One million rubles in the production of polymer-sand manholes. Polymer sand paving slabs: composition, application, technical characteristics

Polymer-sand products are products made using waste polymers ( plastic bags and PET bottles).

Is it profitable to engage in this production and how quickly will it pay off?

The main forms of polymer-sand products are facing and paving slabs, curbstone, shingles and occasionally manholes.

Polymer-sand products have a number of useful properties:

high impact resistance (compared to cement-sand products) - they do not break during installation and during transportation;

durability - their service life exceeds 100 years;

lightness - polymer-sand products are two times lighter than cement-sand analogues;

cheapness;

not spreading flame and electricity;

impact resistance external environment- they withstand temperature fluctuations from -60 to +200 degrees, are resistant to ultraviolet radiation, absorb sound well, and this is their advantage over metal roofs. Polymer-sand tile does not absorb moisture, washes well, does not accumulate snow, and retains its original color for up to 30 years.

In Europe, these are ANDERA polymer-sand tiles, which have received recognition at various exhibitions and the approval of the Swedish Consumer Association (SVK).

The production technology of polymer-sand materials is very simple. They are made up of polymer sand and dye. The ratio for tiles is 24/75/1, for paving slabs - 5/94/1.

For work, you will need soft (bags, plastic wrap) and hard (polystyrene, polypropylene, PET bottles) polymers. Their ratio is 50/50. Do not use rubber and refractory polymers - polycarbonate, fluoroplastic.

Raw materials for business can be found in a regular landfill or recycling centers. You can buy sorted and cleaned waste, but it will cost much more, and there is no great need for this, because paper and food waste burn out and will not have any effect on product quality.

1 ton of untreated waste on average in Russia - 3 thousand rubles.

As a filler for finished products sand is used. The moisture content of the sand should not exceed 10%, and the clay content should not exceed 20%. Permissible fraction - up to 3 mm.

1 ton of sifted dry sand costs an average of 300 rubles in Russia.

The third component is Bayerferrox dye (Bayer). Its average cost is 90 rubles/kg. If you work without dye, then the finished product will have a gray color (curb stone, paving slabs).

Main steps technological process:

Crushing of polymeric waste. We use the apparatus - polymer crusher PT 2003.00.000 (capacity 900 kg/h).

The resulting mass is placed in an extrusion machine (Extrusion machine PT 2004.00.000 with a capacity of 85 kg / h), where the polymers are heated and mixed. The finished mass cools down and the slightly hardened conglomerate is again placed in a crusher to obtain an already fine homogeneous fraction up to 10 mm.

The resulting polymer mass, prepared sand and dye are mixed and poured into a melting and heating unit (APN PT 2002.00.000 with a capacity of 250 kg / hour). This stage is the most important, mixing, heating the mass and enveloping each particle of sand with a polymer takes place here. This is achieved by a peculiar design of the shaft, the blades of which move the mass with different speed in three heating zones, and this leads to high-quality mixing of the mass.

The resulting mass of the consistency of a tight dumpling dough is placed in a molding press, where the mass is put into molds, and under pressure (250 tons) it is cooled. To obtain paving slabs, the mass is cooled evenly. To obtain a tile, to give it a shine, the lower part of the mold is cooled faster than the upper one.

The average capacity of such a production line is 100 square meters. m per day (two working shifts of 8 hours).

For production, you will need a room with an area of 150 square meters. m with forced ventilation. Ceiling height - 4 m. Renting such a room will cost you an average of 15 thousand rubles per month.

Since the products and equipment are original and non-standard, certificates and licenses for production are not required.

Calculations for 100 m2 of products:

polymer 520 kg x 3 r / kg = 1560 rubles

sand 1580 kg x 0.3 r / kg = 474 rubles

dye 12.5 kg x 100 r / kg = 1250 rubles

electricity 25 kW x 16 hours x 1.8 r / kWh = 720 rubles

salary - 8 people for 8000 rubles. \u003d 64,000 rubles per month: 30 \u003d 2133 rubles

water supply - 100 rubles per day

room rental - 15000: 30 = 500 rubles per day

transportation costs - 300 rubles per day (calculated individually).

The total cost of 100 m2 of finished products will be 7037 rubles.

The cost of the finished product to different manufacturers 250-400 rubles per 1 sq. m. To prove yourself and enter the market, you need to take the lower price - 250 rubles per 1 sq.m. Therefore, 100 sq.m. we will sell for 25 thousand rubles. net income minus the cost - 17963 rubles. per day.

The average cost of a production line of polymer-sand materials (for different manufacturers) is 900,000 rubles + 100,000 for transportation.

Therefore, the payback of the line with an average workload and work in two shifts is 1,000,000:17963 = 55 working days (3 calendar months).

However, by purchasing a set of drawings for the production of equipment, the payback period can be significantly reduced. For example, we purchase a complete set of drawings with all modifications of units for the production of the entire line here: www.polimercherepisa.narod.ru

Next, place an order for the manufacture of all equipment according to the purchased drawings at any tool factory or machine-building plant In your city. The production time of the entire line depends on the capacity of the plant and, as a rule, does not exceed 2 months, and at the same time, its production will cost us no more than 200 thousand rubles.

Let's calculate the payback: (200,000 + 20,000 for the drawings): 17963 = 12.2 work. day.

That is, the payback period when choosing this method of obtaining equipment will decrease by almost five times.

Thus, it is extremely profitable to produce polymer-sand materials and starting a business is quite simple. In addition, the production of polymer-sand products is an effective solution to the problem of plastic waste.

Good luck in building your business!

Based on the article by Serik Ainurov for the project www.polimercherepisa.narod.ru

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 run 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. The cost of all the necessary components, if purchased directly from the manufacturer, is 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 waste.

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 a 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 excessive pressure. 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 has a special cooling system. The configuration of these forms will depend on the type of products you plan to produce. If production is limited to tiles, then you won't need a wide variety of 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 quality products, you will have to spend at least 1,200,000 rubles. 3 people per shift will be able to serve the line of low productivity.
To accommodate the machines, you will need a room of 100 m 2. Given that you have to work with polymers, good ventilation and treatment facilities should be provided here. Do not forget about compliance with fire safety standards.

The financial side of the issue

The production of polymer-sand tiles will eventually begin to bring a consistently 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 a profitable business with a relatively quick payback. With the establishment of distribution channels, you will be able to ship all products to customers and receive consistently high profits.

Technology for the production of polymer-sand products

Polymer sand tiles and paving slabs - production technology
Preparation of raw materials (waste polymers and sand)
All the improbability and uniqueness of this technology is that the raw materials used in the production of polymer-sand tiles are free of charge, lying around underfoot. This is polymer waste various types: packaging, plastic containers, worn-out household items. A shortage of raw materials is not expected, but on the contrary, the volume of polymer waste will only grow, and the need for it will only increase.
Of course there are efficient technologies their processing, allowing the use of polymers reused. As a rule, careful sorting of waste plastics, their washing, drying is required. These are expensive and time-consuming processes. And the quality of recycled raw materials is low, and does not allow using it 100% instead of the original one.

The proposed technology for the production of polymer sand tiles from polymer waste does not involve cleaning and deep sorting of raw materials. It is only proposed to adhere to the ratio of 40-50 / 60-50 of the so-called soft (polyethylene) and hard (polypropylene, polystyrene, ABS plastics, PET, etc.) polymers. In this ratio, the waste is in landfills.
Refractory polymers (polycarbonates, fluoroplasts) and rubbers are NOT suitable. Fusible, such as PVC, can partially burn out, but this does not affect the quality of polymer sand tiles. Impurities (paper, food waste) also burn out, moisture evaporates.

In addition to waste polymers, sand is required in the production of tiles. It is used as a filler and must be dry, sifted without clay and dust inclusions. It doesn't matter what color the sand is and where it came from. Permissible sand fraction up to 3 mm. Another filler, more available in the selected area, can also be used. So this incredible new technology obtaining building materials from free raw materials.

Pre-processing of raw materials.
At the first stage, the selected and sorted plastics are crushed in a crushing machine. It is desirable to have a 50/50 ratio of hard and soft polymers.
For example: polyethylenes behave better at negative temperatures and it is easier to get a gloss on a product, but “hard” polymers will add rigidity and strength when heated in the sun. It is better and more convenient to work with granulate or polymer of the same brand. It turns out geometrically even and regular tiles.
Polymer-sand tiles are obtained the better, the more evenly mixed polymers and sand. No need to pre-clean waste plastics. The only pest may be engine oil that comes in with canisters. But its quantity, as a rule, is insignificant, does not affect the quality of the tile, and if it appears as a stain on the tile, it disappears during re-processing. The remaining impurities burn out. In the future, building materials from a polymer sand mixture are resistant to oils and other chemicals. products.

Preparation of polymer sand mass
After the first grinding, the waste plastics enter the extrusion machine, where they are mixed under heating. Any chemist will say that it is impossible and unscientific to mix dissimilar polymers; It's like mixing kerosene with water. But such a task is not set - to mix polymers at the molecular level, it is enough to mix plastic waste using the viscosity properties of molten polymers.
Polyethylene and polypropylene films occupy a large place in the structure of polymer waste. They are added to the extrusion machine without grinding.
The resulting polymer-sand mass with the consistency of yeast dough is removed by the operator with a mitt at the exit of the extrusion unit of the line, and, having rolled a ball (agglomerate up to 100 mm.) with his hands, throws it into the water for cooling. Taken out of the water, not completely cooled, but already hardened, the agglomerate dries quickly, cooling down.
It happens that the polymer mass overheats, and it flows out of the extrusion machine onto the floor until the operator turns off the heat. Cooled such a mass, then suitable for use. The entire cooled agglomerate is subjected to repeated grinding into chips with a fraction size of up to 1-10 mm. Thus, a ready-made raw material for the polymer-sand mixture is obtained.

Obtaining polymer sand mass and molding tiles
This stage of tile production is the final one. Some separate it from the harvesting area, located in a separate room. In addition to aesthetic considerations (the preparation of an average polymer mixture is accompanied by the release of gases, and requires the provision of an exhaust), there are also practical benefits: it is easier to control and account. And in cases of work in correctional institutions, it is simply necessary because of the security of the enterprise.
The mixing of sand, polymers and dyes takes place in a thermal mixing unit (Melting and Heating Unit). It is important to keep the mass of the mixture in the APN constant, adding new portions as the finished mass is consumed. The crushed polymer-sand mass is mixed with sand and dyes in different proportions, depending on the products being manufactured. For, for example, tiles, this ratio is: 24/75/1, and for paving slabs it can be 5/94/1.
The ratio of sand and polymers also affects performance - the mass that has more sand in its composition will take longer to heat up.
This property should be taken into account when calculating the cost and accounting for products.

It is important to obtain a high-quality mixture - sand particles must be completely enveloped in polymers, without gaps. This is achieved by a unique shaft design calculated empirically. More precisely, not calculated, but tortured by experimental designs and scientific research. As a result, the blades on the shaft are located in such a way that when the shaft rotates, the mass advance rate is different in 3 heating zones, which ensures complete polymer melt and high-quality mixing with the filler.
By the way, in this node we see some design flaws, the change of which leads to an increase in the productivity of the entire line.

Thus, the resulting polymer-sand mass with an outlet temperature of about 170-190 degrees and the consistency of a tight dumpling dough is squeezed out of the machine after the damper is opened. The operator cuts off the required amount with a knife, weighs it on the scales, and having received the right amount (about 2 kg.), Puts it into the mold with an ordinary scoop.
The form, mounted on a press with a movable bottom plate, is cooled in different ways.
The upper part has a temperature of about 80 degrees, and the lower 45, or cooled as much as possible, for the fastest formation of tiles (30-50 seconds).
This is done to create a gloss on the outside of the polymer sand tiles, as if the polymer is squeezed up, filling the pores between the filler.
This is another secret of technology. Although such uneven cooling can lead to the bending of the tiles, for which it is placed on the cooling table and pressed with a load until the final molding.
To obtain a matte surface of polymer-sand tiles, it is enough to cool the upper mold as much as the lower one. This is applied to the production of polymer-sand paving stones. The dye may not be added, and the product turns out to be gray in color, like concrete.

Product range
Depends directly on the availability of additional forms. Of course, makes the business competitive. Market building materials not saturated, and while some manufacturers in the season only sell tiles for months ahead. And you can produce a wide range of goods for construction: tiles, trays, bricks, fixed formwork elements, manhole covers for wells. Laid, e.g. on the basement floor, a chemically resistant polymer sand tiles will also carry the function of waterproofing.

Problems arising in connection with the production of building materials from a polymer sand mixture
By premises
Equipment manufacturers recommend using rooms of 150-300 m2. The dimensions of the equipment for the production of tiles are small, and will allow it to be placed on smaller areas - about 50 m2, but you still need to have a place for storing raw materials and finished polymer tiles. The recommended ceiling height is 4 meters. The press has a height of 1780 mm.

By raw material
If raw sand is used, then during the heating process, gases will be released, leading to pore formation in the product, which is highly undesirable. Large inclusions can also lead to a loss in the quality of tiles, wear of the forming tool. It is necessary to avoid the ingress of machine oil into the polymer-sand mixture, metal inclusions.

Other
In general, the produced tiles are not subject to mandatory certification, as well as equipment, since it is non-standard. But here are the requirements for the premises, labor protection and environment may be presented. It is necessary to establish control over the quality and accounting of products.
There is a danger of equipment failure when starting the engine. The screw cannot rotate in a polymer or polymer sand mixture that is not heated to the plasticizing temperature.

Equipment for the production of polymer sand tiles
The capacity of the proposed lines allows to produce about 40 m2 of polymer-sand tiles per shift. All equipment is serviced by 7 people. In one square meter 9 tiles including overlap, weight 1 m2 - 20 kg. Power consumption 26-28 kW/h, installed power 42 kW, three-phase power supply.

Waste crusher
The crusher used in the line can be replaced by any other crusher used in the production of polymers and products from them. Crushes waste into fractions up to 30 mm. and agglomerate up to 10 mm. Engine installed, 3000 rpm. Productivity is high, sufficient to provide 3 lines with polymer raw materials.
dimensions: 1000x1100x1200 (WxDxH) Weight 420 kg.

extrusion plant
It differs from traditional ones in that the volume of the zone of heating and plasticization of polymers changes by changing the outer diameter of the working cylinder. It is justified by the ease of manufacture, and the task that is set is to mix the plastics by heating.
The disadvantage of the design is frequent congestion of the mass at the place of change in the diameter of the working cylinder, which leads to overheating of the mass, a delay in the loading of polymers. Heating elements are used as heating elements, which are easily changed in case of failure. The shaft is centered by the polymer mass at the exit, has a low rotational speed. A design flaw is the non-installed thrust bearing, because a linear load also acts on the shaft. The performance is sufficient to ensure the operation of 2 presses and thermomixing units.
Dimensions: 520x3300x1230 (WxDxH) Weight 580 kg.

Thermal mixing plant (APN - melting and heating unit)
Unique knot throughout the line. To achieve a high-quality mixture of polymer and sand, the loaded mass passes at different speeds and with different heating modes through the pipe. A shaft with blades arranged in a special way was installed, and their location often changed to achieve high-quality mixing of the polymer sand mixture. The shaft has a large load, including linear, and the thrust bearing is not installed. Auger blades wear out quickly.
Two temperature control devices are installed in two mass heating control zones. Works continuously, ensures the work of one press.
Dimensions: 520x3200x1230 (WxDxH) Weight 800 kg.

Press
Small hydraulic press with movable bottom plate. 4 hydraulic cylinders dia. 125 mm., stroke 300 mm. Working pressure 10 MPa. A matrix with cooling and ejectors is installed on the bottom plate. Moreover, the temperatures of the matrix and punch are different, which is achieved by two different cooling circuits.
The press is equipped with a hydraulic station, tanks for cooling the coolant. The productivity of the line depends, among other things, on the productivity of the press, the cooling rate and the molding of the product. The components used in the manufacture of the press are available if they need to be replaced. Overall dimensions: 2600x1500x1780 (WxDxH) Weight 1300 kg.

Additional forms for the manufacture of paving slabs, tiles, paving stones and much more
A large selection of molds is offered, allowing the production of an expanded range of products, thereby making the business competitive. At the very least, paving slabs are required in the kit.

LINE FOR THE PRODUCTION OF POLYMER SAND PRODUCTS

The line for the production of polymer-sand products (hereinafter referred to as LPPI) is intended for the manufacture of polymer-sand products (sewer hatches, GTS hatches, tiles, roofing elements of varying complexity, paving slabs, road curbs, posts, road and sidewalk gratings, MAF, etc.)

Thus, LPPI is equipment for the production of polymer sand tiles, equipment for the production of polymer sand tiles, equipment for the production of polymer sand hatches, equipment for the production of various other polymer sand products.

Compared to traditionally used cement paving slabs and ceramic tiles, polymer sand products have a number of unique properties. They are twice as light, have almost zero water absorption, are more than twice as strong in bending, have excellent frost resistance (more than 150 frost cycles), and have low abrasion, which is especially important for paving slabs.

Purpose

PURPOSE OF THE LINE FOR THE PRODUCTION OF POLYMER SAND PRODUCTS LPPI:

The line for the production of polymer-sand products (hereinafter referred to as the line) is intended for the manufacture of polymer-sand products (tiles, roofing elements of varying complexity, paving slabs, road curbs, road posts, sewer manholes, HTS hatches, small architectural forms, road construction elements, TOTAL MORE THAN 20 TYPES OF PRODUCTS AT THE DESIRE OF THE CUSTOMER, etc.).

The raw materials for the production of polymer-sand products are primary polymers, secondary polymer raw materials and polymer waste: polyethylene waste, used polyethylene film, polymer waste, secondary polymers, various polymers (PET, PVD, PVC, HDPE, PP, PS) and plastics obtained in sorting and selection municipal waste, as well as sifted sand and pigments dyes.

Advantages of equipment for the production of polymer sand products and the selected technology:

Availability of cheap secondary polymer raw materials (bags, greenhouse film (used), industrial waste from polymer production).
Ability to work in a long production cycle (2-3 shifts).
Manufactured products in the production process can be painted in any color at the request of the Customer.
High level of profitability, not less than 100%.
Small staff of workers.
Small footprint, compact placement possible.

Part of the equipment

THE STANDARD PACKAGE INCLUDES:

Sand heating plant with overpass(designed to heat sand):

Overall dimensions: 3000x3400x3100 mm
Heating power: 19.2 kW
Sand volume: 0.13 m3
Hopper weight (without sand): 400 kg
Productivity: 150-250 kg/h

Polymer concrete mixer(designed for a mixture of sand and polymers and extrusion of the finished mass):

Overall dimensions: 3500x900x1400 mm
Engine power: 15 kW
Heating power: 12.5 kW
Weight: 907 kg
Productivity: 150-500 kg/h

Press 100 t/s(one for all product molds, designed for pressing the polymer-sand mass into finished products):

Overall dimensions: 2200x1450x960 mm
Weight: 2.5
Drive: 4 kW
Pressing force: 60-100 t/s

Switchboard(designed to control the technological equipment of the line):

Overall dimensions: 660x510x1900 mm

Agglomerator of polymeric materials:

Overall dimensions: 1200x620x1600 mm
Engine power: 18.5 kW
Weight: 450 kg
Productivity: 150-200 kg/h

Designed for grinding polymer film waste and obtaining an agglomerate suitable for further processing in extruders and injection molding machines into finished products.

Shredder of polymers and films(designed for grinding polymers for further production of a polymer sand mixture):

Overall dimensions: 1325x1156x1843 mm
Engine power: 15 kW
Weight: 1 t
Productivity: 180-200 kg/h

Press forms- according to the catalog of molds.

Received products: tiles, roofing elements of varying complexity, paving slabs, road curbs, road posts, sewer manholes, small architectural forms, elements of road construction.

A photo

Sand heating plant:

Polymer concrete mixer:

Switchboard:

Shredder of polymers and films:

Products

Below are some samples of products obtained on the production line of polymer sand products: polymer sand tiles, tiles, hatches.

Video

Line for the production of polymer sand products in operation.

Frequently asked questions about polymer sand products

How long has polymer-sand tiles been present on the Russian market?

For the first time this finishing material appeared in the early 2000s, when in Russian production imported technologies for the manufacture of composite products from a half-sized sand mixture (sand, polymer, pigment) began to be introduced. From now on, the products of this commodity group are confidently leading in the implementation of various projects, seriously competing with analogues made of concrete and metal. Our company has been working in this direction since 2007, which allows us to talk about serious experience in the production of polymer sand products. According to our data, finishing materials in this category are trusted by an increasing number of users who have been able to appreciate the numerous advantages of polymer pavement in practice.

What is the scope of polymer sand paving slabs?

Polymer sand tiles can be laid on almost any area - sidewalks, garden paths, industrial premises, service stations, livestock complexes, including private garages. At the same time, the scope of use is not limited to climatic conditions. A necessary condition for the installation of a polymer functional decor in areas with an increased weight effect is the presence of a concrete base on which a sand cushion is installed.

How to pave a porch with polymer tiles?

When installing tiles on the porch, it is recommended to use a metal corner as a fixing limiter. Otherwise, the process is similar to the usual installation on a cement-sand base, followed by filling the joints with a dry cement-sand mixture. The allowable seam size is 6-8 mm.

How to lay tiles on a plinth and an exploited flat roof?

At installation work of this type, special supports are used to support piece elements. In order to lighten the weight of the structure, the tiles are laid on a layer of fine gravel, which is installed directly on the roof waterproofing.

Is it advisable to install polymer paving slabs in car washes?

In this case, there are risks of washing out the fillings of tile joints, which sooner or later will lead to surface deformation, so it is better to use tile adhesive. At the same time, the tile can be successfully used for paving car services and parking lots as a chemically passive material with high climatic resistance.

How to cut polymer tiles?

With the help of the usual "Bulgarian". Moreover, in this case, there will be much less dust and waste than when sawing a concrete analogue.

How do polymer tiles react to the main climatic factors?

Due to the extremely minimal porosity and low water absorption coefficient, the use of this road decor, unlike ordinary paving stones, does not deform under the influence of rain and cold weather.

Equipment for the production of polymer sand products

At the same time, polymer tiles perfectly withstand critical heat, practically without fading under the influence of active ultraviolet radiation.

What weight loads are polymer tiles designed for?

It all depends on the thickness of the piece decor. Terrace tiles 22 mm thick are designed for paving pedestrian pavement and landscape areas for a wide range of purposes. Paving slabs with a thickness of 35 mm can easily support the weight of a truck.

What are the environmental characteristics of polymer sand tiles?

This finishing material is made from three main components - natural sand, polymer (stretch and PVD) and coloring pigment. The last two components have the highest environmental safety, which is reflected in the relevant certificates. And the ecological cleanliness of the prepared sand does not raise questions.

Is it possible to reuse polymer paving slabs in other areas?

This high-end travel décor is not deformed even after prolonged use. Therefore, dismantling allows the tiles to be reused for finishing pavements of the appropriate specification. The created surfaces are highly maintainable, allowing you to quickly replace damaged piece elements without much labor.

What are the features of the operation of polymer sand paving slabs in the winter season?

Polymer tiles compare favorably with an anti-slip coating that provides good adhesion of the soles or wheels of vehicles to the working surface. Snow and ice are easily removed from the respective areas. At the same time, even accidental strong blows of a crowbar are not capable of fatally damaging piece elements that have an enviable impact strength. With any slightest thaw, the tile, like a small heat accumulator, immediately absorbs the necessary portion of heat, which contributes to the rapid thawing of the ice crust without outside interference.

How long does the color of the tile last with active solar exposure?

If the manufacturer conscientiously observes the technology for the production of polymer sand products, namely, the percentage ratio of the components of their quality. For example, if the production process does not save on pigmenting dye, the tile will look attractive throughout its entire service life (up to 25 years). Such priority is provided by the principle of production technology, which forms a combination of pigment with other components at the molecular level. That is, the color of the finished tile is its natural physical and chemical state.

As for pricing, in this case you can directly buy polymer sand paving slabs from the manufacturer without unnecessary trade margins.

How strong heating affects the strength of the tile flooring?

With active long-term exposure to sunlight, the tile can expand within the tile joints, that is, in a linear manner. Similar changes are included in technical conditions operation. Thus, there can be no talk of any serious deformation, and even more so of subsidence or “swelling” of the surface.

Can polymer tiles "swell" after installation during use?

Only in case of non-compliance with the laying technology - as a result of the wrong selection of components for the "cushion", the creation of too large or small seams, as a result of poor-quality tamping, etc. Subject to all technical recommendations (TR - 158-04) for the installation of sidewalks, there should be no problems with the operation of polymer tiles!

Production of polymer-sand tiles, paving slabs, hatches

Photo galleryDelivery Production Certificates

The raw materials used in the production of polymer-sand tiles are polymeric materials in various forms: packaging, plastic containers, household items. More and more goods are packaged in polymers, and the range of building materials made from plastics is growing. Raw material preparation

The proposed technology for the production of polymer sand tiles from polymer waste involves cleaning and deep sorting of raw materials. It is proposed to adhere to the ratio of 40-50 / 60-50 of the so-called soft (polyethylene) and hard (polypropylene, polystyrene, ABS plastics, PET, etc.) polymers. In addition to polymers, sand is required in the production of tiles. It is used as a filler and must be dry, sifted without clay and dust inclusions. It doesn't matter what color the sand is and where it came from. Permissible sand fraction up to 3 mm. Other fillers, more readily available in the locality, may also be used, but before commercial use, it is necessary to investigate its effect on product quality.

Pre-processing of raw materials

At the first stage, the selected and sorted plastics are crushed in a crushing machine. It is desirable to have a 50/50 ratio of hard and soft polymers. For example: polyethylenes behave better at negative temperatures and it is easier to get a gloss on a product, but “hard” polymers will add rigidity and strength when heated in the sun. It is better and more convenient to work with granulate or polymer of the same brand. It turns out geometrically even and regular tiles. Polymer-sand tiles are obtained the better, the more evenly mixed polymers and sand.

Preparation of polymer sand mass

After the first grinding, the plastic enters the extrusion machine, where it is mixed under heat. Any chemist will say that it is impossible and unscientific to mix dissimilar polymers; It's like mixing kerosene with water. But such a task is not set - to mix the polymers at the molecular level, it is enough to mix them using the properties of the viscosity of the melted polymers. Polyethylene and polypropylene films occupy a large place in the structure of polymeric materials. They are added to the extrusion machine without grinding. The resulting polymer-sandy mass with the consistency of yeast dough is removed by the operator with a mitten at the outlet of the extrusion unit of the line, and, having rolled a ball (agglomerate up to 100 mm.) with his hands, throws it into the water for cooling. Taken out of the water, not completely cooled, but already hardened, the agglomerate dries quickly, cooling down. The entire cooled agglomerate is subjected to repeated grinding into chips with a fraction size of up to 1-10 mm. Thus, a ready-made raw material for the polymer-sand mixture is obtained.

Obtaining polymer sand mass and molding tiles

This stage of the production of polymer sand tiles is the final one. Some separate it from the harvesting area, located in a separate room. In addition to aesthetic considerations (the preparation of an average polymer mixture is accompanied by the release of gases, and requires the provision of an exhaust), there are also practical benefits: it is easier to control and account. The mixing of sand, polymers and dyes takes place in a thermal mixing unit (Melting and Heating Unit). It is important to keep the mass of the mixture in the APN constant, adding new portions as the finished mass is consumed. The crushed polymer-sand mass is mixed with sand and dyes in different proportions, depending on the products being manufactured. For, for example, tiles, this ratio is: 29/70/1, and for paving slabs it can be 24/75/1.
The ratio of sand and polymers also affects performance - the mass that has more sand in its composition will take longer to heat up. This property should be taken into account when calculating the cost and accounting for products.
It is important to obtain a high-quality mixture - sand particles must be completely enveloped in polymers, without gaps. This is achieved by a unique shaft design, calculated by the "Polymer Technology" Orsk. More precisely, not calculated, but tortured by experimental designs and scientific research. As a result, the blades on the shaft are located in such a way that when the shaft rotates, the mass advance rate is different in 3 heating zones, which ensures complete polymer melt and high-quality mixing with the filler.
By the way, in this node we see some design flaws, the change of which leads to an increase in the productivity of the entire line.
Thus, the resulting polymer-sand mass with an outlet temperature of about 170-190 degrees and the consistency of a tight dumpling dough is squeezed out of the machine after the damper is opened. The operator cuts off the required amount with a knife, weighs it on the scales, and having received the right amount (about 2 kg.), Puts it into the mold with an ordinary scoop.

Price for polymer sand equipment

The form, mounted on a press with a movable bottom plate, is cooled in different ways.
The upper part has a temperature of about 80 degrees, and the lower 45, or cooled as much as possible, for the fastest formation of tiles (30-50 seconds).
This is done to create a gloss on the outside of the polymer sand tiles, as if the polymer is squeezed up, filling the pores between the filler. This is another secret of technology. Although such uneven cooling can lead to the bending of the tiles, for which it is placed on the cooling table and pressed with a load until the final molding.
To obtain a matte surface of polymer-sand tiles, it is enough to cool the upper mold as much as the lower one. This is used for the production of polymer-sand paving stones. The dye may not be added, and the product turns out to be gray in color, like concrete.

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NOT BUY FROM US IF YOU DON'T BELIEVE US!

Most manufacturers motivate the overpricing of their polymer-sand products by the high cost of high-quality raw materials. But this is correct only when the manufacturer does not have the equipment and production facilities for the preparation of polymer raw materials on their own.

Learn more about the production of polymer-sand products at Polisand.

NOT BUY FROM US IF YOU BELIEVE NOT US!

Time is running fast and everything around is changing. Now we all communicate through cell phones, although some 15 years ago it was an unaffordable luxury. You look out into the yard: on playgrounds, instead of wooden swings, in almost all yards there are brand new, "anti-vandal" children's attractions. Break them - don't break them ... They won't break anyway. New technologies make it possible to increase the consumer qualities of goods several times over.

Who would have thought that there would be paving slabs that do not crack from impacts, do not absorb moisture and are not destroyed by time? Over the past decade, we have become accustomed to the fact that new technologies bring relief to our daily work, speed up work processes and decisions, and improve the quality of life in general. And we are ready to take a chance and try to lay out the grounds and paths of our beloved dacha with new tiles, but ... only if it lasts long enough to justify the investment made. The only thing that holds back is the questions that arise before applying the novelty that has not been tested by time: what if it darkens or burns out in the summer? How will she survive the winter? Will it not split? And in general - the manufacturer writes only about positive qualities, what if it will be worse than classic cement? Suddenly it will be harmful, will it emit any odors or gases when heated?

We will try to answer the questions that inevitably arise from the buyer.

It is safe to say that any product in this category, manufactured conscientious manufacturer, different high quality and will last a long time. And one more thing: equipment for the production of polymer sand tiles is expensive.

Overview of machines for the manufacture of polymer sand tiles

And there are no cheap analogues. In a garage, you can’t make such a tile, unlike cement, using a artisanal method. And it will not be possible to greatly reduce the cost of technology through the use of low-quality cheap materials. By the way, high-quality concrete tiles are made only large companies, and it is expensive, and everything else that is sold in the markets and is cheaper, and will last less. That is, in most cases, the quality of polymer sand tiles should obviously be higher.

As for odors, it is necessary to refer to the composition of the polymer sand composite. Composition: quarry sand (75%), a mixture of plastics (25%): high and low pressure polyethylene (allowed for storage food products and absolutely safe plastics with marking and in the international system), and a heat-resistant dye. These components are heated at a temperature of 250 °C. These plastics are absolutely harmless and do not emit carcinogens into the atmosphere when heated. In addition, you need to understand that 75% of the product still consists of sand, and plastic is a binder.

In general, the presence of plastic as a binder (compared to cement - the binder of concrete tiles) gives advantages to polymer sand tiles.

Let's analyze all the properties in order:

+ Water repellency plastics give polymer sand tiles almost zero water absorption, and this extends the service life of polymer sand tiles up to 20 years without destruction. Polymer-sand tiles do not collapse in the thaw with sudden temperature changes. Recall physics: during the phase transition from a liquid to a solid state (ice), water increases in volume, which leads to the fact that water, having absorbed into the pores of the product, and then freezing, increases in volume and literally breaks the tile with high water absorption from the inside. That's why it happens that in the spring on a freshly laid last fall concrete paving stones and paving slabs are already showing signs of destruction. A polymer-sand tile is whole and dry.

+ The water resistance of polymer-sand products makes them attractive also because on the surface of products ice does not form in winter- the tile is absolutely non-slip, and the snow is easily removed with a shovel.

+ The low water absorption explains and increased frost resistance of the material(i.e. full freeze-thaw cycles in a state of full moisture saturation) - more than 500 cycles.

+ Plastic is lighter than concrete, so polymer sand products 3-4 times lighter than concrete(This allows for easy loading/unloading, hand-carrying along the track or track). This property enables our customers to independently organize the delivery and laying of garden paths, blind areas, porches and burial sites. This property of the polymer-sand material was quickly appreciated by electrical installation companies - a plate for closing a cable made of a polymer-sand composite completely replaced a brick for protecting 0.4-35 kV cable lines in two or three years from the moment of its invention.

Anyone who has ever tried "in work" products made of polymer sand composite no longer refuses them - their use is very convenient and affordable.

+ The presence of polyethylene in the composition gives products unique impact resistance– plastic is a more elastic and astringent material, which gives advantages in load tests. Polymer sand tiles 20 mm thick withstand the load of pedestrian areas, comparable to the load on concrete tiles or paving stones 40 mm thick! In addition, it refers to "anti-vandal" materials - such material can only be split with considerable effort. Polymer-sand tiles do not break during cargo transportation and when falling.

+ The plastic envelops every grain of sand and paint in the mixture and, when melted, provides uniform coloring throughout the product. In addition, the coloring ability of plastic is higher than that of cement - such products are brighter, their color is more resistant, paint does not fade. If pigments with high hiding power are used, polymer-sand materials do not lose color for a long time, continuing to delight with the brightness of color even after several years.

+ Plastic, as you know, durable material not destroyed by time. It also transfers these properties to polymer sand products. The declared service life of the coating without destruction is 20 years.

+ The properties of the plastic also give the material: acid resistance, alkali resistance, low abrasion, non-sparking. This is important for coatings with high traffic (entrance groups), as well as coatings: garages, industrial premises, livestock farms, etc.

± Plastic, as a binder, transfers paving slabs from the non-combustible (NG) section to the low combustible (G1) and flame retardant(IN 1). The material in the fire does not burn and does not melt (because it contains ¾ of sand), but is charred. This means that when exposed to an open flame for a long time, the polymer sand material may begin to smolder, however, as soon as the source of fire dries up, smoldering will immediately stop.

+ Environmental friendliness of the polymer sand composite undeniable - "food" plastic, building sand and dye are absolutely inactive at elevated temperatures and in aggressive environments and are harmless to humans. These are not harmful plastics polyvinyl chloride (PVC) and polystyrene (PS), which emit toxic compounds when exposed to them. It is simply impossible to work with such plastics in polymer sand production - after all, the production is carried out by high-temperature processing, which is possible only for harmless plastics.

± Plastic gives polymer sand products longitudinal thermal expansion. At an unstable temperature (sharp warming) in the bright sun, a slight increase in geometric shapes in horizontal surface- up to 1-2 mm. The solution is to leave gaps between the plates - 3-5 mm. If this fact is not taken into account, individual slabs may be pushed out of the coating - perhaps the tile will rise like a “house” and the coating will have to be shifted. This feature must be taken into account when laying, especially since not only polymer-sand tiles have such features - even concrete slabs on the highway rise from the heat.

The expansion of polymer-sand tiles should not worry gardeners - after all, they do not have a question about strict fixation of their coating - for the arrangement of paths, the tiles are laid on the ground with a sand cushion (prepared site) and rammed with a mallet. From the sides of the track must be securely fixed with curbs. Subject to thermal seams, this coating will serve for many years without requiring re-laying. If, however, when laying tiles, geotextiles are used as a substrate, then the issue of aggressive growth of weeds will be resolved - after a while, only small weeds with a superficial root system, easily removed from time to time, may appear on such paths.

By the way, in winter the reverse process does not occur - the tile does not shrink during cooling, but remains within its linear dimensions.

± The presence of plastic reduces the adhesion (adhesion of surfaces) of polymer sand tiles and cement mortar- the tile will be held on the cement mortar due to the presence of internal grooves into which the mortar will fall. It is allowed to lay on a mortar bed layer (the most dense sand-cement mortar). However, tile adhesive, such as EK-3000, with filling the joints with grout or sealant in the color of the coating, fixes the polymer-sand tiles to the concrete coating much better.

+ And finally, plastic in the composition of products gives ease of processing(using an angle grinder, the so-called "Bulgarian", a cutting wheel for stone), it is sawn evenly, easily, without "battle" and cement dust like cutting concrete tiles.

Polymer sand tiles are called eternal. She deserved this epithet thanks to the highest operational characteristics. The material is based on a filler - quartz sand, and a binder - a polymer. This tile is replacing cement tiles and is conquering the market at a tremendous pace. Its advantages are lightness, abrasion resistance, durability and a variety of shapes.

Brief business analysis:
Business setup costs:1.6 - 1.9 million rubles
Relevant for cities with a population: from 50 thousand
Situation in the industry:manufacturing industry is underdeveloped
The complexity of organizing a business: 3/5
Payback: 9-15 months

What is a polymer-based tile?

Polymer sand tiles are named so for their composition. The bulk and 3/4 of the volume is occupied by ordinary purified quartz sand - an environmentally friendly and very cheap material. The other 25% of the composition of the tile is a binder - LDPE (polyethylene) granules high pressure). In addition to it, impurities of other refined products get into the tile, but their amount is insignificant.

Polymer-based tiles can be used in the toughest conditions. It is durable and works great for compression, and hence for abrasion. This gives her a head start over cement tiles, which begin to crumble after five years, its corners and cuts are gradually destroyed.

The polymer in the composition of the tile makes it plastic, which protects the product from such phenomena as cracking in the cold. main reason, along which it collapses pavement, plinths of buildings and tiles based on cement - this is repeated freezing and thawing. Water gets into the microcracks of the material, freezes, expands and breaks the stone.

After thawing, moisture penetrates deeper through new cracks and the situation worsens. Polymer sand tiles are made on the basis of a plastic material that does not break, but stretches and returns to its original position, providing the same durability.

Product Advantages

Polymer sand tiles have a rich set of positive characteristics that determine the scope of its application. This material has the following features:

compressive and bending strength;
abrasion occurs extremely slowly, it has been experimentally established that the life of such tiles when laid in a pedestrian zone is 30 years;
the material is chemically neutral, therefore it can be used in aggressive environments;
the tile has a rough surface, which is convenient in winter in areas in front of shops and public buildings;
polymer-sand paving slabs are easy to install, as they have larger size compared to traditional cement tiles;
rich color range and choice of textures.

Production technology

The polymer, which is part of the tile, is chemically neutral, it can only be dissolved nitric acid, and then under certain conditions. In order for it to form a homogeneous mixture with sand and pigment, it must be melted. This happens at a temperature of 180 degrees and atmospheric pressure, this process is called extrusion.

Raw material preparation

Polymer sand tiles are made from quartz sand, polymer and pigments. Sand must meet technological requirements: have a moisture content of not more than 10% and not have foreign inclusions. Sand preparation consists of sifting and drying.

Polymer is LDPE granules or polyethylene in any other form. In the case of recycled plastic, it must be crushed literally into dust in order to be able to evenly mix the components. Pigment is an integral element of the composition, which gives the tile its decorative properties. As a pigment in the manufacture of tiles most often used:

iron oxides to produce orange, red and brown;
chromium oxide - green pigment;
titanium dioxide is a white dye.

Mixing and melting

After the components are prepared, they are sent to a concrete mixer, where a homogeneous mixture is obtained from disparate substances. This mixture is manually or semi-automatically fed into the melting apparatus - extruder. At this stage, the polymer is melted and mixed with the main component - sand.

Molding

The mixture leaves the melting furnace in the form of a plastic mass and enters the molding section. To give the amorphous mass the appearance of a finished tile, molds and a hydraulic press are used. The higher the pressure force, the faster the molding will be.

The strength of polymer sand paving slabs is gaining in the process of cooling, which should be fast enough. To comply with the requirements of technical specifications, it is necessary to provide a cooling system. After extrusion, liquid LDPE must polymerize again, turning the individual components into a monolithic stone, and the temperature regime is of decisive importance in this process.

Equipment and premises

The production does not require complex technological lines, however, it will be necessary to invest some amount of money in equipment. Each of the three stages listed above requires specific machines. Below is a list of the required instruments and machines in the order of their use:

device for crushing polymeric conglomerates;
scales - to load the required amount of raw materials;
concrete mixer - for the preparation of a homogeneous mixture;
melting furnace - for the extrusion process;
press 100 tons or 150 tons and a set of molds;
finished product cooling system.

In addition to the equipment on which polymer-sand paving slabs are manufactured, premises for production and a warehouse will be required. Since polymer sand tiles are heavy products, moving them will require a specialized storage equipment- hand or truck loader.

Attachments

Any industrial production, even on a small scale, requires start-up investments. The equipment listed above is mandatory, without it it will simply not be possible to make a tile. If you make a choice in favor of used cars, then for a complete set will have to spend at least one and a half million rubles. The exact amount depends on the condition of the equipment, its origin, age and performance.

When buying used equipment, there is a risk of running into hidden malfunctions that will lead to a stop in production. There are options for purchasing new production lines - these are financial lease or leasing. Its meaning lies in the fact that the lessor company buys the necessary equipment at its own expense, puts it on its balance sheet, and leases it to the entrepreneur. A businessman carries out production using equipment leased to him, pays lease payments on time, and after a while completely redeems the production line.

Who uses tiles

Due to its high performance, the scope of the tiles is extremely wide. It is gradually replacing cement tiles, artificial and natural stone, asphalt and concrete. Potential buyers tiles can be:

companies engaged in laying paving slabs;
owners of private houses who are interested in finishing the local area and exits from garages;
owners of industrial premises, stations Maintenance, petrol stations, open warehouses with flyovers;
owners of cafes and restaurants who are interested in decorating courtyards and summer areas;
owners of shops, public buildings, who are faced with the task of finishing the adjacent territory;
landscape designers, for whom tiles are suitable for decorating park paths.

When planning the production of polymer sand tiles, you need to understand what target client the business will be focused on. If for decoration and landscape design the visual component is important, then for the warehouse owner or service station the most important criteria are price and quality. Having studied your target audience in detail, you can find a way to compare favorably with others at the production planning stage and thus have a clear competitive advantage.

Marketing strategy

No matter how good and advanced the production is, customers play a decisive role in achieving the success of the entire enterprise. The production of polymer sand tiles is profitable business, but over time, competition in this area is only growing. Classic business textbooks and experienced business practitioners say that success is achieved by those who are different from others. What can distinguish a new manufacturer from dozens of the same masters?

Quality- this is the desire to fully satisfy the needs of your client, this is the ability to think for him and solve his problems. In practice, this is expressed in the ability to listen to the wishes of your customer and implement the notorious individual approach. Of course, the quality of the product must be impeccable.

Commitments is the ability to respect the time of your client and know the value of your word. In practice, this means that delays in terms are unacceptable, as well as an increase in cost without prior warning. The client should be treated with respect.