Extruder for polymer sand tiles drawing. Polymer shingles. The main stages of production

Polymer-sand products are products manufactured 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, curbs, tiles and, occasionally, sewer manholes.

Polymer-sand products have a number of useful properties:

high impact resistance (in comparison with 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 analogs;

cheapness;

no spread of flame and electricity;

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

In Europe, it is ANDERA polymer-sand tiles, which have been recognized at various exhibitions and approved by the Swedish Consumer Association (SVK).

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

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

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

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

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

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

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

The main stages of the technological process:

Crushing of polymer waste. We use the device - polymer crusher PT 2003.00.000 (productivity 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 a fine, homogeneous fraction of up to 10 mm.

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

The resulting mass of the consistency of tight dumplings is placed in a molding press, there we put the mass in molds, and under pressure (250 tons) it is cooled. To obtain paving slabs, the mass is cooled uniformly. To obtain a shingle, to give it a shine, the lower part of the mold cools faster than the upper one.

The average productivity of such a production line is 100 sq. m per day (two work shifts of 8 hours each).

For production, you will need a room with an area of ​​150 sq. m with forced ventilation. The height of the ceilings is 4 m. The rent of such a room will cost you an average of 15 thousand rubles / month.

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

Calculations per 100 m2 of product:

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, 8000 rubles each. = 64,000 rubles per month: 30 = 2,133 rubles

water supply - 100 rubles per day

rental of premises - 15,000: 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 finished products by different manufacturers is 250-400 rubles per 1 sq. m. To establish 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 less cost - 17,963 rubles. per day.

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

Consequently, 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 the modifications of the units for the production of the entire line here: www.polimercherepisa.narod.ru

Next, make an order for the manufacture of all equipment according to the purchased drawings at any tool plant or machine-building plant in your city. The production time of the entire line depends on the plant's capacity 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 per drawings): 17963 = 12.2 slaves. day.

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

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

Good luck in creating your business!

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

Periodically, polymer sand tiles appear on the market at very attractive prices. And very often buyers “fall for” precisely the low price, initially being very happy about their “profitable” purchases at first glance. But, unfortunately, in 99% of cases - the "fabulous" price means the same "fabulous" quality of products. There are several ways that you are deceived:

1. The cost of production can be significantly reduced when using as a binder polymer absolutely unsuitable for the purposes for which the tiles are used, low-quality (usually from solid waste landfills), often frankly toxic plastics.

2. It happens that in the manufacture of tiles, good, suitable for these purposes, polymer materials are used, but they are not treated with special additives that would allow the use of tiles in the open air. This is allowed by the old technical conditions for the production of tiles, significantly reducing the cost. Usually the manufacturer does this either unconsciously, because he does not know about the need to use these things, or openly deceives the buyer, since these additives are very expensive. These manufacturers claim on their websites that they know how to produce these products correctly, use various stabilizers, reinforce polymer composite, but for unknown reasons, none of the suppliers of these stabilizers could find these craftsmen in the register of their customers.

3. There is such a way to reduce the price of tiles - savings on the technological and technical aspects of production, quality acceptance. This is often expressed in the elementary absence of staff in charge of these actions. The result here will be - the delivery of products to the customer with irregular geometric parameters, a strong variance in color, a large difference in the mass of products. Something will not be reported, something will be shifted.

4. Some of the manufacturers insist that the low price of their products is obtained due to the fact that they independently process secondary plastics for their own needs, as a result of which they receive savings. This approach looks reasonable outwardly, but there are also pitfalls here. Waste polymers for recycling ALWAYS require a high-quality bulkhead, separation by type of plastics and sorting, and a lot of waste is generated. The percentage of waste reaches 50. The composition of this waste contains many types of plastics that absolutely cannot be compatible with each other, many of them cannot be used at all for products working under the sun. What will the manufacturer do in this case? Usually the desire for profit pushes the manufacturer not to throw away these "bad" polymers, he then paid for the ENTIRE volume, but to say that it is "soft and hard plastic in the correct ratio" (as in the old technical conditions), grind this waste and shove it into the product. "The magician Suleiman is all honest - without deception." In fact, it is very close to the situation described in paragraph 1. That cannot but affect the quality of the product.

5. Again, unsuitable plastics. Use of TETRA-PAK film production waste as a polymer raw material. This is a film coated with a thin layer of aluminum. Such films are used as the inner layer of milk bags, bags in which wine is sold, etc. The material is good, but none of those who use it bothered to read the relevant literature. It turns out that the metals in polymers accelerate the aging process, that is, these businessmen, without knowing it themselves, and perhaps deliberately, planted a time bomb in the tiles, a catalyst for the oxidative aging process, accelerating the process of destruction of tiles at times. Such a tile looks as if it were added to its composition "silver". Silvery aluminum particles are visible to the naked eye. TETRA-PAK material is cheap, as it is difficult to process and is used in the production of a limited range of products, hence the savings.

6. Unsuitable plastics again. The manufacturer buys technological plums of polymers from various industries, the so-called "sprues" - lumps of solidified plastic of various sizes. They are crushed, then go into production. They are sold cheaply, but it is impossible to unequivocally determine their composition. As a result, the situation is similar to item 1, item 4. This is especially true for those who have a shredder in the equipment of the production site.

7. More about the wrong plastic. They take a covering material in the form of a film from the fields, which is used in greenhouses and as a greenhouse for growing various crops. The so-called "greenhouse", the cost is penny. Since the material is thin-layer and was exposed to ultraviolet radiation, it has largely lost its useful properties for polymerization and has aged. Products made from such material will not last long - it's like buying a tile that has already been in use for 30 years.

8. Sand with a high clay content is used - it is cheap. As a consequence, the fragility and hygroscopicity of products.

Thus, the low cost of the tiles with a high degree of probability may indicate that the technology was violated, that they saved on raw materials, and that the methods of manufacturing products that should work in the open were not followed. Such products do not last long and are likely to have a negative impact on health.

It is very difficult to visually recognize a counterfeit product, but it is still possible. The smell of a polymer sand product will tell you that they are trying to deceive you first of all, it will be unpleasant, sharp. The added or "forgotten" to put special additives is very difficult to determine, it is best to look at the financial documents showing the transfer of such additives to the manufacturer of the suppliers of these materials. The product should not contain non-melted plastic particles and, moreover, no silvery aluminum particles.

These photos show what excessive savings can lead to when buying tiles after the first 3-5 years of operation:

Our company has already been repeatedly approached by buyers who, somewhere, were once deceived when buying tiles. She began to fall apart. We offer these buyers to purchase our tiles, produced under the Tetto brand, to replace the counterfeit products they bought.

BEWARE OF COUNTERFEITS! Be careful! Appreciate your health and the health of your loved ones!

Polymer sand tiles are considered an analogue of natural ones, however, this material can be called qualitatively new, with advantageous characteristics compared to other market proposals. This covering material is 2 times lighter than natural material, and wins significantly in cost. With it, you can make the roof more noise and heat insulating than using metal tiles. The absence of corrosion is one of the important advantages. The roof is more durable than bitumen. And during the installation process, there is no need to carefully prepare the surface.

Features overview

Polymer sandy tiles are resistant to ultraviolet light and temperature extremes, as evidenced by laboratory tests. Operation of the material is possible at temperatures ranging from -65 to +100 ° C. The tile retains its appearance for many years of operation, because it takes about 100 years for the complete decomposition of the polymer film.

Thermoplastic composite material has an insignificant moisture absorption coefficient, therefore it is protected from the emergence and further development of moss, mold and mildew. In addition, the roof surface will be resistant to acid rain. Polymer sandy tiles have low thermal conductivity, which allows maintaining the temperature regime under the roof. Under such a roof it will be cool on hot days and warm in winter. That is why this covering material is often used in the construction of terraces and attics. As a result, it is possible to form a reliable barrier for condensate.

Additional properties

The roof structure is reliably protected from destruction, which is especially important for wood elements. Shingles are excellent at blocking out noise. No sound absorbing layer is required during installation. The roof will be silent in any bad weather. Another important advantage is impact resistance, which makes installation economical. During transportation, the material does not break, as well as during installation. It meets all the standards and requirements of sanitary, epidemiological, fire and radiation safety.

The main advantages

Polymer sandy tile has many advantages. During the production process, it is coated with a substance that is resistant to ultraviolet radiation. This indicates that even over time, the color remains pristine and the surface does not fade. The material perfectly copes with the harsh continental climate, it is frost-resistant and is able to withstand about 200 freeze-thaw cycles.

Compared to metal roofs, the latter have a drum effect. The shingles do not corrode, they are resistant to chemicals. It is water-repellent and prevents blooming of the roof. The material is dielectric, so the roof does not need lightning protection. The canvases are easy to install, for this the master does not need to have special skills. Even if you have to work with roofs of complex shapes, the waste will be minimal. A roof made of polymer sand tiles can be operated at a point load ranging from 150 to 360 kg.

Negative reviews

In order for your idea of ​​the described material to be complete, it is necessary to note its shortcomings. Among them, consumers note that over time, the roof erodes, which suggests that its thickness may decrease under the influence of negative factors.

But many consumers do not consider this disadvantage so serious, because the process is sluggish, in addition, the initial thickness of the material is quite impressive. Although the quality of the material itself, in the opinion of consumers, does not deteriorate under the influence of temperature deformations, the tool joints can be depressurized, which results in a leakage of the coating.

What else should be considered

Choosing the described tile, many consumers emphasize that the buyer can run into a fake. Some manufacturers use low-quality raw materials in the manufacturing process, which affects the final product. Although editing is not so difficult, neglect can lead to the opposite effect. In this case, the roof will be damaged. Therefore, many consumers believe that it is better to involve specialists in laying the material. However, this will entail additional costs, which also cannot be called an advantage.

Installation features

The roof tile is equipped with a projection on the back side, which is fixed to the lathing. The elements are fastened to each other with side locks, which allows you to get a solid carpet. For additional fixation, a pore of technological holes is provided on each element. It is necessary to start the installation of polymer shingles from below.

The elements are not very rigidly attached to the crate, it is important to ensure the presence of backlash, otherwise the material will not be able to move when exposed to temperature. If everything is done correctly, the roof will take up loads from wind, snow, temperature changes and precipitation quite freely.

Rust streaks should not appear on the front side after fixing. To do this, use galvanized nails or anodized self-tapping screws as fasteners. The former are preferable, because they allow you to speed up the installation process, in addition, they provide non-rigid fastening.

The front and ridge tiles should be fixed with anodized self-tapping screws. Some shingles will be attached to the valley gutter, this applies to ridge elements. They are additionally fastened mechanically using anti-wind or stainless ridge clamps.

Roof tile production line

The line for the production of polymer sand tiles is a heating device that mixes and heats the ingredients, including:

• polymer;
• sand;
• pigment.

As a result, it is possible to obtain a uniform consistency in the form of a tight dough. The productivity of such equipment can reach 1000 kg per hour. The mixture is preliminarily prepared and heated, and then it is fed into the heated chamber through the receiving hopper. The material is pushed inward by the screw, which rotates and provides mixing of the mixture. It moves inward and undergoes three heating zones.

Polymer sand tiles, the reviews of which were presented above and should help you make the right choice, are dried at the first stage of heating, where residual moisture is removed. The second zone involves the plasticization of polymers. This allows a homogeneous composite mass to be obtained. The last zone is to maintain the temperature of the mass, which is required for molding.

The finished mass moves to the outlet port, which is located in the front flange of the body. For production, molding presses can be used, which provide a force of 100 tons. The resulting mass is put into a mold, while the mixture is subjected to pressure and simultaneous cooling, which increases productivity. The production of polymer sand tiles at the final stage involves the extraction of products with the lower pusher. After the tiles are stacked on pallets and cured, this is what distinguishes them from cement products.

In the process of manufacturing the described material, a radial crusher may be needed, which prepares polymers by crushing them to a homogeneous fraction. Raw materials help to save on polymer, because the cost of waste is an order of magnitude lower than the cost of finished raw materials. The production of polymer sand tiles can involve the use of the following polymers:

• shredded film;

In the second case, we are talking about low-density polyethylene, in the third - about high-pressure polyethylene. The use of recycled polymers not only saves on the purchase of raw materials, but also solves the problem of waste disposal.

Conclusion

If you decide to purchase the material described in the article, then you should be interested in the manufacturers of polymer sand tiles. One of them is the Bistot company, which provides a complete set of roofs. You can also buy tiles from the manufacturer "Polisand", which is located in the Moscow region. An additional advantage of this company is the opportunity to purchase from it the remnants of roofing material at reduced prices.

Paving slabs of various colors, most of the types of tiles, paving stones - all of this refers to polymer sand products.

At first glance, the manufacturing technology is complex. But if you choose the right equipment for the production of polymer sand products, you can soon get a good profit from sales.

Manufacturing technology

The main feature of this type of products is the use of natural raw materials (sand, clay) together with polymeric substances. To do this, it is necessary to mix these materials in the correct proportion and after heat treatment, finished products can be made.

Many manufacturers of polymer sand products keep the composition of their products secret. This is due to the complexity of drawing up the correct "recipe". Depending on the type of equipment and its mode of operation, the final product can acquire different operational properties.

However, the principles of constructing a technological scheme are the same for all types of production. It consists of the following steps:

• Preparation of raw materials for subsequent mixing. With the help of crushing equipment, it is crushed to the same fraction.
• Melting the material until it reaches a plastic mass.
• Manufacturing with a mold of the final product.

When choosing equipment, one should pay attention to its performance, the possibility of modification, and operational qualities.

Preparation and mixing of raw materials

Refined sand and several types of polymers are usually used as the main production material. Equipment for the production of polymer sand products is designed to process almost all types of plastics that are necessary for binding the components.

It is best to use several types of polymer - hard (polystyrene, PET, etc.) and soft (HDPE and LDPE). In the process of heating in the melting equipment, they will gradually form a homogeneous mass.

For mixing the components, a crushing machine is used, which crushes all the elements to the desired fraction. Its main parameters are the total volume of the processed mass and the degree of its grinding. When completing the line, it should be borne in mind that the performance of the crusher is the main parameter affecting the amount of grazed products.

After that, the resulting mass must be heated to the desired temperature.

Melting heating equipment

This stage of processing is mandatory, since only in this way high-quality polymer-sand products are formed. The technology of their production consists in gradual heating and constant mixing of the composition.

The initial mixture is placed in a hopper in which the auger is located. With its help, the mass moves through heating zones with different temperatures. With a gradual increase in the heating level, the raw material acquires plasticity. It does this by melting the plastic granules. At low temperatures, soft polymers are plasticized, and when the critical heating point is reached, hard polymers.

The smelting heating installation is selected based on the maximum possible loading volume and the speed of obtaining the composition of the desired consistency. The average productivity of modern models is 250-300 kg / h.

Molding

At this stage, pressing equipment is used for the production of polymer sand products. The heated composition is placed in molds, where, under the influence of pressure, future products are formed.

The line for the production of polymer sand products can produce one type of product or several. It all depends on the design of the press and the possibility of prompt replacement of forms. The main material for their manufacture is high-strength steel. Depending on the area of ​​the press, from 2 to 12 paving slabs can be made at the same time. It is noteworthy that the finished products do not need additional drying. After their manufacture, the batch can be packed and sent to the warehouse or directly to the installation site.

At the first stage, it is necessary to choose the place of installation of the equipment. The room must have a power supply line of the required power with an optimal area for placing the machines. Equipment for the production of polymer sand products can be selected from different manufacturers. Some of them offer complexes where the heating and forming process is combined in one structure. This significantly reduces labor costs, since there is no operation to move the heated mass from the melt line to the press.

The choice of a particular type of product depends on the state of demand. Currently, paving slabs are especially popular - they are used both in municipal services and in private buildings. If it is necessary to expand the range of products, new molds can be purchased. However, this step must be calculated, since their cost can reach several hundred thousand rubles.

So all of us favorite activity in childhood - the molding of cakes from wet sand and even the construction of whole cities from it - turns out to be quite in demand in adulthood. Buildings, of course, cannot be built from this material, but it is quite possible to produce a whole range of the most diverse products from a polymer sand mixture.

To obtain the desired composite, all you need is to mix the sand with the polymer and add the appropriate color pigment to this solution. And then from this mixture create: roofing, construction, decoration and other improvement elements. These include tiles, sewer manholes, paving and facing tiles, paving stones, curbs, trays, gutters and many other products of various shapes and colors.

What to work on?

To organize this business does not require complex and cumbersome equipment. Basic kit polymer sand equipment includes 3 machines: radial crusher, melting and heating unit (extruder) and molding press. In addition, of course, you will need molds, as well as auxiliary installations: screw and belt conveyors, systems for feeding and dosing the mixture, oil stations and, finally, tables for curing the finished product.

We will not talk about secondary equipment, since this is a universal equipment and there should be no problems with its choice. But the main machines are worth paying attention to.

First of all, we think about purchasing shredder plastic... It is best to take a radial crusher. This will allow you to save a lot on raw materials, since the cost of the finished polymer is much higher than crushed used waste. And the shredder can recycle absolutely everything: cans, bottles, cans, films, etc. You just need to find a supplier of this waste (you won't collect it yourself).

Further we select an extruder... The task of the smelter is to heat up and mix all the components into a single mass to the consistency of a tight dough. The productivity of these machines can reach 1000 kg / h, so you need to take the device in accordance with your needs.

Well, the last car in the production chain - molding press... In our case, it should be with an effort of at least 100 tons and with a variable size of the desktop. The latter factor is necessary for the placement of various molds (curbs, tiles, etc.). By the way, it is better not to save on their cost. The fact is that only high-quality molds made of heat-hardened alloy steels can last a long time and withstand up to 5 million moldings.

Despite the ease of operation of polymer sand equipment, it is better to entrust its commissioning to professionals. The suppliers of this equipment will not only set up production, make technical connections to other equipment of the workshop and conduct a trial production of products, but also tell your staff about all the intricacies of working on these machines.

Machine overview

Let's start right away with the good news. mass produced in Russia. Therefore, there is a choice, as they say, and prices are quite reasonable. A complex of installations can be purchased literally in every region of the country, which, of course, significantly reduces the cost of transporting machines to the place of their future operation.

If we talk about the leaders, the most popular among customers are the POLIMERSTROY 18 machines. The production company from Izhevsk offers not only a wide range of high-quality installations of its own design, but also equipment from proven suppliers from the Middle Kingdom. For example, their product line includes 2 universal crushing units for polymer raw materials of Russian and Chinese production. 300-watt machines are designed for grinding hard, soft and film plastics up to 5-8 mm fraction.

Also POLIMERSTROY 18 offers an extruder of its own design, which, due to a variety of modifications, can be combined with various types of related equipment. The productivity of the melting and heating machine is 600 kg / h. Depending on the tasks, you can also select presses from the D24 series with an effort of 100 to 400 tons. Digital control units of foreign production are used as the program-controlling body of the press. With their help, you can make, say, up to 50 sewer hatches or about 140 square meters of paving slabs per day. Well, in general, Izhevsk molds made of alloyed design steels (40X and 45X) make it possible to produce about two dozen types of various products.

Another leading manufacturer of polymer sand equipment is located in the city of Zlatoust, Chelyabinsk region. The MONOLIT enterprise has established itself throughout the country from the Baltic States to the Far East. Here you can purchase a set of machines for organizing a full-fledged production. First, a radial shredder for plastics up to 8 mm thick and with a capacity of 100 kg / h. Secondly, an economical in energy consumption extruder of its own brand "Mastek", producing 500-600 kg polymer sand mixture in hour. Thirdly, a semi-automatic molding press with a force of 100 tons. As well as additional equipment: a unit for drying and sifting sand, a forced mixer, an agglomerator for processing plastic films into granules, etc.

We will also tell you about one more domestic manufacturer, whose installations are worth paying attention to. This is POLYMER TECHNOLOGY from the city of Orsk, Orenburg region. According to the specialists of this enterprise, the guarantee for polymer-sand products made on their equipment is at least 50 years! And the resource of each mold, if used correctly, is 5 years! The minimum set of installations includes 3 units: a polymer crusher, a thermo-screw mixing machine and a forming unit with a vertical hydraulic press. Chopper productivity - 700 kg / h; extruder - 250-370 kg / h. And another competitive advantage of this manufacturer is the cost of equipment. The basic kit (and in fact - a whole mini-plant) will cost only 772 thousand rubles.