Polymer sand products technology. Required production areas

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Consider an example of calculating the cost of production of polymer sand paving slabs, which can be taken as the basis for drawing up a business plan and a feasibility study for production.

The data is up to date January 1, 2011 for the Udmurt Republic. All prices are without VAT. The simplified taxation system was taken for calculation.

You can also order and substitute your details.

INITIAL DATA

Material characteristics:

• size 330*330*35mm
• tile weight - 3.1 kg.
• number of pieces in one m2 - 9 tiles
• weight 1m 2 - 27.9 kg.
• water absorption 0.37%
• tensile strength 152 kgf \ cm 2
• compressive strength 300 kgf / cm 2
• abrasion 0.003 g \ cm 2
• frost resistance 500 cycles.

INITIAL INVESTMENT

The total cost of a set of equipment, including the cost of turnkey commissioning, is: 2,382,780.00 rubles, excluding VAT.

A plastic crusher may not be needed if you use ready-made primary or secondary polymers, but this will lead to an increase in the cost of the product;

The mixer can be replaced with a concrete mixer, but with a loss of performance.

PAYMENT FUND

Three people are enough to operate the site - a manager (25,000 rubles), an APN operator (20,000 rubles), an auxiliary worker (20,000 rubles). The wage fund is 65,000 rubles per month for one shift and 130,000 rubles. at the rate of 2 shifts.

Volume finished products per month 140 sq.m x 30 days = 4,200 sq.m. m

Payroll fund for the month 130,000 rubles. : 4,200 sq.m = salary costs for 1m 2 is 30.95 rubles.

UST - 30%, gives 9.3 rubles. in the cost of 1m 2 of finished products.

REQUIRED PRODUCTION SPACES

To accommodate equipment and storage areas for raw materials and products, it is necessary to provide about 100 m 2 of production space and 100 m 2 of a warehouse (may be located outside the premises). The production room does not have to be heated, heating occurs due to the heat generated by the equipment. Finished products are stored in the workshop, and then moved to the warehouse.

At a rental rate of 100 rubles per sq.m. the cost of renting production space will not exceed 10,000 rubles. Thus, the cost of rent for 1 m 2 of the product is 2.38 rubles.

COST OF ENERGY AND MATERIALS

In total, the cost of raw materials (polymer + sand + pigment) per ton is 5,000 rubles. Thus, the cost of raw materials per 1 m 2 tiles is 139.5 rubles. For 1 piece 15.5 rubles.

ELECTRICITY CONSUMPTION per shift

• A crusher with a capacity of 300 kg/h consumes 22 kW/h. To produce a mixture of 3,906 kg, 960 kg of polymer are needed. For its preparation, the crusher will work for 3.2 hours and consume 70.4 kW of energy.
• APN - 29 kW / h during heating, when working around the clock with a heated ALP, consumption decreases by 4 times, i.e. calculation: 7.25 kW x 24 hours = 174 kW / day
• Hydraulic press - 5.5 kW / h. When molding the product, the program on the presses is designed for the consumption of el. Energy in the mode of raising and lowering the upper punch, when forming el. Energy is not consumed. The travel time of the slider is 40 seconds per day 1260 pieces x 40 seconds. = 50 400 sec. = 840 min. = 14 hours of press operation
• Consumption per day 77 kW.
• Mixer - 5.5 kW / h 1 batch - 3 min. Mixes 0.5 tons per mix. 3,906 tons of mixture for 1,260 tiles per day. Per day 23.0 min. Electricity consumption 1.8 kW.
• Lighting - 12 kWh

Total electricity consumption per day will be 335.2 kW / day, per shift for 12 hours 167.6 kW.

The cost of electricity for 1 kW / h - 4.03 rubles. Thus, the cost of electricity is 675.4 rubles. for 12 hours in the production of 630 tiles, the cost per 1 tile will be 1.07 kopecks.

Equipment depreciation is set by the enterprise independently

Cost price 1 m 2 paving slabs

FINAL CALCULATIONS

Net profit per day 44,830.8 rubles, Gross revenue per day 600 rubles. x 140 sq.m. = 75,600 rubles. Net profit / Gross revenue x 100 Profitability is 59.3%

This business is highly profitable as of 2011. Rate of return - 59.3%

Modern materials, characterized by good quality indicators, quickly gain the trust of consumers. This can also be safely attributed to polymer tiles, which are actively used in the construction industry for the construction and repair of structures.
This business is good because the production of products does not require huge costs, and all investments pay off pretty quickly. So why not start your own workshop? Let's talk about how to open your own production of polymer tiles from scratch with minimal investment.

Technical equipment of the workshop

The manufacturing technology of polymer sand products is not particularly complex. As a rule, all operations are carried out on special machines. The main raw materials here are sand, polymer waste and dyes. Costs for everything necessary components, if you buy them directly from the manufacturer, are minimal.
The first thing you need to do to organize a workshop is to buy equipment for the production of polymer tiles. Buying a ready-made line will be more profitable than buying each device separately.
The standard line includes the following set of machines:

• Radial crusher. It is used for grinding polymer raw materials to a homogeneous fraction. It is better if the crusher is universal, so that it is possible to process not only solid waste but also film.

• extruder. In this unit, all prepared raw materials are mixed and heated to a certain temperature. The output is a homogeneous mass of thick consistency. Extruders differ in their performance. For small workshop a capacity of 100 m 2 of finished products per day will be sufficient.

• Forming press. Further, the production of polymer-sand paving slabs is reduced to laying the molten mass in special forms and processing it under overpressure. Ready product cooled and transported to the warehouse.

• Press forms. It is in them that the mixture is poured. The molds themselves are made of high quality alloy steel. It provides special system cooling. The configuration of these forms will depend on the type of products you plan to produce. If production is limited to tiles only, then big variety You don't need molds.

The average price of equipment for the production of polymer tiles varies in a wide range, depending on the capacity of the line. To produce high-quality products, you will have to spend at least 1,200,000 rubles. Serve the line low productivity 3 people can do it per shift.
To accommodate the machines, you will need a room of 100 m 2. Considering that you will be working with polymers, there must be good ventilation and treatment facilities. Do not forget about compliance with fire safety standards.

The financial side of the issue

The production of polymer-sand tiles over time will begin to bring stable high income. The main thing is to properly establish distribution channels.
Your potential clients:

• industrial enterprises,
• base building stores,
• building stores,
• private buyers.

But when will all the investments pay off?

Assume that the plant will produce 100 m 2 of finished material per day.
Let's present the profitability calculations in the table:

We have proven that the production of polymer paving slabs is profitable business with relatively fast payback. With the establishment of distribution channels, you will be able to ship all products to customers and receive consistently high profits.

Polymer sand tiles appeared on the domestic construction market recently. Such an innovation caused some distrust among buyers, but gradually polymer slabs proved their superiority over traditional pressed and cast concrete tiles.

Consider the main characteristics of polymer sand tiles, the technology of its manufacture, the scope and procedure for paving slabs on different types grounds.

Technology for the production of polymer sand tiles

When developing polymer-sand tiles, the technologists set themselves the task of creating a durable and frost-resistant material with a long service life. I must say that they succeeded and the performance characteristics of polymer sand tiles surpassed cement paving stones in many respects.

Park area paved with polymer sand tiles: photo

The working mixture for the manufacture of tiles consists of three main components:

• sand of medium fraction (no more than 3 mm);
• crushed primary polymers (secondary polymers can also be used - from an economic point of view, this is more profitable);
• dyes are inorganic pigments.

The main filler of the tile is sand, it makes up 75% of the total volume. Before use, it is thoroughly washed and sieved. After that, the sand is placed in a special oven and pierced at high temperature.

The entire production cycle of polymer sand tiles can be divided into the following stages:

1. Crushing or agglomeration of raw materials. If polymer chips are used, then this step can be omitted.
2. Mixing sand, polyethylene chips, dyes and additives.
3. Melting of raw materials in an extruder at a temperature of 250°C.
4. Pressing polymer-sand mass and forming ready-made plates.
5. Product packaging.

For the manufacture of plates used modern automated equipment. The product at the output is dense and homogeneous, there are no internal and external cracks or voids throughout the entire array of material.

Technical characteristics of polymer sand paving slabs

Specifications tiles depend on the quality of the raw materials used, the structure of the working mixture and production equipment. However, one can distinguish General characteristics polymer sand paving slabs:

Advantages and disadvantages of polymer sand tiles

The combination of a polymer component with a sand filler causes a number of advantages of laying and operating paving slabs:

The disadvantages include the peculiarity of polymer products - under the influence of high temperatures, the material tends to expand. If the paving technology is not observed (the gap between the plates is less than 5 mm), then the coating may deform in the hot season - some elements will begin to warp and protrude.

Scope of polymer sand tiles

Polymer sand tiles are in demand among professional builders, summer residents, owners suburban areas and private houses.

Paving slabs based on polymers and sand are used in the arrangement of:

Polymer sand tiles can be produced in the form of tiles for roofing. In addition, there is a facing tile made of polymers for finishing the facades of the building.

Overview of manufacturers of polymer sand products

On the market, a range of polymer sand products is presented large quantity domestic and foreign companies. Among Russian manufacturers of polymer-sand tiles, Namus LLC, Prompolimer LLC, SibTopProm-14 CJSC, Budprom-Technology Private Enterprise and Polimerika LLC have won a good reputation.

OOO "Namus"- a major manufacturer of polymer-sand products. All products of the company are tested in accordance with GOST 3634-99 before being delivered to the market. The main production is located in Tatarstan, and there are branches and sales offices in different cities of Russia.

The polymer-sand tiles of Namus LLC are produced in the size of 330 * 330 mm, 35 and 20 mm thick, basic colors: green, light gray, chocolate and red. The texture of the tile can be of three types: "parquet", "smooth" and "8 bricks". The cost of paving polymer-sand tiles is about 500 rubles / m2.

In addition to tiles, Namus LLC produces from a polymer-sand mixture: curbs, gutters, well rings, speed bumps, pedestrian crossings, drainage trays, cable protection plates, monuments and storm water inlets.

Company group "Prompolymer", founded in 2006, manufactures products for various market segments: polymer sand products, building metal structures and soft packaging.

The tiles are produced in sizes 330*330 mm, 20 and 40 mm thick. Forms of paving slabs: smooth, broken stone and rhombus. The price of a tile is from 350 rubles / m2. The quality of polymer-sand products "Prompolimer" is confirmed by the sanitary and epidemiological conclusion.

Company ZAO SibTopProm-14(Tyumen) appeared on the market of polymer-sand products recently - in 2012, but already competes with experienced manufacturers.

Paving slabs are available in four basic colors: red, brown, gray and green. Plate dimensions 330*330 mm, thickness - 20, 30 and 35 mm. Paving slabs are produced in three grades - depending on the quality of the feedstock. The cost of tiles of the first grade is 490-620 rubles / m2, the second grade - 430-510 rubles / m2.

LLC "Polymerika" (Yaroslavskaya oblast) specializes in the production of polymer-sand tiles and paving slabs. The company's products have been tested for UV radiation, checked for compliance with sanitary and epidemiological standards and radiation safety indicators. Each research is confirmed by the corresponding document.

Paving slabs are produced in the size of 330*330 mm, thickness - 25, 30, 35 and 40 mm. Types of textures: smooth, parquet, curly and paving stones. The price of tiles is 495-630 rubles / m2 (the cost depends on the thickness of the plates).

Tips for choosing high-quality polymer paving slabs

When choosing a polymer-sand tile, you need to pay attention to the following parameters:

Foreign inclusions on the plates indicate the use of poorly processed or low-quality raw materials, white stains are the result of non-compliance temperature regime. The quality of such polymer-sand tiles deteriorates significantly, the strength and durability of the material decreases.

Do-it-yourself polymer sand tile laying

Paving of polymer-sand tiles can be carried out on a sand cushion, crushed stone or on concrete screed. The choice of base for installation depends on the type of soil and the purpose of the paved area.

Laying on sand is used in the arrangement of garden and walking paths, sidewalks. If there is heaving soil on the site or the site will be used for parking cars, then the slabs must be laid out on crushed stone. Installation on a concrete screed is carried out when the tile will be used to receive heavy vehicles.

Preparatory activities

To work, you will need the following tools:

• crowbar, shovel and jackhammer - to remove the old coating and excavation;
• trowel, bucket;
• rubber mallet;
• cord and wooden stakes for marking the site and controlling evenness;
• building level;
• rake;
• concrete mixer - if the tile is laid on a concrete screed;
• mop and broom - for filling sand into the gaps between the plates.

The initial preparation of the soil does not depend on the further method of laying the tiles:

Further actions will depend on the type of flooring - sand, gravel or concrete.

Sand paving technology

Work sequence:

The procedure for laying tiles on gravel

After the “bed” for the site is prepared and the curbs are set, the following work is performed:

1. Pour a layer of crushed stone 10-20 cm onto the leveled surface and level it, adhering to the selected slope.
2. Tamp the rubble with a rammer.
3. Pour a dry cement-sand mixture over the rubble (layer thickness - 5-10 cm).
4. Level and compact the surface.
5. If significant loads are planned on the paved area, then it is advisable to lay a reinforced mesh before installing the tiles.
6. Lay the tiles, keeping the gaps - about 5 mm.
7. Level the surface with a rubber mallet. Slopes to control the building level.
8. Fill the joints with a dry cement-sand mixture (ratio 1:5) and moisten.

Gravel paving technology produces a durable surface that can support the weight passenger car

Installation of slabs on a concrete base

First stage this method similar to those described above: the soil layer is removed, the surface is leveled and curbs are installed. Next, perform the following steps:

1. Pour a layer of gravel or crushed stone over the entire area (thickness - 20 cm), tamp.
2. Make a screed of concrete, taking into account the slope of the surface. Screed thickness - 5-10 cm.
3. Paving slabs are laid on a cement mortar grade M-150 (the proportion of cement and sand is 1: 3). Instead of this solution, you can use tile adhesive - this method is more reliable. tile adhesive In this case, it is recommended to connect with cement mortar in a ratio of 5:1.
4. Until the solution has completely dried, the platform cannot be loaded and used.
5. After the "setting" of the solution, sprinkle the surface of the site with sand and fill the seams between the plates.
6. Moisten the site and wipe the seams with a cement-sand mixture.

Every year there are new and new technologies that improve the properties of familiar materials. Polymer-sand tiles are the product of such innovations. The product is universal in use, practical, durable and competitive from a financial point of view.

Proposed technology and equipment for the production of polymer-sand tiles will cause increased interest, especially managers industrial enterprises, which have not resolved the problem of recycling polymer waste obtained in technological processes and stored for years in the "backyards" of enterprises and industrial dumps. The uniqueness of this technology lies in the fact that as a binder, instead of traditional cement, waste polyethylene of low and high pressure, used polymers, including those that are not suitable for recycling in the traditional way.

The total cost of a set of equipment 1 856 000 rub. excluding VAT and transport costs. Commissioning works are paid additionally and amount to 3% of the total cost of equipment. Staff training is included in the cost of the equipment.
The payback period of the equipment is from 6 months, depending on the shift work, load, cost Supplies and other indicators (feasibility study is available upon additional request).
Delivery is carried out by rail or by road, the volume of the equipment set is no more than two 20-ton containers (depending on the configuration).

At the request of the customer, we additionally supply molds for ridge elements, various kinds roof tiles, paving and facing tiles, molds for individual orders. It is also possible to supply an insulated production hangar. The equipment manufacturing time is 2-3 months (depending on the configuration) from the moment the prepayment is credited to the Supplier's account (to be agreed additionally).

The main feature of the proposed new production technology sand-polymer products is a fundamentally new approach to obtaining a press mass for their manufacture. The resulting product has higher performance than traditional sand-cement products. According to the technology widespread throughout the world, the press composition of the closest analogue of sand-cement products is made by mechanical mixing of two components of river sand or screening of crushed stone production and a binder. The properties of this composition are determined only by the degree of surface interaction between the particles and the binder. At the same time, the binder is quite expensive and environmentally unsafe. In the proposed technology, polyethylene waste and river sand, which are usually not used in other technologies, serve as raw materials. The original development includes technological methods, at which the physicochemical interaction of both components occurs with simultaneous mutual influence on the structure of each other. By controlling the degree of this interaction (by changing the technological parameters), a whole range of sand-polymer composite materials is obtained, the properties of which vary over a wide range (from properties close to those of concrete to the properties of plastics). New products are environmentally friendly. Sand-polymer compositions make it possible to obtain a new range of products with a wide range of colors applied to roofing, facade finishing, sidewalk paving, etc. Depending on the technological equipment used, it is possible to manufacture products in a wide range of sizes and shapes at the request of the customer. Directly in technological process products can be given a curvilinear shape, it is possible to manufacture profiled surfaces. Products can be subjected to any kind of mechanical processing without compromising environmental cleanliness. The surface of the products allows any additional types finishes, including painting, varnishing, enameling, etc. The use of cheap waste of substandard polyethylene (or waste of its processing) makes it possible to ensure the low cost of the developed materials in relation to the cost of traditional products. Thus, the new technology, according to which the "know-how" is offered, belongs to the category of environmentally friendly resource-saving technologies. New technology can be implemented at small businesses and in particular at enterprises for cleaning landfills, waste processing chemical industries, and any industries where there is polyethylene waste. There are no disadvantages inherent in sand-cement products in PPM, since the used initial components and processing methods provide conditions for the full flow of the process, as a result of which they turn into a material with hydrophobic properties and improved physical, mechanical and operational characteristics. PPM due to its properties can have a wide variety of applications. The high hydrophobicity of the surface and resistance to rotting make it possible to use PPM for cladding the exterior surfaces of buildings, as roofing, and also makes this material indispensable in cottage construction, pallet making, etc.

Weight characteristics of polymer-sand building materials

Note: polymer sand tiles cannot be used in foundry and welding production. The "combustibility" parameter is regulated by the composition of the thermoplastic composite from G2 to G4.

Order this item

The Rostpolyplast company is engaged in the production and sale of such products as plastic paving slabs, which will always decorate your yard in any weather, and the price will not disappoint you, as it is available to all customers.

Polymer sand paving slabs are durable and strong. Unlike vibropressed concrete, polymer-sand tiles are almost impossible to split. High heat resistance, frost resistance, durability, excellent appearance, various colors!

The characteristics of polymer-sand paving slabs are many times superior to vibropressed concrete paving slabs.

Polymer sand paving slabs. Concrete vibropressed tile.

Comparative characteristics of polymer-sand paving slabs

Comparison of our polymer and concrete tiles

Polymer sand paving slabs

Given the relatively low weight of polymer sand paving slabs, the cost of transporting a large volume of products is significantly reduced. The combination of all properties makes it possible to use it in conditions of places of mass attendance (both outdoors and indoors). internal application). This is the best way for covering areas of recreation areas (parks, cafes, etc.).

The tile production technology ensures full repeatability of sizes, shapes and colors, so with the help of such tiles you can reproduce any geometric, color combinations. The result obtained is an order of magnitude superior to the use of conventional tiles, both in terms of appearance, as well as operational parameters.

Indeed, polymer sand paving slabs are much more durable, more resistant to external environment than normal. Especially if it is an urban environment, where there must be resistance to abrasion, high mechanical stress, the effects of oils and acid-containing liquids, hardness and strength, resistance to point splitting, and many other indicators of reliability.

The theoretical (calculated) durability of the polymer sand material exceeds 150 years, and in terms of color stability, the tile does not lose the color of the pattern forever. Its coloring with modern dyes that do not fade even under direct sunlight is carried out to the entire depth of the material.

An important feature is the absence of dust emission from the surface of the coating (which is typical for other materials) and fumes in the hot season. Even under the scorching sun, the coating does not “gas” with carcinogens, like the same asphalt. Polymer-sand paving slabs are easy to clean, are designed for repeated use, and make it easy to repair, disassemble and re-lay individual sections of the coating.

Technologies do not stand still, but at the moment, among paving surfaces, polymer sand tiles are the most cost-effective and durable material that is versatile in use due to its unique properties.

5 reasons to buy our polymer sand tiles:

• Your yard, playground, paths will always look beautiful, well-groomed, clean!
• The area paved with our polymer sand tiles withstands significant loads, great for industrial premises, car washes, car parks, etc.
• Durable, beautiful, safe coating for long long years! The service life of polymer sand tiles is more than fifty years.
• You save on the transportation of tiles, because. It's lightweight and easy to stack!
• Our polymer sand tiles consist exclusively of environmentally friendly clean materials: river sand, polymers, mineral dyes!

Black	400 rub/sq.m
Gray	600 rub/sq.m

The production of paving slabs by our company is carried out on modern and professional equipment and is based on the needs of customers. The order of production is carried out in any volume and quantity. The cost of polymer sand tiles can be clarified by contacting our specialists.