In recent years, the use of crumb rubber and materials made on its basis for decorating sites, organizing paths, and covering roofs of houses has become fashionable. You can also use crumb rubber to create waterproofing for building foundations. In order to use crumb rubber elements on your site, you can contact a company that professionally works with crumb rubber. However, working with this material is not so difficult. If desired, and if you have free time, crumb rubber can be made at home with your own hands.
What is rubber crumb made of?
There are two ways to go about solving this issue. Path number one relies on the transition of rubber to a brittle state at low temperatures. If at home it is possible to cool the source material for preparing crumbs to a temperature of -70 ... -80 degrees Celsius, then it will be possible to obtain crumbs from any type of source materials. However, solving this problem at home is not so easy.
Path number two is the competent selection of source material. As we know, crumbs can be obtained from tires and tubes from car wheels. But tires are very difficult to grind under normal conditions, and it is also difficult to extract the metal cord from them later. For this reason, to obtain crumb rubber at home, it is better to use old worn-out cameras as raw materials. This material can be easily cut with the help of improvised tools available in any home.
How to make crumb rubber at home?
At the initial stage, it is necessary to prepare a sufficient amount of raw materials, i.e. old car cameras and the appropriate cutting tool. For the manufacture of a coating with an area of one square meter and a thickness of 10 mm, about 8 kg of crumb rubber is needed. In the production of crumbs from old chambers, the loss of material by weight is minimal. Thus, it is necessary to prepare the source material at the rate of 8 kg of old cameras per 1 square meter of coverage.
To grind rubber, you can use ordinary scissors or an ax. If desired, you can build special guillotine shears. In extreme cases, you can organize the cutting of cameras with a fairly sharp knife.
Crumb production must be performed according to the following algorithm:
- Remove all metal elements from the old camera
- Cut the camera into thin strips
- Thin strips obtained in step 2 grind
Every year, thousands of tires go to landfills and landfills, despite the fact that for an enterprising person they are a free resource from which crumb rubber can be produced.
If it was needed only once, you can buy it in the right amount from manufacturers.
But where can you get crumb rubber if you need it on an ongoing basis and in large quantities?
Consider purchasing your own tire recycling equipment.
However, not everyone can afford a full-fledged installation, and such an investment will not be profitable for everyone. The way out is to create equipment with your own hands, and use it to produce crumb rubber from tires at home.
Recycling small amounts of rubber at home
If you need very little raw materials, you can do without equipment at all.
This will require only scissors and a cutter.
The metal cord is first removed from the tire, then it is divided into strips and crushed into smaller fractions to the required size.
At this point, the process is considered complete.
Material for the design of paths, flower beds or a separate playground is ready to use.
But to get more raw materials or have an income from tire recycling at home, you need the right equipment.
Tire crusher construction
Three main methods of crumb production are used:
- Tire crushing after cooling with liquid nitrogen to -190 degrees.
- Obtaining crumbs on industrial equipment of a full cycle with the removal of the cord and subsequent grinding of rubber.
- Recycling using universal crushers, which you can do yourself at home.
The first two methods require large investments. The third option is available to anyone who has the ability and desire to make a crusher at home.
The necessary units can be made independently in the workshop or at the production site - where there are metal-cutting machines (turning, milling) and a welding machine for the manufacture of component parts.
If it is impossible to perform the machining of blanks on your own and you have to order them according to your own drawings, the cost of tire processing machines will still be several times cheaper than similar purchased units.
The main component of the tire recycling line is a shredder (rubber grinder). Let us consider in more detail the purpose of the nodes of this machine.
Unit device
The machine consists of the following main units:
- electric motor 5 kW - 2 pcs;
- housing with disc shafts;
- lattice;
- worm gearbox - 2 pcs;
- shredder frame;
- loading bunker;
- guide tray;
- control cabinet.
Details of the installation are mounted on a powerful frame welded from channels.
Box with cutting discs
The main unit of the crusher for rubber is the body with milling rolls.
At the same time, the cutting knives are made of high-strength steel and heat-treated, which significantly reduces their wear. They practically do not require sharpening during operation.
The calculation of the openings of the box, shafts and cutting elements must be accurate, so it must be done by a specialist in this field (designer).
Grid for crumb calibration
In order to obtain a calibrated fraction of tire raw materials, shredders are equipped with a special grate, which is installed under the rolls.
Worm gear
The rotation of the shafts with disk cutters is carried out separately, directly from the worm gearboxes connected to the electric motors through couplings.
The gear ratio is selected from 25 to 35 so that the cutting is without sticking and at a sufficient speed.
Machine frame
The frame is welded from profile elements, ensures the reliability and stability of the unit during operation, as well as loading and unloading operations.
loading hopper
The tire recycling plant is equipped with a tire loading hopper and a tray for removing finished crumb rubber.
Thanks to its design, the hopper eliminates the formation of blockages from the raw materials and guarantees a directed movement of the mass towards the rotating rolls.
Tire cutter
The tire cutting and cord removal plant consists of a carrier frame and a stand.
On the carcass is a tire clamping mechanism that rotates with the tire during cutting. The engine speed is reduced due to the different diameter of the pulleys. There is a built-in wedge-shaped cutter on the stand, which is adjusted to a certain size by moving the quill.
How to grind tires?
The technological chain consists of several preparatory stages before the production of the required fraction is obtained.
This procedure includes:
- Inspection and removal of foreign objects from the tire cavity.
- Cord cutting.
- Cutting the tire into strips of 50-80 mm in size.
- Grinding of raw materials by means of a shredder.
- Separation and separation of metal from textile parts.
- Calibration of crumbs into fractions using a vibrating sieve.
Equipment performance
The work of these two main units during the processing of tires is done in a semi-automatic mode.
For the normal operation of this line, a room of about 150-200 square meters is required. meters. This is due to the fact that you need a place for the location of not only equipment, but also for storing worn tires, finished tire products and metal waste.
The output of rubber crumb on this equipment per hour will be approximately 200-800 kg and up to 100 kg of scrap metal, 2-3 unskilled workers will be needed to service the machines.
In addition to tires, this equipment can process other rubber (conveyor belt, cameras, gas masks). The output is a crumb with sizes from 0.7 to 4 mm, while it is 65-85% of the total mass of raw materials.
Where to apply the obtained raw materials?
Rubber crumb can be:
The price of crumbs will depend mainly on the quality of raw materials, and secondarily on the fraction.
The most popular is the crumb, the fraction of which is 2-4 mm.
It's great for creating:
The popularity of such crumbs is due to the fact that the minimum amount of glue is used to glue these granules. A polyurethane binder is sometimes 5-8 times more expensive than crumbs.
Related videos
In this video you can see how to grind rubber and make crumbs at home.
Conclusion
Building a DIY tire crusher is a good idea for those who want to make their own rubber crumb but aren't ready to spend tens of thousands of dollars on equipment.
You can create a chopper with a carpentry workshop, as well as certain skills and materials, or use the services of people who specialize in this.
The crumb obtained at home can be used for your own needs or sold to enterprises and the public.
In contact with
Classmates
rcycle.net
Recycling tires into crumbs at home: how to do it
It has long been known that worn-out tires that are out of service are a potential source of environmental pollution and environmental damage. Recycling tires into crumbs at home is the same popular method, along with factory ones. Rubber waste from used tires is virtually non-biodegradable, taking hundreds of years to decompose.
It should be noted that this rubber waste is a flammable material, and if a huge number of tires ignite, they can pose a threat of poisoning to everyone nearby, since rubber, when burned, releases carcinogenic toxins, such as benzpyrene. Storage in landfills leads to the reproduction of rodents and insects, which are sources of dangerous infections. To avoid the deterioration of the environmental situation in Russia and abroad, proper disposal is required, namely, waste processing. Without constant recycling, an environmental crisis could set in very soon.
Recycling
Recycling is also economically beneficial. From car tires, you can get various types of valuable recyclable materials, as well as produce a huge amount of finished products. From the waste of powder rubber of a very fine fraction (about 0.2 mm), new car tires and rubber shoes are produced, this secondary resource is popular in Russia and the CIS countries.
Powder from waste of larger fractions is used in the production of composite roofing materials, rubber-bitumen mastic, waterproofing materials, and rubber coatings. Scrap metal is obtained from a metal cord, which is also used by Russian entrepreneurs. Also, textiles and rubber are obtained from tires.
Recycling at home
Especially active and advanced people have the opportunity to process rubber with their own hands. What is needed for this? Spent chambers, tires, tires and a little ingenuity. Recycling tires into crumbs at home is a rather complicated undertaking. According to their properties, cameras from old tires are more suitable. They are softer and more easily amenable to external influences.
According to one of the scenarios, the rubber should be cooled to a temperature of approximately -75°C. Agree, not everyone has such an opportunity. So let's use the traditional scenario:
- Take the cameras
- Remove all unnecessary elements from them
- Cut them into thin strips
- Grind those stripes
The rubber grinder in this case is an ax or scissors.
Mechanical processing method
The most professional way. The technological line is a sequence of installed working devices, overcoming which the material becomes a finished product.
Processing into crumb rubber goes through three stages:
- Tire preparation. Initially, they are washed and cleaned of impurities, after which they are transported by a conveyor to the primary crushing unit, where they are ground with knife crushers to large pieces (30-50 mm).
- At the second stage of the technological process, the primary processed raw material is fed by means of a belt conveyor to a hammer crusher, where it is re-crushed to smaller sizes (10-20 mm). It is at this stage of processing that the metal and textile cord, bead wire is separated from the rubber. Textiles are separated by a special textile removal system, and metal is separated by a magnetic separator. The collected metal waste is then briquetted.
- At the final stage, processing into crumbs is already underway. As equipment for processing tires into crumbs, an extruder - grinder is used, in which the rubber mass is ground into a fine powder. At this stage of tire processing, additional cleaning of crumbs from textiles and metal is also carried out using a gravity separator. After that, the crushed rubber crumb is divided into fractions and packed in polyethylene bags of 20 kg or in big bags (soft containers) with a carrying capacity of up to 1000 kg.
Today, there are a sufficient number of manufacturers of this equipment on the Russian market.
Chemical processing method
With the chemical method of processing, automobile tires are subjected to pyrolysis. With this processing method, the thermal decomposition of rubber into its constituent elements occurs. Tires are pre-crushed into a homogeneous mass and sent to an oven, where they decompose at a temperature of 500 - 800 ° C. This procedure lasts 10 - 20 minutes. In the process of thermal decomposition of rubber, about 50% hydrogen and 26% methane are formed, as well as solid pyrolysis products, which are then used in wastewater treatment at wastewater treatment plants in Russia.
There is also an effective, but expensive physico-chemical method of processing tires into crumb rubber - cryogenic grinding of car tires. Crushing of rubber is carried out in a special cooling chamber at extremely low temperatures (up to - 120 ° C). A refrigerant (liquid nitrogen) is supplied to this chamber, cooling to ultra-low temperatures. In conditions of strong cooling, the rubber acquires a glassy state. Crushing of rubber occurs when struck with a special hammer. After grinding, textiles and metal are removed from crumb rubber.
In modern times, there are many mini-factories for the processing of tires. The business plan for recycling car tires is quite simple. Its implementation will require modern tire recycling equipment, warehouse equipment, fuel tanks, tools and overalls for workers, as well as equipment installation costs. It is necessary to register an enterprise and a license that will allow you to engage in this type of activity. Starting this business will require significant start-up capital.
vtorothodi.ru
scheme for creating a homemade grinder for PET
Polymer materials have become very firmly established in our lives and now they can be found in any industry.
But due to the fact that these materials do not decompose naturally, they cause serious damage to nature.
A positive feature is the possibility of their recycling.
To do this, the plastic is first prepared and brought to the state necessary for this, it is crushed. To do this, special devices were invented - crushers (shredders, machine tools, shredders) for plastic. You can make such a crusher with your own hands.
Varieties of choppers
In total, there are three types of such devices, which differ in the possibility of processing a particular polymer material.
They are divided into options:
- The design looks like V-blades on scissors and is suitable for shredding plastics such as acrylic, film and nylon.
- A type that is used primarily in plastics factories and recycling plants.
By design, they are of several types: hammer, cone or jaw crushers. They are used for processing large-sized plastic products, like a window profile.
- The most common option has a rotary design and is used for processing thin-walled plastics like bottles, foam.
The plastic shredder will allow its owner to contribute to the environment and even earn money. For domestic purposes, a rotary version of the crusher is usually used. Its design consists of a rotor on which the knives are securely attached.
Crusher Mesh
After switching on (and it can work both from a liquid-fuel engine and from a conventional electric motor), the axis with knives begins to rotate and, as a result, under fast and strong blows, the raw materials that have got inside such a device are crushed.
At the bottom of the body for grinding there is a grate, which has a certain mesh size. It is determined depending on what diameter the fraction should ultimately have.
The raw material in the device is processed until it reaches the desired size and exits through this sieve.
Specialist note: the quality of the metal of the knives used should be used as strong as possible. It is best to use high-quality hardened steel so that the blades wear out less quickly and the sharpness of the knives lasts longer.
Materials and tools
To assemble such a device at home, you will need certain skills in working with a welding machine.
The total plastic shredder consists of such elements as:
- circular saws. The optimal number is approximately 20 pieces.
Since this is the basis of the entire apparatus, they should be selected only with high-quality and various tooth configurations, which will allow better grinding of waste;
- as a drive, it is best to use an electric version of the engine. The reason is a wider choice and the ability to use not only outdoors, but also indoors;
- axis for fastening saws;
- to create a frame and frame, you will also need a metal profile;
- various elements for fastening;
- a hopper through which the material will be fed for processing and a protective cover;
- to connect the rotor you will need a special belt, as well as a pulley and several bearings.
Incorrect choice of crusher saws can lead to an imbalance on the axis, due to which the structure will vibrate strongly and wear out faster.
Process of creation
Schematic diagram of plastic crusher
After preparing everything necessary for work, you can begin the manufacturing stage:
- First, a cutting block is made by putting circular saws on a pre-prepared axis. In order to leave the necessary space between such impromptu knives, it is worth using nuts.
- Next, we mount the structure on the pulley and ensure free rotation due to the bearings.
- Now we make a rectangular frame and a support frame from prepared metal materials.
- The next step is to weld the height-adjusted legs, also using welding.
- Further, the frame is covered with a steel sheet, for this we weld it to the frame. We make a hole of the required size in it and mount the engine at the correct distance from the cutting elements. The protective cover and material supply container are necessary for safety and work efficiency.
- After creating the frame, we begin the last stage of assembling the plastic crusher. To do this, a so-called protective cover and a bunker are put on the knives, through which the raw material will be fed. During the installation of the casing, it is worthwhile to provide a hole in it for connecting the axis to the pulley.
- The final touch is the connection of the cutting block to the motor shaft using a belt for this. Everything, the design is ready.
The main recommendation given by experts is the need to draw up a drawing of how the planned structure will look like before starting work. This will make it possible to avoid inaccuracies and inconsistencies in the dimensions of individual parts.
Having designed and assembled such a unit with your own hands, you can, knowing its entire design, easily make changes and refine it.
The shredded plastic will have the size that is laid down in the design capabilities of the unit itself.
When choosing a power unit, it is necessary to determine in advance how often the device will be used. If the work on it is rare and the loads are insignificant, then a low-power electric motor will suffice, but for active use, a more powerful option and with a large number of revolutions will already be required.
And in order not to have to collect the processed fractional material on the floor, it is advisable to provide a place under the saws for attaching a special container in which it will be collected.
Watch a video review of a quality do-it-yourself plastic crusher:
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6sotok-dom.com
Do-it-yourself plastic crusher for recycling
Polymeric materials have firmly entered modern life, and there is not a single industry where they are not used, from the production of containers to space technologies. Every year, about 180 million tons of various plastics are produced on the planet. Most of them cannot independently decompose into simple components and be disposed of on their own.
This brings irreparable damage to nature and can cause an ecological catastrophe. A positive feature of almost any polymer (plastic) is the possibility of recycling, so that old plastic things can get a “new life” as useful items. Recycled plastic is slightly inferior in terms of strength characteristics to the primary polymer, but with certain proportions, products made from recycled plastic practically do not differ from the original.
Varieties of choppers
Before being recycled, any plastic must be shredded. For this, there are special devices - crushers. Depending on the physical qualities of the polymer placed in them, the devices can be classified into several categories:
- for shredding PVC film, nylon or acrylic. The design resembles large scissors with "V"-shaped blades;
- for large plastic waste. Most often used in recycling plants or plastics factories. There are hammer, jaw or cone designs. With their help, window profiles and large parts and cases are crushed;
- for PET bottles and thin-walled plastics. The most common version of the grinder, structurally called rotary.
The required type of apparatus can be purchased or made by yourself. This is a small household appliance from the third category. Do-it-yourself plastic crusher is quite easy to do and does not require serious knowledge and specialized tools, except for a welding machine.
Learn more about rotary shredder
The most common design is the impact crusher. It consists of a rotor on which the knives are fixedly fixed. Under the action of a driving force - from a diesel, gasoline engine or an electric motor, the axis with knives sets in motion and grinds the raw materials that have fallen under the knives with quick blows. Depending on the purpose, there are low-speed machines and high-speed units.
At the bottom of the working chamber, a sieve or grate with a certain mesh size is installed, depending on the required quality and diameter of the obtained fraction. Raw materials are cyclically processed by knives and gradually pass through a sieve.
Particular attention is paid to the quality of the metal from which the knives are made - it must be a good hardened steel, which prevents rapid wear and ensures that the sharpening is maintained for a long time.
We make our own crusher
There are several of the most popular varieties of plastic shredders that are made at home. In order to assemble this device with your own hands, you will need a little patience and minimal skills. As a special tool, you only need a welding machine or a household inverter.
A do-it-yourself plastic crusher, the scheme of which will differ slightly depending on the skill level of the manufacturer and his imagination, has the following common elements:
- drive unit. The most commonly used electric motor. Thanks to a large selection and affordable prices, you can choose the model of the required power. In addition, the electric drive crusher is quieter and can be used both outdoors and indoors;
- circular saws. This will be the basis of our apparatus. It is necessary to select a sufficient number of them and a different configuration of teeth for better grinding of waste. The optimal number of saws on the axis is about 20;
- the axis on which the saws will be attached;
- metal profile or pipe for the manufacture of the support frame and frame of the crusher;
- protective cover and feed hopper. They can be made independently at home from galvanized sheet metal with metal scissors, a hammer and a vice;
- a pulley, two bearings and a special belt, with which an interaction is created between the electric motor and the rotor;
- fasteners (nuts, washers and self-tapping screws for metal).
When all the necessary materials and tools are prepared, you can begin to manufacture the unit.
First of all, you need to build a cutting block. To do this, we put circular saws on the prepared axle. The diameter of the axle and the seat of the saw must match. There should be a minimum distance between improvised knives, which is provided by ordinary metal washers. At the ends of the saw should be well fixed with nuts. Then we install the axle on the pulley and use two bearings so that the structure rotates freely.
The next step is the manufacture of the supporting frame. We make a rectangular frame from a metal corner, profile or pipe by welding. Then we weld the legs of the required height to it. We cover the frame with a sheet of metal, which is welded to the frame. We cut a hole in the sheet equal to the size of the cutting block. We mount the engine at a short distance from the knives.
After the frame is ready, you can proceed to the final stage of assembling our device. To do this, we put a protective cover on the knives and install a hopper on top for supplying raw materials. A hole must be provided in the casing through which the axle will be connected to the pulley. Using a special belt, we connect the motor shaft and the cutting block. Our simplest plastic crusher design is ready.
People who have extensive experience in the manufacture of various units with their own hands recommend that they first draw up a drawing of the future design. In this way, you can avoid size mismatches or miss a node or part.
Before purchasing an engine, you should decide on its power and output speed. For infrequent use and at low loads, a compact electric motor of low power is sufficient. The more actively the crusher will be used, the more powerful and “resourceful” the motor should be.
Circular saws are better to choose light-alloy ones. They are slightly more expensive than standard products, but they retain their sharpness much better, which will save you from regularly and often removing the cutting block to sharpen saws. The design itself should be thought out in such a way that you can easily get to any of its nodes.
For greater convenience, you can make a special container where the processed raw materials will be located. The container is fixed directly under the saws of the crusher. If you need to receive recycled plastic of various sizes, you should take care of manufacturing and installing a special mesh or grid under the disks with the desired cell size.
Small Conclusions
A plastic crusher is a tool that will not only help fight environmental pollution, but also bring some income to the owner. Shredded plastic can be handed over by weight to recycling points and earn some money. In addition, depending on the design of the cutting unit and the power of the motor, the device can be used to grind leaves and branches - and this is already a serious help to any summer resident or owner of a private house.
The assembly of the unit is not particularly difficult, and thanks to your own developments, you can improve the design. Assembled independently, the crusher will not differ in any way from mass-produced grinders for household needs, and in terms of reliability it will surpass cheap Chinese counterparts. One of the options for what a plastic crusher can be - a video story is attached.
polymerinfo.com
We make a garden shredder with our own hands on circular saws
After spring tree pruning, most gardeners are faced with the problem of disposing of old branches. If you are a thrifty owner who is used to using all the waste, then most likely you send all the branches to the compost heap. There, all this stuff rots and in 3-4 years you are guaranteed to receive an excellent organic fertilizer - compost. All this, of course, is wonderful, but too long. If you first chop the branches and leaves on them, then your compost will ripen in a season, or even in a couple of months. And here a garden shredder can come to your aid - a device that will turn the source material into chips or flour. The devices that are on sale are not cheap, so we suggest that you familiarize yourself with the instructions for making a garden shredder with your own hands.
We will make such a bandura ... let's go!
We will not convince you that a homemade shredder will be completely free. Naturally, some details will go into its manufacture, which will cost money. However, on average, a home-made unit will cost you 2 times cheaper than a ready-made chopper of a popular brand. Judge for yourself, for the chopper you will need:
- Circular saws - 15-25 pieces
- Motor - gasoline or electric
- Stud (rod) M20, washers and nuts to it
- Pulley (for example, from a VAZ generator) and a tight belt
- Bearings
- Metal pipes for the frame
- Sheet Metal for Hopper
- Plastic washers 14-24 pieces
Crushing of material in the garden shredder is carried out with the help of knives. In finished models, the knife is most often a metal disc with 2-3 cutting surfaces. A large amount of work quickly makes the teeth unusable and they have to be sharpened periodically - you see, this is not very convenient, and besides, it takes your time. If you decide to make a garden chopper with your own hands, then you can not repeat these design flaws, but assemble a reliable, high-performance and, most importantly, durable knife.
We suggest using carbide-tipped saw blades for this. It will take not one disk, but several to collect a system from them - a package. In ready-made garden shredders, the knife, as a rule, has a thickness of 3 cm, but we can pick up a package of any thickness - everything will depend on the number of saws purchased. On average, for a quality knife 6-10 cm thick, you will need 15-25 pieces. Each disc has many teeth, originally designed to cut through hard wood. Therefore, grass stems, leaves and branches for them will be the same as seeds. As a last resort, if the teeth on the saw become dull, there is nothing to stop you from going to the nearest tool store and getting a replacement for it.
Circular saws can be successfully used as chopper knives
However, the knife is not everything. In order to set it in motion, we need an engine. For fast chopping of branches in small volumes, it is easier to use an electric motor. Its use may seem somewhat inconvenient due to the cable and the need to connect to an outlet, but it works almost silently and does not emit exhaust gases. The walk-behind tractor has more power, so it is ideal for those cases when you need to crush coarse material often and for a long time.
1. Saws are assembled on an axis, the diameter of which is determined by the bore diameter of the discs (20mm). For this, a stud with an M20 thread is suitable. Accordingly, washers and nuts of the same diameter will be needed.
Saws assembled on the axis of the future chopper
If we install discs on a hairpin close to each other, then the knife will not work. And here's why: the width of the saw teeth is greater than the width of the blade itself, so when rotating, the teeth will cling to each other. To prevent this from happening, it is necessary to separate the disks a short distance. This is easy to do with homemade washers that you can cut out of thin plastic. Their number should be 1 piece less than the number of circular saws.
2. A pulley is put on the stud axle (from the VAZ generator or from the pump). To rotate the axis, two VAZ intermediate shaft bearings with an inner diameter of 20 mm are also used.
3. A frame is welded from profiled metal pipes, on which the walk-behind tractor bar is attached. The engine is mounted on the frame so that it can be moved relative to the circular saws. This is necessary to change the tension of the drive belt if necessary.
An axle with circular saws is attached to the frame
4. For ease of use, a thrust bar made of a metal profile is fixed on the frame, into which branches and stems will rest during crushing.
5. The cutting block must be fitted with a metal casing that is welded from sheet metal or cut from galvanized steel. For reliability, it is better to use the first option.
The casing is better to be made of sheet iron - it is more reliable!
6. Another hopper with a socket is attached from above to load the material to be crushed. There are no special requirements for this part, so most often it is made of flexible galvanized steel.
The receiving hopper is easy to make from galvanized steel
Unlike factory models, a homemade chopper does not require an overly careful attitude. It will become a universal helper in the household and will help not only to chop branches and other household waste, but also to crush fruits (apples, pears, plums), and along with the seeds. This is very convenient if you need to make jam, puree or homemade wine when the fruits are crushed to a paste.
Garden shredder in action
The circular saws that form the blade of the unit are capable of processing fairly large pieces of wood. Of course, we are not talking about logs, but branches with a diameter of 10 cm will be quite “too tough” for him. This home-made shredder compares favorably with the factory product, the body of which simply will not let large parts of the material through. Accordingly, you will significantly save your time, because you do not have to sort the branches by size and think about what to do with too large fragments. Also, it will not be necessary to monitor the moisture content of the material, while the purchased grinder requires adjusting the degree of dampness of the feedstock. The fact is that in most modern ready-made shredders, the electric motor is located at the bottom of the structure, so when processing wet stems, moisture will inevitably get into the engine, and this will lead to breakdown. In a homemade product, you are free to decide where to install the engine, in the version described above, it is located horizontally, on the same level as the knives.
It is also worth paying attention to the cost savings when using a homemade chopper. Firstly, manufacturing will initially be cheaper than buying a factory device, and secondly, a “home-made” will not need to purchase expensive parts in the event of a breakdown - all of its elements are not expensive.
Homemade garden shredder is able to crush even large branches, turning them into chips
In addition, a homemade garden shredder has a high performance. All waste loaded into the hopper will be pulled in by the circular saws and disappear at an incredible speed. Thus, a home-made device can be no worse than an expensive and modern garden tool. In a word, if the chopper is really needed, but there is no money to buy it, there is only one way out - to make it yourself!
A rubber grinder from AMD Plast, a leading enterprise in our country, will turn into a small crumb the marriage of production of rubber products of all shapes and densities. The choice of such a shredder for a particular enterprise will be determined by the amount of waste and the technical properties of specific models. Crushers of the brand AMD-200D, AMD-400D, AMD-600D, AMD-600DU are suitable for rubber recycling. We invite you to familiarize yourself with them and compare them with the needs and characteristics of your production.
Rubber grinder AMD-200D
This model of rotary type grinds mainly hard plastics and waste products from the production of dense rubber, the thickness of which should not exceed 5 mm. It is advisable to use a machine with a power of 4 kW and a productivity of 50-70 kg / h for processing small volumes of waste from your own enterprise. You can install such machines in toy factories, in the production of rugs, seals and other products for a wide range of applications. The equipment is small, economical and safe. The package includes 5 knives of double-sided sharpening, a rotor with a rotation speed of 1500 rpm, a low power consumption motor, a vibrating grid with a hole diameter of 8 mm.
Andrey Lyashchenko
Rubber grinder AMD-400D
Rotary type equipment of increased power and productivity up to 100 kg of waste per hour. Its acquisition will be of great help for the industrial processing of large volumes of rubber residues. In addition to warehouses, hypermarkets and points for the procurement and disposal of recyclable materials, it is used in mechanical engineering and instrument making. The wall thickness of processed products is 5-8 mm. Rigid materials are preferred. Engine power 7, 5 kW. 6 knives are staggered on the rotor and 2 more on the bed. The crusher will not cause harm to employees, it will pay off in a short time, it does not consume a lot of energy, it takes up little space. Its maintenance is not a problem.
Lebedev Kirill Vitalievich
Rubber grinder AMD-600D
With its help, high-quality and efficient industrial grinding into crumbs of rubber waste of various densities and elasticity takes place. Soft and thin rubber does not hang or wind. Centrifugal forces cause crumbs to come out. The equipment is in demand among manufacturers of tires, insulators, structural parts, seals, warehouses and professional processors of raw materials. The 11 kW motor does not consume much electricity. With the help of holes in the calibrating grid with a size of 10 or 20 mm, it is possible to adjust the diameter of the outgoing crumb. The range of processed materials is very wide: from hard and soft polymers to textiles, hay, foam rubber and packaging.
Miroshkin Yaroslav Nikolaevich
Rubber grinder AMD-600DU
The equipment is the result of the improvement and modification of the AMD-600D crusher model. This explains the similarity of the characteristics and capabilities of the machines. Their productivity is 80-120 kg/h. Engine power 11 kW. However, the engine in the latest model is placed on the frame, and side-cut knives in the amount of 6 pieces become less dull and less likely to require re-sharpening. Due to the belt drive, the load and vibration are reduced. Thus, the model will serve even longer, work more efficiently and better. Models do not have large dimensions, are not pretentious to environmental conditions, are not traumatic, and are affordable.
Senkin Dmitry Eduardovich
All models of our equipment, working with rubber of various degrees of elasticity, meet modern quality and safety requirements. To buy a rubber grinder, just dial our phone number and discuss your choice, time and place of delivery with the manager. The customer will not have to wait long, because our warehouses are constantly replenished with new models.
Recycling hazardous types of waste in Russia is relevant. With an increase in the number of cars, the number of used tires is growing (according to statistics, it reaches 1 million tons per year).
There are not enough enterprises involved in their processing, although each region annually accumulates 50 tons of worn-out rubber. Not all cities have places to store this type of waste. Discarded tires are found on the side of the road or near suburban roads.
The Moscow region has the greatest experience in the recycling of tires (2 specialized plants operate), but they process only 10%. Therefore, the tire recycling business will occupy an empty niche.
The advantage of such a business is the ability to get old tires for free. Recycling tires into crumb rubber is a promising type of business.
In Russia, there is no system for recycling tires, experts attribute this to the imperfection of the legislation.
Advantages and disadvantages of the processing business
The benefits of this business include:
- inexpensive raw materials in large quantities;
- location near the places of sale;
- few competitors;
- the ability to use any room;
- economic benefit.
Flaws:
- initial investment required;
- selection of raw materials with the same composition.
Room selection
The main parameter is the area of the premises and the cost of rent. When choosing a room, consider:
- the area must be sufficient to accommodate production equipment;
- places for loading and unloading;
- necessary support facilities;
- connection to water supply and power lines;
- convenient access roads;
- distance from the residential area of 300 m or more.
An industrial area located outside the city will be the most suitable place.
Required documents
To open a business, you will need documents confirming or, the conclusion of the sanitary-epidemiological and fire service, an agreement for the supply of electricity. The licensing of this type of activity was canceled by the Federal Law No. 93 dated 06/25/2112.
What documents are required for registration of an individual entrepreneur and how to properly issue them in accordance with the requirements of the law - read
Activity registration
The choice should be approached responsibly: this affects the registration procedure, payment of taxes and other factors. When opening an LLC, the responsibility arises:
- as a legal entity;
- as individuals founders and participants.
An LLC is liable for its obligations to the extent of its property. If it is impossible to repay debts during bankruptcy, obligations can be transferred to the founders, participants.
For an individual entrepreneur, in the event of debt obligations, property is not considered personal and that which is used for entrepreneurial activity (this also applies to property acquired before the start of entrepreneurial activity).
Industrial processing of tires into crumbs: a business plan with calculations
The technological line processing tires into crumbs has a capacity of up to 700 kg/h. The output of finished products from the initial mass of raw materials is 60 - 70% of the granulate, which is in special demand (fraction 2 - 4 mm).
The area of the premises is 250 m2, the number of workers is 4 people, the electricity consumption is 120 kW. The annual output of crumb rubber will be 2,000 tons.
- The cost of the main equipment is 10.75 million rubles.
- Delivery and adjustment 250 thousand rubles.
- Additional expenses 30 thousand rubles.
- Machine that sews bags 10 thousand rubles.
- Scales 20 thousand rubles.
- The cost of bags for crumbs is 20 thousand rubles.
- Staff salary 100 thousand rubles.
With a minimum monthly tire recycling of 150 tons, the output is:
- metal cord 30 tons;
- crumb rubber 100 tons;
- textiles 20 tons.
Income from product sales
- 1500 thousand rubles from rubber crumb (100 tons x 15 rubles / kg);
- 90 thousand rubles metal cord (30 t x 3 thousand rubles/t);
- 40 thousand rubles textiles (20 tons x 2 thousand rubles/ton);
- 150 thousand rubles acceptance for recycling of tires from individuals and enterprises.
Total: 1780 thousand rubles.
Production costs
- 100 thousand rubles staff salaries;
- 4 thousand rubles on packing bags;
- 20 thousand rubles communication services, economic;
- 100 thousand rubles electricity (120 kW x 4.5 rubles);
- 50 thousand rubles rental of premises;
- 50 thousand rubles line maintenance;
- 20 thousand rubles garbage removal.
Total: 344 thousand rubles.
The profit is 1780 - 344 = 1436 thousand rubles. Return on investment 8 months.
With an increase in the output of finished products, selling them at a price higher than the minimum monthly profit indicators will increase.
Starting a business requires large investments, which scares aspiring entrepreneurs. You can use a bank loan or receive a subsidy under the state program. To do this, you need a business plan with calculations.
and tips for implementing them are contained in our new article at the link.
Possible risks
The production cycle includes the supply of raw materials, the operation of equipment and the sale of finished products. Risks that may arise:
- breakdown of technological equipment (to reduce this risk, it is necessary to maintain the line in a timely manner, follow the recommendations for its operation, replace worn-out mechanisms, consumables);
- interruptions in the supply of raw materials (it is possible to conclude a contract for the supply of raw materials simultaneously with the search for equipment);
- sales difficulties (a long-term contract should be concluded with an enterprise that needs rubber crumb and a distribution channel should be established to nearby regions);
- damage to products during storage (special conditions are not required, however, crumb rubber is afraid of moisture).
A business based on the processing of car tires into crumbs will turn out to be profitable if the entrepreneur manages to resolve the issue of marketing finished products. This direction is promising, consistently brings good profits.
You can find out how the lines for processing tires into crumbs work in practice in the following video:
Each of us knows that a vehicle cannot 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. You can partly solve this problem 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 the production line is quite serious. 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 make a 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. This is not a good solution, but the emission resembles the exhaust gases of a truck. As for the remaining mass, it passes through a magnetic separator, in simple words, it is sifted through a sieve. Metal elements are screened out and sent to the warehouse. Fuel oil is transported by 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 is another rather interesting idea that has not received proper 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 of worn tires are thrown away on the territory of the Russian Federation every year. Approximately 20-25% is disposed of properly, everything else is either simply lying in landfills or burned. So, the processing of tires into crumbs can bring 5-8 billion, but this is already an 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 the 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% of the 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 fuel additives, complex chemical reactions and other points. 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 get 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 manager, 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.
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