Production line and factory setup overview
A small downstream moulding line producing resilient rubber flooring tiles from purchased qualified tire crumb and optional coloured EPDM top granule through crumb screening, recipe weighing, controlled polyurethane-binder mixing, two-layer hand or semi-automatic mould filling, levelling, heated hydraulic compression moulding or controlled curing, demoulding and conditioning, trimming, dimensional inspection and density, hardness, tensile, abrasion, compression, slip, odour and binder-emission testing.
Recommended lowest-entry line configuration Launch one 500 x 500 mm black-base tile in one thickness using purchased 1-4 mm clean crumb, a metered mixer, two-layer mould set only if a qualified coloured top is sold, one guarded 50-120 t multi-daylight heated press, conditioning racks, trim tools and flooring tests. The upstream tire-crumb plant is separate. Cure chemistry and ventilation must be approved before production.
Production process and implementation sequence
- Crumb and binder lot release
- Screening and recipe weighing
- Binder mixing
- One- or two-layer mould filling
- Levelling and heated pressing
- Demoulding and conditioning
- Trimming and dimensional inspection
- Flooring performance release
Products, capacity and market fit
- Low-entry moulding can use qualified crumb without owning a tire plant.
- Playgrounds, gyms, walkways and livestock areas create project demand.
- One tile size and thickness minimize mould and inventory cost.
- Binder ratio, cure, odour and performance tests determine durability and safety.
- Black recycled-rubber floor tile - Size, thickness, density, hardness, tensile, elongation, abrasion, compression set, slip, odour and colour - Gyms, walkways, livestock and selected play areas
- Coloured-top playground tile - Separate EPDM top-layer, impact attenuation, weathering and chemical-safety approval - Playgrounds after certified testing
Core production machinery and line specifications
| Machine / stage | Function / value | Production note |
|---|---|---|
| Crumb screen and weighing station | Controls particle and recipe | 1-4 mm base crumb |
| Metered crumb/binder mixer | Coats granules uniformly | Timed batch |
| Moulds and filling fixtures | Defines one tile size/thickness | 500 x 500 mm |
| Guarded heated hydraulic press | Consolidates and cures tiles | 50-120 t multi-daylight |
| Conditioning racks and trim tools | Completes cure and edges | Ventilated area |
| Flooring test laboratory | Tests physical, slip and ageing performance | End-use protocol |
Raw materials, utilities and factory requirements
- Qualified clean 1-4 mm tire crumb
- Approved polyurethane binder with SDS and cure data
- Optional qualified coloured EPDM granule and pigment
- Release sheet/agent, wrap, labels and pallets
- Stable three-phase electricity with verified connected load
- Ventilation, fire protection, guarded drives and lockout procedures
- Dry segregated raw-material and finished-goods storage
- Maintenance workshop, lifting tools and critical spares
- Local exhaust and controlled cure/conditioning area
- Binder spill control, PPE and chemical storage
Indicative low-entry investment and implementation plan
These planning ranges prioritize economical machinery, local labor and local civil works. Final pricing follows confirmed capacity, product specification, delivery terms and site conditions.
| Scope | Indicative range | Entry-plan note |
|---|---|---|
| Screening, weighing and mixer | US$7k-18k | Purchased-crumb entry |
| Heated press, moulds and racks | US$14k-38k | One tile size/thickness |
| Laboratory, ventilation and trim tools | US$8k-22k | Performance release |
| Freight, installation and spares | US$7k-18k | Cure trials included |
| Indicative installed low-entry total | US$36k-96k | Tire crumb plant, building and materials excluded |
Detailed proposal and next step
The proposal contains the complete line flow, machinery scope, raw-material and utility requirements, implementation stages and indicative entry planning. Final configuration follows confirmed products, capacity, site and budget.