Equipment for the production of polymer sand products. Business for the production of polymer sand tiles. Technical characteristics of polymer sand paving slabs

Polymer sand equipment allows the production of new types of materials with unique properties and consumer qualities, which distinguishes them favorably from classic types products from concrete and plastic building materials.

Products for the garden and vegetable garden

Polymer sandy garden tile
Polymer sandy garden fencing
Polymer sand board

Road surfacing products

Polymer sandy paving stones
Polymer sandy paving slabs
Polymer sandy curbs
Polymer sandy channels for water drainage
Polymer sandy sewer hatches
Polymer sandy dacha hatches

Roofing materials

Polymer shingles
additional elements for the roof

Cladding materials

Polymer sandy basement tile
Sand polymer board
Wood-polymer board (WPC)

Polymer sand composite is an artificially created material that does not occur in nature and combining qualities unusual for other materials: high strength and reliability, durability, low weight, attractive appearance and ease of installation.

Production technology

Composition of the composite mixture for the manufacture of polymer sand products includes filler (sand), polymer and colorant. Waste from mining and processing plants and rock screenings can be used instead of sand.

At the first stage of production, polymer waste is crushed (plastics, plastic), or in the case of polyethylene, agglomeration is carried out to obtain polymer from secondary raw materials.

At the second stage, the main components are uniformly mixed: filler + polymer + dye. The color of the future product will depend on the choice of pigment.

At the third stage, a thoroughly mixed dry mixture is placed in a melting unit (AL) and subjected to heat treatment, as a result of which the polymer envelops each filler particle.

During subsequent molding and solidification, the polymer sand mass forms a homogeneous monolithic structure with high strength. The finished material is stacked on pallets and sent to storage.

Basic equipment

Melting and heating unit (APN)

APN is designed for mixing and heating the components of the polymer-sand composite (sand, polymer, pigment) and obtaining a homogeneous mass of the consistency of a tight dough.

A preliminarily prepared, evenly mixed mixture of polymer components is fed into the heated working chamber of the APN through the receiving hopper, and is pushed into the depth of the chamber by a screw. The screw, rotating, provides mixing of the composite mixture and its advancement inside the working chamber passing through the heating zones.

Molding press

The press is used for molding products. The resulting mass in the extruder is put into the mold installed on the press worktable, the product is molded under pressure while the mold is cooled, which significantly increases productivity, the finished product is automatically removed from the mold by the lower pushers and is ready for stacking on pallets without additional aging (as opposed to cement products).

Press forms

The molds are installed on the molding press and allow the production of a wide range of products.

Crusher

The purpose of the crusher is to prepare polymer from secondary raw materials (crushing to a homogeneous fraction) for further use, the offered crushers are universal, since they can process both hard and soft film materials (agglomeration is not required), depending on the production intensity of the crusher, they can have different capacities , cans, bottles, cans and other polymer waste can be recycled.

Polymer sand equipment can be used in the production of composite materials with various formulations, for the manufacture wide range products based on them (polymer-sand, polymer-glass, polymer-rubber, polymer-faience, etc.). 100% by mass of secondary constituents.

A number of unique technical solutions were used in the design of the equipment., which made it possible to achieve high quality and reliability indicators of products manufactured on it.

The advantages of the equipment can also include the possibility of using in the production of difficult-to-process types of plastics: layered plastics, packaging materials made of cross-linked polyethylene, plastic materials with a foil layer, scraps of polyester needle-punched pile thermally bonded cloth, etc. Such waste is taken out for burial at landfills or burned.

With the help of the proposed polymer equipment, you can create a full production cycle - from the preparation of raw materials to the finished product at a favorable price. This allows us to manufacture a wide range of products.

In this article you will find information about the new variety paving slabs based on plastic and sand. We will conduct comparative analysis quality properties of similar materials, and also compare the price for them. The article contains video of tests, production technologies and installation instructions.

Polymers are firmly established among the most used materials. They are used for the production of almost everything - furniture, dishes, coatings, household products, auto parts and industrial equipment... At the same time, their unsurpassed consumer and operational properties are constantly being improved, discovering more and more new facets of these substances.

What is polymer

Without going into chemical details, we can say that a polymer is a plastic (petroleum product) in one form or another. In a cold and solid state of aggregation, it is chemically inactive and harmless so much that it is used to make bathtubs for bathing children. The polymer enters into a chemical reaction only in two cases - the use of a strong solvent or heating. Heating is used in the production of polymer sand tiles. In the molten form, it becomes a plastic mass or thick liquid, which readily reacts, mixes, adheres, vulcanizes, in general, exhibits chemical and physical activity. It is this property that is used in manufacturing.

What is the peculiarity of polymer sand tiles

In the manufacture of products, instead of cement, dry plastic mass is used - ground waste. Then the polymer is mixed with sand and preheated to 180 ° C. The cooled molten mass is sent under a heat press, which forms it in the form of a tile. In the cement-sand mortar, mixing occurs due to the chemical activity of the cement. The polymer, in turn, simply solders the grains of sand together. Even water is not required for the reaction.

Video about the production and testing of polymer sand tiles

Which is better - polymer or cement tiles

A popular and long-known "substitute" for natural granite paving stones - paving slabs based on cement mortar - is an extremely simple and relatively cheap solution. However, this simplicity and cheapness turns out to be a mismatch. modern requirements- durability, convenience, environmental friendliness. Exist whole line disadvantages of cement tiles and asphalt, which are eliminated in polymer sand tiles:

Impact resistance. Even a sledgehammer cannot split the polymer tiles on purpose. Its strength is 250 kg / cm 2.
Wear resistance. The polymer solders the sand so tightly that the material only lends itself to special processing (grinder, perforator, cutter). Cement tiles wear out over time and form dust due to the low relative adhesion of the particles.
Environmental Safety. This claim applies to asphalt, which, when heated to 45 ° C, releases harmful substances. As mentioned above, to enter into a reaction (with atmospheric oxygen), the polymer must be heated to 120 ° C, which is impossible without special equipment.
Saving natural resources... Cement production is about factories, quarries, emissions. Crushed stone extraction - subsoil extraction, screening, transportation. Asphalt requires petroleum products, while powerful emissions of toxic gas occur at the time of laying. Raw materials for polymer paving slabs are sand, plastic waste (bottles, bags) and dye. Waste disposal takes place along the way.

Strength test of polymer sand tiles, video

Does polymer sand tile have disadvantages

Of course, in addition to the obvious advantages, there is also a reverse side of the coin. Manufacturing process is a cross between the production of cement tiles and asphalt. The simplicity and low cost of cement tile production affects its unreliability. At the same time, the durability of asphalt requires a complex and expensive process, which involves: an asphalt plant, heavy vehicles, expensive special equipment (pavers, rollers) and many workers.

Disadvantages of polymer tiles:

Limited shapes and sizes. Polymer sand tiles are produced in workshops using relatively simple equipment, but they require powerful steel molds. They serve for a long time, but are quite expensive. A new mold is a tangible cost for the enterprise.
High cost (relative to cement tiles). Expensive equipment and machines require respectful attitude... In addition, the process is partially automated and consumes a lot of energy. Hence the high costs of personnel labor and the production process.

Price of polymer sand tiles

One square meter of such a tile costs about 15 cu. e. For comparison, a concrete analogue costs $ 10. e. (for 1 m 2), vibropressed - 12 cu. e. We will not give the cost of asphalt, it is too high. Undoubtedly, polymer tiles "work out" every folded penny due to the quality and safety margin. Moreover, the quality characteristics are incorporated in the technology, and the cost of raw materials is so low (part of the raw materials is waste) that saving on proportions is meaningless. What can not be said about the consumption of expensive cement, the deficit of which in the products gives the concrete paving slabs a bad name.

Laying polymer sand tiles

The procedure for laying polymer products does not fundamentally differ from other piece elements. To do this, you need the usual stacker kit: a mallet, cord, spatula, buckets, wheelbarrow and shovel. Preparation will take most of the time and effort - you will need a rammer.

Operating procedure:

Determine the horizon level of the top of the laid tile.
Break the "pie" of the base into layers - soil, drainage (crushed stone), preparation (sand or grit), base (grit).
If necessary, remove the soil to the desired level.
Fill in crushed stone (150-300 mm) and compact it with a vibratory rammer.
Fill up with sand or punching preparation (50-70 mm) and tamp.
Install curbs (if any).
Lay the tiles on a loose grinder with a mallet along the cord.
After laying, push the harness into the slots and joints.
Spill the plane with water.

You can fully operate the laid area (put the car) in 3 days.

Replacing familiar and proven products and materials with new ones is not always justified. The novelty must prove its right to life. In the case of polymer sand tiles, this was achieved using the strength tests carried out; it showed advantageous differences from analogues. The reliability and durability of this tile ensures the integrity of the coating, a beautiful and unchanging appearance for many years.

Having recently appeared on Russian market, polymer sand paving slabs, immediately won the trust and love of buyers. Due to its characteristics, it has become a worthy replacement for cement tiles. Polymer tiles, which are produced using modern methods, easily compete with classic concrete products.

The following characteristics are considered to be the advantages of this material:

strength;
ease;
variety of forms;
wide range of applications;
durability.

The demand for this material is constantly growing, so do-it-yourself production of polymer tiles will soon become a "gold mine" for businessmen. The main thing is the correct approach and a sober assessment of all the advantages and possible risks in this business.

Advantages of polymer tiles

Polymer sand tile consists of the following components:

quartz sand (3/4 of the composition);
polyethylene high pressure(25% of the composition);
insignificant part of other refined products.

This composition makes the material plastic and resistant to negative external influences.

The advantages of the product include

durability - the polymer coating lasts up to 30 years;
stability - the material is not afraid of frost, moisture, heavy loads, liquids containing acids and oils;
decorativeness - tiles are often made of any shape. However, it often has a glossy, matte or structured surface. And also in the manufacture of polymer tiles, craftsmen can use a wide range of colors;
lack of toxic fumes when exposed to direct sunlight;
repeated use and easy repair in case of damage;
ease of cleaning the coating (tiles are easy to clean);
wide range of applications. Polymer sand tiles are used as a decorative coating for a private courtyard, parking lots, playgrounds and sidewalks in public places.

Material production

The raw materials for the manufacture of polymer tiles are simple and affordable components:

various pigments;
polymers;
quartz sand.

To reduce the cost of purchasing components, you should use secondary raw materials, which will be cheaper, but will not spoil the quality of the products.

The exact recipe for making sand tiles as such simply does not exist. Each manufacturer independently develops the composition. The best option is to draw up a recipe on your own experience, but the masters also recommend resorting to the help of a technologist.

The tile production technology is quite simple. To comply with it, you do not need special knowledge and skills.

Since the polymer that is part of the tile has a neutral chemical composition, then the solvent for it is only Nitric acid under certain conditions. To form a homogeneous mixture with sand, the polymer must be melted at a temperature of 180 degrees and atmospheric pressure. This process is called extrusion.

To color the tiles in different colors, I use various inorganic substances: iron oxide to get brown, red or orange, chromium oxide to get green, titanium dioxide will give the product a white color.

Do-it-yourself polymer sand tile production is carried out as follows:

crushing or agglomeration of raw materials. But if you buy polymer chips, then this stage is easy to avoid;
mixing of components using a concrete mixer;
melting the mixed mass in the APN (extruder);
pressing products into molds;
movement and storage finished products.

Necessary equipment

For the production of polymer sand tiles at home, you will need to purchase special equipment:

crushing device;
scales;
concrete mixer;
Press;
Press forms;
cooling system for finished products;
loader for moving finished products.

The total cost of equipment and its adjustment depends on the capacity and configuration of the machines. With the minimum configuration, the amount will be 800 thousand rubles.

Polymer-sand paving slabs

Room for work

The room for the production of sand tiles must be at least 100 square meters. Of these, 30 will occupy an area for storing raw materials and 70 - an area for installing equipment.

And also it is necessary to provide a place for storing finished products. It is often recommended to store this material outdoors.

Work force

Even for the production of tiles with their own hands, the master will need labor. The best option would be to run continuous production (in two shifts). To do this, you will have to hire one foreman, two APN operators and one auxiliary worker for the batch. To pay for labor for one month, the master will spend about one hundred thousand rubles.

Electricity and heating

On average, the production of 1 square meter of tiles will take about 8 rubles to pay for electricity. But this will help save on heating. During the operation of the APN, a large heat transfer occurs, which replaces the heating pipes.

Sales market

The high performance characteristics of sand tiles significantly expand the scope of its application, thanks to this, sand tiles confidently displace materials such as concrete tiles, asphalt, concrete, natural and artificial stone.

The demand for tiles is constantly growing. And what is more profitable than buying materials from the manufacturer itself?

Selling your own products will be pretty easy.

But for this, it is necessary to monitor existing buyers of these products.

It can be:

various building materials stores;
companies that are engaged in tile laying;
owners of private houses, summer cottages, cafes;
owners of restaurants, shops, warehouses, public buildings;
landscape designers.

It is best to decide on your target audience even at the stage of production planning in order to please your customers and favorably distinguish yourself from competitors.

Marketing

The success of any production, even the most modern and high-quality, depends entirely on the number of customers.

And the production of polymer sand tiles is attracting more and more businessmen, which increases competition in this area.

To stay afloat and get high profits, you need to be fundamentally different from your competitors. The main advantages are:

high quality products. The manufacturer's sole purpose must be to satisfy all the needs of its customer. Everyone should have an individual approach;
execution of obligations. This means respecting the client. Do not let him down by disrupting the agreed terms, do not raise prices for products without warning him in advance;
good publicity. There is no need to explain anything here. Everyone knows that advertising is the main sales engine. Be sure to participate in exhibitions, create samples of products, collect a portfolio of photographs of completed works.

Profitability and return on production

The production of polymer tiles in practice pays for itself very quickly. The launch of the production line will take about one and a half million rubles. This includes:

expenses for equipment, raw materials;
rent;
preparation of the premises;
company registration.

Even the smallest tile workshop can easily produce a thousand square meters of tiles per month. One square meter on the market costs from 250 to 500 rubles. That is, on average, with a full-fledged sale of products, the profit will be 500 thousand rubles.

Business brings decent income

This is a fairly high rate of profitability in a small business.

To calculate revenue, you need to subtract the following indicators:

taxes and wages;
rental of premises;
utilities;
purchase of new raw materials;
fare.

If we take into account all the expenses, then, subject to full sales, the monthly profit will be equal to 60 thousand rubles. Production of polymer sand tiles - profitable business... The main thing is adherence to technology, production of quality material and active promotion business in the market. For the active manufacture of polymer sand tiles, you will need initial capital, a small tiling shop, workers and accounting. Do-it-yourself tiles always have a high price.

At modern approach to the production of polymer tiles, the production will be profitable from the first month.

Video: Polymer Sand Tile

There are a lot of materials on the construction market with a wide variety of properties. And many of them can be a source of high income for an entrepreneurial person. We also include the production of polymer sand tiles here. And the main advantage of the business being organized will be not only the great demand for products in the market, but also the fact that they can be manufactured on relatively inexpensive mobile equipment. Polymer sand tiles - construction and finishing material made on the basis of sand and polymers. He possesses several positive qualities, for which he won the trust of buyers - strength, frost resistance, durability.

Our business valuation:

Initial investment - from 1,000,000 rubles.

Market saturation is low.

The complexity of starting a business is 5/10.

It is not difficult to open the production of polymer-sand tiles - neither huge investments, nor hiring highly qualified personnel. What does an entrepreneur have to take into account here?

Product receipt process

Generally available and inexpensive components are used as raw materials for the production of finished tiles. You can get them in every region of the country.

Technological scheme for the production of polymer sand tiles

These include:

cleaned sand,
polymers,
pigments.

To reduce the cost of purchasing all the necessary components, you can buy secondary raw materials - they are much cheaper.

As for the exact recipe, everything is strictly individual here - each manufacturer works with its own composition. You can develop a recipe yourself, or you can invite an experienced technologist for consultation.

The technology for the production of polymer sand tiles is extremely simple and does not require any specific skills and knowledge from the entrepreneur (if he decided to carry out all the work with his own hand).

Making polymer sand tiles with your own hands is carried out as follows:

Prepare all ingredients and mix them.
Melting of the raw material.
Pressing products.
Storage of finished products.

Business prospects.

Purchase of equipment for obtaining products

The next thing an entrepreneur will need to do is buy equipment for the production of polymer sand tiles. And even home production will require certain machines.

Line for the production of polymer sand tiles

The technical equipment includes the following items of equipment:

Dispenser - from 30,000 rubles.
Concrete mixer - from 40,000 rubles.
Melting and heating machine - from 350,000 rubles.
Press - from 150,000 rubles.
Molds - from 1500 rubles / piece.

The final price of equipment for polymer sand tiles will depend on the capacity of the machines, their configuration and the degree of automation. The minimum cost of a production line for a mini-workshop and its commissioning is ≈800,000 rubles. And this figure can be much higher if we talk about a more powerful enterprise.

Sales of finished products and profitability of the workshop

The sale of polymer sand tiles, with well-established distribution channels, should bring a high profit to the entrepreneur. And given the demand for products, there is no doubt that many customers will be interested in purchasing high-quality tiles from a direct supplier. It is used for paving roads, interior and exterior cladding.

Products can be sold:

hardware stores and warehouses,
developers,
repair firms,
private buyers.

Despite the fact that the bulk of the profits will come from wholesalers, private buyers should not be discounted. For this, a small pavilion can be organized in the workshop, where the manufactured products will be displayed in front of customers.

The production of polymer sand paving slabs, as practice shows, will begin to pay for itself rather quickly. The launch of a small workshop will require investments of at least 1,000,000 rubles. This will include the following costs:

purchase of the most basic equipment,
preparation for the operation of the premises (supplying light, water and sewerage),
providing a raw material base for the release of the first batch of goods,
company registration.

To calculate the profitability of the planned enterprise, let us take as an example a low-power line with a capacity of up to 50 m 2 of finished tiles in an 8-hour shift. It turns out that more than 1000 m 2 of products can be received monthly. Polymer sandy tiles for a basement stand today on the wholesale market 250-500 rubles / m 2. This means that if you immediately sell all the products released, the entrepreneur can receive revenue in the amount of 500,000 rubles. And these are excellent profitability indicators for the shop floor in the small business segment.

To calculate net income and total revenue, subtract variable costs:

The Rostpoliplast 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, since it is available to all buyers.

Polymer sandy paving slabs are durable and strong. Unlike concrete vibropressed, 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 concrete vibropressed paving slabs.

Polymer sand paving slabs. Vibro-pressed concrete tiles.

Comparative characteristics of polymer sand paving slabs

Comparison of our polymer and concrete tiles

Polymer sandy paving slabs

Considering 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 places of mass traffic (both in outdoor and indoor use). This is the best option for covering areas of recreation areas (parks, cafes, etc.).

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

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

The theoretical (calculated) durability of the polymer-sand material exceeds 150 years, and according to the color fastness parameter, the tile does not lose the color of the pattern forever. Its coloring with modern, non-fading even in direct sunlight, dyes is performed to the entire depth of the material.

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

Technologies do not stand still, but at the moment, among sidewalk coatings, polymer sand tiles are the most effective material in terms of durability and cost, which is universal 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 can withstand significant loads, excellent for industrial premises, car washes, car parks, etc.
Strong, beautiful, safe coating for many years to come! The service life of polymer sand tiles is more than fifty years.
You save on transporting tiles, because it's lightweight and stackable!
Our polymer sand tiles are made exclusively of environmentally friendly 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 a modern and professional equipment and is based on customer needs. Products can be ordered in any volume and quantity. The cost of polymer sand tiles can be clarified by contacting our specialists.