity, significant energy costs, significant financial costs and, as a result, very high cost of crumb rubber.

When using mechanical shredding of tires with the use of cutting tools, energy consumption increases significantly. They reach 500−900 kW/h per 1 ton of tires. If energy costs are reduced, noticeable savings will still not be achieved due to downtime and high costs for the restoration of cutting tools and maintenance of process equipment.

Changing the chemical structure of a material

With such tire processing the rubber component of the rubber is not preserved. Produced products of rubber and technical decomposition. carbon has a lower value than tire recycling products that retain the rubber and return it to the production field.

The dominant disadvantage of these two options is the high cost of the final product and, as a result, unsatisfactory profitability and low production efficiency.

Alternative methods

There are alternative methods for recycling tires that are not widely used, but nevertheless they can also be used and get the desired result:

The sleeves of a rotary dispersant, which are very expensive and are its main element, soon wear out, and this leads to the rapid exit of the dispersant from its working condition and, as a result, to the high cost of producing the product.

There are a number of even less popular methods for crushing worn tires, which involve high energy consumption and low productivity, costs for preventive maintenance of equipment and high product costs.

Tire crushing technologies

When recycling old tires, the following parameters are of decisive importance:

According to experts, tire crumb processing lines have optimal parameters. Processing of old tires into small crumbs can be done at negative and positive temperatures using various grinding methods:

• cutting,
• compression
• abrasion,
• explosion.

Each technology for shredding car tires has its own advantages and disadvantages. As an example, we can compare the shock wave method and the classical mechanical method of crushing tires. In order for the comparison to be correct, we will select lines that have the same productivity parameters - 30 thousand tons of tires per year (the maximum mark of modern lines) and equal amounts of the resulting crumb - finely dispersed with a high purification rate.

Mechanical technology is presented by German equipment from INTEC, explosive circulation technology is presented by the domestic line G.K. Explotex.

The mechanical method consists of several steps:

• cutting of bead rings on a specialized machine,
• cutting tires into large pieces of approximately 10 square centimeters, several steps of subsequent crushing to a fraction of 0.5−1 mm,
• cleaning from steel cord using magnetic separation,
• grinding the crumbs obtained in the previous stages to the required size.

Explosion-circulation technology consists in the fact that the shredding of tires by explosion is carried out in a closed ring system with the appearance of a circulation flow, and also in the fact that a set of tires is formed in the form of tightly sealed layers, and its primary disintegration occurs under conditions of free stretching to the point of destruction of its removed layers .

It should be noted that the processing of rubber to the state of crumbs using the shock wave grinding method is carried out in only two or three steps.

According to the presented parameters of efficiency and economy, as well as detailed information on the processes and volume of processing on the official cleandex website, Russian equipment clearly outperforms the Germans. A similar situation is observed in equipment segments with lower productivity.

Business idea

Processing tires into crumbs is currently one of the most common business ideas, for which more than one business plan has been written. The Internet offers a wealth of ideas and detailed designs to create our own mini-plant for tire processing. Such a decision is within the power of any person who has the appropriate capital and a firmly established goal. If you implement your plan, then you don’t have to worry about such issues as the demand for the business, the availability of material for work, support from society and environmental friendliness.

There are many damaged tires, and their number increases by tens of tons every year. City landfills are prohibited from accepting them for disposal. Old tires are thrown away anywhere or stored in garages. Tires are flammable, do not decompose, and become a haven for rodents and insects that spread infection.

The good thing about a business plan for recycling tires into crumbs is that the development of such a business reduces the level of waste that pollutes the planet. The recyclable materials produced by the tire recycling plant are needed by various organizations.

In Russia, the industry for the disposal and processing of worn-out materials is poorly developed. Setting up a business for producing crumbs will be profitable and will slightly reduce global pollution of the planet.

Market analysis for crumb rubber production

Most old tires are not recycled. In many cities there are no places for their storage and disposal. A large number of People throw used tires on the roadsides.

The problem is only getting worse due to the constant increase in the number of vehicles. As a result, the volume of tires subject to recycling is increasing. The country does not have a system for recycling old tires. There are very few tire recycling plants.

Tire recycling as a business may be of interest to entrepreneurs. There is a demand and need for crumb rubber, but competition is low. You can occupy a profitable niche in the market, because in most regions there are no tire recycling plants.

Competitiveness assessment

In Russia, they have recently begun to think about a structured system for recycling old materials. There are few competitors in the tire recycling business market.

There are only four large tire recycling plants in the entire country:

• Volzhsky Regenerative Tire Repair Plant
• Chekhov Regeneration Plant
• KCT-ecology company
• Tire Recycling Plant No. 1

These enterprises account for about 60% of the processing of all used tires in the country.

There are small enterprises producing up to 5,000 tons of crumb rubber per year. In the country, 24 regions have large or small enterprises for recycling old tires. This is not enough to process more than 1 million tons of raw materials.

Registration of activities

Business planning begins with choosing the form of economic organization of the business. It depends on where funds are invested in the business.

Opening an individual entrepreneur

Registration of an individual entrepreneur is possible if the entrepreneur has enough finances to open. In the tire recycling industry, this form of business is acceptable and requires less costs.

To register a business, you need to pay a state fee of 800 rubles at the tax office. You need to get your own stamp, the cost for it is up to 1000 rubles.

Opening an LLC

If the entrepreneur does not have enough funds for business development, an LLC is registered. To share costs, you can find a co-founder of the organization or take out a business loan.

The state duty for business registration for the tax service will be 4,000 rubles.

There are many organizations offering services in opening an LLC, but it is better to do it yourself. You can also agree with an existing large organization and work under its franchise.

The production process of tire shredding is working with hazardous waste. An illiterate approach to processing old tires can harm the environment. This risk requires obtaining permits from several supervisory companies. Environmentalists and the Sanitation Station will inspect the production premises for the presence and condition of equipment filtration systems, and how far the place is from residential areas. Permission from the State Fire Supervision Authority will be required to ensure that the site complies with fire safety regulations.

Choosing a location for a production facility

A recycling plant cannot be located near places where people live. The shortest distance from residential areas is 300 meters.

It is better to look for a place for the enterprise as far as possible from houses. The most acceptable option is a city industrial zone or a place outside the city. You can rent premises for a business from one of the factories. Many workshops are now empty and already meet the necessary requirements:

• The working space is equal to or more than 300 square meters.
• The work area is equipped with running water, sewerage system, electricity and central heating.

Equipment needed to shred tires into crumbs

The most expensive part of a business plan for processing tires into crumbs is purchasing the equipment necessary for the operation.

A small plant will need equipment:

• main apparatus - a machine that produces crumb rubber
• unit that removes tires from the bead ring
• devices that process tires into rubber crumbs of various sizes
• tire cutting machines
• two vibrating sieves for coarse and fine cleaning of material
• two magnetic separators
• air separator
• three conveyor belts and pneumatic conveying systems
• hopper for collecting rubber crumbs
• wire storage bin
• electrical shield
• loader

In addition to this equipment, you will need:

• packaging containers
• rental of a warehouse for storing unsold products
• vehicle and garage
• special clothing for workers and protective equipment
• computer

The process of making crumbs is divided into the following stages:

• inspection of tires to determine if a product is unsuitable for disposal
• tire cutting
• separation of all metal components
• tire shredding
• making crumbs using a crusher
• separation
• sorting and cleaning crumb rubber on a vibrating screen
• packaging of products and preparation for transportation

After the process is completed, several finished products are obtained: carbon dioxide, fuel oil, metal cord, crumb rubber.

Raw materials are transported from tire stations, service stations, large trucking companies, and recycling collection sites.

You can open collection points for used tires. The cost of old tires is low. They are easy to get for free, and sometimes you can make a profit for the possibility of recycling.

Recruitment

Three to five people can operate the belt of a small tire recycling plant. The following personnel are required for administrative management:

1. Accountant
2. Receiver
3. Manager
4. Driver

Approximate financial plan for processing tires into crumbs

Based on the above data, you can draw up a rough business plan with calculations for processing tires into crumbs.

Costs (RUB):

1. Registration of an enterprise - up to 150,000.

2.Rent of workshop premises - up to 180,000.

3. Arrangement of premises - up to 150,000.

4.Fuel tanks - up to 80,000.

5.Equipment - up to 1,500,000.

6.Tools - up to 200,000.

Total expenses: 2260000.

Also, the business organizer needs to regularly pay monthly expenses:

1. Staff salary - 120,000.
2. Utility costs - 30,000.
3. Rent - 180000.
4. Transport costs - 150,000.

Total expenses: 4800000.

Revenue from a tire recycling plant

The price of 1 kilogram of crumb rubber is 17 rubles. During the day, the production line at full capacity can produce no more than 2100 kilograms.

The monthly income from the production of crumb rubber at full capacity will be 750,000. The income also includes the sale of production by-products: fuel oil and metal cord - 375,000 per month. The total monthly revenue will be 1,125,000, and the net income before taxes will be 645,000 rubles.

This business pays off from six months to 21 months. Such a spread in time is associated with possible risks and unforeseen expenses.

Production will become unprofitable if the requirements of environmental services are not met. Most often, they are not satisfied with the quality of the cleaning equipment.

Possible risks

A business plan for processing tires into crumbs must include possible risks in production. Therefore, it is important to remember some business nuances:

1. Selection of equipment. Russian-made tires have a mixed or textile cord. Foreign equipment will not be able to process Russian tires. Therefore, it is necessary to purchase equipment adapted for processing old domestically produced tires.
2. Purchase of defective parts. This risk arises when ordering Chinese equipment. Already in the first months of plant operation, breakdowns will appear, requiring costs for equipment repairs and leading to downtime in production.
3. Inflated equipment performance characteristics. Some manufacturers overestimate equipment parameters. You need to realistically evaluate the price-quality ratio, otherwise there is a big risk of buying low-quality equipment. Then the payback of the business can reach decades.

Sales of finished products

Before starting a business, you need to find out which businesses need products.

Organizations for the sale of crumb rubber can be found among the following companies:

• Enterprises related to construction and production of construction equipment.
• Enterprises that produce sports, road surfaces, paving slabs, moisture-proof roofing and a variety of rubber products.
• Firms serving oil production enterprises.

The list of products using crumb rubber is quite extensive.

Many entrepreneurs do not limit themselves to simply processing old tires into crumb rubber, but launch an additional business for the production of a product ready for sale and increase the company’s profit several times.

This business requires significant costs and solving organizational issues, but the industry of processing tires into crumb rubber is recognized as promising.

There are more and more cars on our roads, which means the number of used tires is growing. The question arises about what to do with them, how to dispose of them? Many people simply quietly throw away used tires, but this only leads to the emergence of spontaneous landfills. But you can make money from this garbage. Let's learn how to open a tire recycling plant.

Bargain trash

Why is tire recycling so beneficial? This category of waste contains polymers, which are widely used in a wide variety of industrial fields.

Tire processing products are used to make new tires. Crumb rubber is used in decoration and as a waterproofing material in construction.

It is used in the design of running tracks, arranging children's and sports grounds.

Deep pyrolysis processing of rubber makes it possible to obtain fuel oil at the output.

In addition, you will not have problems with raw materials. Owners of used tires will gladly take the opportunity to get rid of annoying garbage. Often you won’t even have to pay for the rubber junk, you just have to offer tire pickup.

In addition to cooperation with individuals, you may well enter into cooperation agreements with companies that buy outdated cars for scrap. And agricultural enterprises always have a lot of unusable equipment tires in stock.

It often makes sense to seek support from local authorities. This will speed up the issue of obtaining a license.

Tire recycling license

Since your activity will involve hazardous waste, you will have to obtain a license to work with it. Passing an examination confirming the safety of your production will cost you certain financial costs.

To avoid problems with sanitary inspection, do not ignore the requirements of environmentalists about the need to install appropriate filters. They usually come complete with a production line.

Also, strictly observe the distance of your enterprise from any residential settlements. Whether it is a small village or a densely populated residential sector, a tire recycling plant must be located at least three hundred (four hundred) meters away from them.

What documents are needed to start

Before opening a tire recycling plant, register your business and register with the tax office.

Settle the issue with the firefighters in advance. You need to get permission from them. You will also need it from the sanitary inspection.

In addition, take care to conclude an agreement with energy suppliers.

We are looking for premises

Tire recycling production cannot fit into a tiny space. You'll need some serious space. About 500 square meters are required to accommodate the equipment. You also need to allocate space for a warehouse for raw materials and finished products.

And remember the required distance to residential buildings. All these indicators should be reflected in your business plan. Tire recycling shouldn't upset your unwitting neighbors. Public complaints may well lead to the closure of your plant.

A site located outside the city in an industrial zone is best suited for these parameters. Finding vacant land within the suburbs is difficult, so focus on former factory buildings. Nowadays it’s not difficult to find something that doesn’t work. industrial enterprise. Then there’s just one small thing to do – you need to sign a lease agreement.

When renting a room, check the proximity of electrical networks and the possibility of connecting to them. Access roads are required.

What does recycling consist of?

Tire recycling technology consists of several stages:

• the bead rings are removed from the tires on a special stand;
• remove the cord;
• the tire is divided into pieces;
• the resulting parts are crushed to obtain fractions of 3 or 4 millimeters;
• Metal inclusions of the cord are removed from the mass using magnetic separation;
• the fractions are ground to a powder state in which the particles do not exceed one millimeter.

Now a little more detail. The assembled tires first end up in a warehouse. After that, they go to the initial screening. Line employees find out whether the tires contain metal parts (rims, rings). They remove anything that might interfere with the initial cutting of the tires.

The crushed raw materials enter the reactor bunker. The decomposition process starts in the reactor, and at the output you get a carbon-containing sediment, gas, and liquid fuel fraction. The gas is returned to the reactor to maintain its operation, and the remainder, which is excess, is simply removed to the outside. Since they contain harmful substances, it is necessary to install filters.

It is necessary to distinguish between the mechanical method of disposal and pyrolysis.

The result of the first is the production of rubber crumbs, granules, and chips. In the second case, the product of processing becomes fuel oil, which is close in characteristics to fuel oil.

Turning tires into fuel oil

Pyrolysis tire recycling has already been mentioned above. The liquid fuel fraction, which is formed as a result of the decomposition of rubber powder in the reactor, is pyrolysis oil. From one and a half tons of raw materials, about 40 percent of this substance can be removed.

But only after the refinement stage will the oily liquid turn into fuel oil. It is purchased for the needs of private homeowners and industrial enterprises.

We equip production

Equipment for tire recycling is usually supplied by technological lines. They are already equipped with all the necessary installations and assemblies. At the same time, you need to understand whether you will be focused exclusively on mechanical recycling of raw materials. Or your plans include the production of fuel oil. Although usually the owners of mini-factories prefer to do both to increase profits.

So, tire recycling equipment includes:

• hydraulic shears;
• air separator;
• eraser;
• tape cutter;
• cut out the ring;
• squeezer;
• chip cutter

To start the decomposition process, a reactor is needed. And for storing pyrolysis liquid - a tank.

When choosing installations for your plant, remember the safety of your production. Additionally, install cleaning units and install filters. To save resources, select lines with low level energy consumption.

Before opening a tire recycling plant, check with the equipment supplier about the terms of service for the plant. The cost of the line is very high, so do not skimp on quality staff training.

We are recruiting employees

For uninterrupted operation installation does not require a huge staff of workers. Two technical employees can handle it quite well. For the second shift, two more are needed. In total we have four people.

To operate an office, you need an accountant, a sales manager, and a manager for the purchase of raw materials. Sometimes a storekeeper's rate won't hurt.

Staff salaries are included in the business plan. Tire recycling is unthinkable without freight transport. Therefore, either hire truck drivers under a contract agreement, or maintain a transport department.

It is better to entrust the selection of personnel to recruitment agencies, taking over the final interview. As mentioned above, you will most likely have to train the employees you hire. A company that manufactures equipment for recycling plants can support you with this. They usually have orientation programs.

Sometimes enterprise managers invite employees who previously worked at similar enterprises.

Profitability

It is necessary to calculate expenses and income in advance, at the stage when you are preparing a business plan. Recycling tires is a costly business. The cost of the equipment will cost you a hefty sum. Even the most budget installations cost over a million. And this does not take into account the delivery of the complex. It is unlikely that it will be possible to do without attracting investments.

In addition, without the presence of treatment units, you will not be able to sign permits. This is another significant expense.

Every month, a certain amount will be consumed by rent, electricity consumption, and employee salaries.

So does it make sense to recycle?

Let's now count the pros. You get the raw materials practically free of charge. And in some cases, businesses will even pay you for the opportunity to get rid of old tires

In addition, the resulting product, be it polymer powder or fuel oil, is sold at a high cost. The main thing is to find sales points. So your enterprise will pay off and begin to generate stable income.

The problem of recycling used tires is acute in many countries. In this matter, not only the environmental aspect is important, but also the economic one, because the material obtained during processing is a good raw material for chemical industry. Let's find out what processing methods are currently used in the world, how effective and safe they are.

Types of recycling of used tires can be divided into two groups:

• electromechanical grinding;
• processing that changes the chemical structure.

Tire processing using these methods differs in the principle of operation and the resulting raw materials. Each of them has its own advantages and disadvantages, which are worth talking about in more detail.

Mechanical tire shredding

This method is considered relatively safe from an environmental point of view and is widely used throughout the world. Tires are subjected to the following processing:

1. Old tires are washed, the beads are removed and cut into large pieces.
2. Raw materials are cleaned from steel cord using magnetic separation.
3. The pieces are then heated (for elevated temperature processing) or cooled (for cryogenic processing).
4. Rubber is crushed by cutting, impact, explosion, compression or abrasion.
5. The resulting raw material is ground to obtain crumbs of the desired size.

The disadvantage of this method is the high cost of the final product, since tire shredding requires special equipment and is considered an expensive processing method. Electricity costs are also high - up to 1000 kWh per 1 ton of processed raw materials.

At the same time, shredding has significant advantages over chemical methods of tire processing: technical simplicity, lack of toxic emissions (unlike combustion or pyrolysis). Rubber processing by grinding preserves the technological parameters of the material.

Crumb rubber obtained by grinding is widely used in industry and construction: for the manufacture of household products, additives in mortar, and for laying roads.

The following video shows how tires are processed into crumb rubber and what equipment is used.

Other Tire Shredding Methods

There are other methods for shredding old tires, but for various reasons many of them are not widely used. The most well-known processing methods:

• using a rotary disperser;
• ozone knife method;
• barodestruction method;
• shock wave grinding (explosive circular).

For the rotary disperser, the tire is crushed into small pieces. The rubber is then compressed in the sleeve and passed through a hole with a diameter of about 1 mm. The result is fine rubber dust with a highly developed surface that can effectively react with other components of the mixtures. Such dust is used for the manufacture of sorbents, new tires, roofing materials, etc.

Tire recycling using the ozone knife method involves exposing worn rubber to ozone in a special chamber and subsequent mechanical grinding. Ozone promotes the destruction of the rubber structure, facilitating further grinding of the tire by mechanical methods. As a result, pure rubber crumb and metal are obtained from the old tire, and there is no need for separation, since the metal and rubber themselves separate from each other when exposed to ozone.

When treated with the barodestruction method, tires are first cut and shredded, and then in a special chamber under the influence of high pressure and temperatures bring the rubber to fluidity, separating it from the metal cord. The result is fine rubber crumbs with a granule size of about 0.8 cm.

Processing methods that change the chemical structure

Recycling of car tires, which changes the structure, is also not very profitable. The rubber component disappears after processing, and the resulting product has a lower cost than in the case of mechanical processing. At the same time, the cost of final raw materials is quite high.

Among the chemical methods for recycling tires, the most common are the following:

• pyrolysis;
• thermal destruction (combustion);
• dissolution.

Pyrolysis is a thermal decomposition that occurs in a special chamber without air access. This method is most often used to obtain thermal energy. Rubber processing by combustion and pyrolysis has a number of limitations; they are associated with the release of carbon dioxide and toxic substances. This method requires more attention from an environmental point of view.

When burned in cement kilns, tires replace combustible materials such as coal and fuel oil. This method is used in the cement industry and to generate heat.

Many experts consider the dissolution of old tires to be promising and very effective method, although it has not yet received widespread use. Under the influence of the solvent, raw materials are obtained that can be successfully used in metallurgy and the chemical industry.

It is expected that this technology will help to effectively recycle tires of all types and sizes in the future.

Tire recycling in Russia and Europe

European countries boast recycling rates of old tires reaching 90%. About 20% of them are recovered and reused, 40% is used to generate heat, and more than 30% turns into crumbs.

Unfortunately, the global average is not that high - less than 40% of tires are recycled, and 60% of unrecycled rubber goes to landfill.

Important! Every year, about 10 million tons of new waste from old car tires appear in the world, which makes the environmental situation simply catastrophic. It is very important to pay close attention to this problem and introduce recycling methods in countries where it is not developed.

In Russia the situation is completely sad, although it is gradually improving year by year. Tire recycling currently accounts for about 10%, and has grown by a quarter over the past few years. Tire recycling organizations in Russia are not yet very active; in our country, people are not used to investing money in secondary production, disposal and recycling.

One of the additional problems is that it is more difficult to recycle domestically produced tires, common in Russia, Belarus and other neighboring countries, than European ones. Our old tires are additionally reinforced with radial synthetic cord, and a large admixture of textiles creates great difficulties for processing. As a result, processing domestic tires is much more expensive and more difficult than Western-made tires with an all-metal cord type.

Additional Information! The most common processing methods in Russia are crushing and pyrolysis. It should be noted that pyrolysis is prohibited in some developed countries due to its harmful effects on the environment. However, domestic entrepreneurs consider more expensive processing methods to be too expensive, so they use them much less frequently.

We hand over rubber for recycling

However, there is still reason for optimism - over the past few years, new environmentally friendly and safe complexes for the production of crumb rubber have appeared in Russia. In particular, such complexes operate in Samara, Kursk, Tver, and Vyazma. A processing center was built in Primorye, and a franchise helped many enterprises operating in this industry launch production.

Almost every major automobile service center in Russia accepts old tires from car enthusiasts. You often have to pay extra to return tires, although some services accept them for free. Companies are increasingly entering into contracts with recycling companies, handing over significant volumes of old rubber for recycling.

You can hand over tires for recycling at factories and complexes that produce secondary raw materials, as well as at car service stations. It is worth considering that large enterprises usually do not accept tires from the population due to the small volume of the product being handed over, so citizens have to monitor promotions at car service stations in order to get rid of one or two sets of tires.

Economics and ecology

The economic benefits of recycling tires are undeniable. In a number of countries, flammable gas that is released when heat treatment Tires are used to heat rooms and also generate electricity. Liquid pyrolysis products are used in the production of plastic, and crushed rubber particles are an excellent raw material for asphalt bitumen.

Note! The decomposition of tires in the ground continues for more than 100 years, all this time dangerous and toxic compounds, such as phenanthrene, diphenylamine and many others, are constantly being washed out of old tires. All of them remain in the soil and are then washed away by groundwater and rainfall, ending up in drinking water sources and agricultural facilities.

Thus, in the coming years, tire recycling methods will be improved, and the volume of rubber recycling will grow. This is especially true for developed countries, where environmental issues and recycling of materials have long been under the close attention of both citizens and authorities.

The situation in Russia is still reminiscent of the situation in African countries, but the principles of responsible consumption are gradually penetrating the consciousness of our citizens. In a few decades, both car enthusiasts themselves and business representatives will know exactly what and how to do with old tires in order to extract maximum benefit for yourself and the environment.