Detailed Project Report on Rubber Powder

RUBBER POWDER

[EIRI/EDPR/2023] J.C.926US$

INTRODUCTION

By the application of heat and chemical agents followed by intense mechanical working to ground vulcanized scrap or worn out rubber tires, tubes and waste rubber articles a substantial regeneration on devulcanisation of the rubber compound to its original plastic state is effected, thus permitting the product to be compounded, processed and revulcanised. There are several types of rubber powder made in different ways. They may be lightly vulcanized and may contain appreciable quantities of anti-agglomerating agents to prevent massing on storage. The trend now-a-days is towards automation in production of rubber goods during handling, mixing and processing. The powder form of rubber is very easy to be handled. The advantages of powder processing have been recognized and include (a) rapid and inexpensive mixing; (b) flexibility in compounding. Powder handling equipments are used in plastics industry also; hence those equipments can be utilised for compounding of powdered rubber before actual processing; thus integration of the two industries can be done without much extra capital outlay.

Rubber powder from used tyres is manufactured by simple cutting, slicing and grinding, finally the product is devulcanised using heat and chemicals and then partially revulcanised and compounded according to consumers requirements.

The plant & machinery, raw materials are indigenously available.

The production process is also not more complicated, demand can also be estimated to be good.

COST ESTIMATION

Plant Capacity            4416 MT/Day

Land & Building (10,000 sq.mt.)    US$ 9.06 Lac

Plant & Machinery                    US$ 7.51 Lac

Working Capital for 2 Months    US$ 22.16 Lac

Total Capital Investment          US$ 41.83 Lac

Rate of Return                          43%

Break Even Point                      41%

CONTENTS

INTRODUCTION

RAW MATERIALS

PROPERTIES

BASIC FACTS ABOUT TYRES

USES OF WASTE /RECYCLED TYRES

USES AND APPLICATION OF RUBBER GRANULATE AND POWDERS

PROSPECTIVE OF TYRE RECYCLING HISTORICAL PERSPECTIVE

LAND FILLING AND STOCKPILING CIVIL ENGINEERING APPLICATIONS

OVERVIEW OF TYRE RECYCLING

MARKET SURVEY

SO WHAT EXACTLY IS RECLAIM?

PRODUCTION, INSTALLED CAPACITY AND CAPACITY UTILIZATION OF RUBBER POWDER

APPARENT CONSUMPTION OF RUBBER POWDER

ESTIMATED DEMAND

DEMAND SUPPLY GAP

GLOBAL MARKET POSITION OF TYRE RECYCLING

SIZE REDUCTION TECHNOLOGY TABLE TYPICAL PRODUCT YIELD FROM SCRAP TYRES

SHREDDING AND GRINDING TECHNOLOGY FOR RUBBER POWDER

SHREDDING AMBIENT GRINDING TECHNOLOGY

SCHEMATIC OF AN AMBIENT SCRAP TYRE RECYCLING SYSTEM

CRYOGENIC GRINDING TECHNOLOGY SCHEMATIC OF A CRYOGENIC SCRAP TYRE RECYCLING SYSTEM   

MANUFACTURING PROCESS OF RUBBER POWDER FROM USED TYRE

PROCESS FLOW DIAGRAM

STEPS OF PROCESSING WASTE TYRE TO RUBBER POWDER

NEW PROCESS AND TREND FOR WASTE TYRES TO RUBBER POWDER

TYRE MANAGEMENT SYSTEMS

THE RANGE OF TYRE MATERIALS

POST – CONSUMER TYRES ARE VALUABLE RESOURCES

THE GROWING NEED FOR RECYCLED TYRE MATERIALS

ENVIRONMENTAL CONCERN OF TYRE RECYCLING

FEATURES OF TYRE RUBBER POWDER PRODUCTION LINE

FLOW PROCESS OF PROCESSING WASTE TIRE TO RUBBER POWDER

TECHNICAL SPECIFICATION OF MACHINERIES

COMPETITORS IN SOUTHERN AFRICA

PLANT LAYOUT

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED IN THE PROJECT REPORT        

PROJECT IMPLEMENTATION SCHEDULES                 

SUPPLIERS OF RAW MATERIALS                 

SUPPLIERS OF PLANT AND MACHINERIES        

SUPPLIERS OF PLANT & MACHINERIES (IMPORTED)        

MANUFACTURERS/SUPPLIERS OF RUBBER POWDER                           

EXPORTER OF CRUMB RUBBER                  

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)