Detailed Project Report on Tyre Recycling Unit

TYRE RECYCLING UNIT 

[EIRI/EDPR/1412] J.C. 188,191

INTRODUCTION

By the application of heat and chemical agents followed by intense mechanical working to ground vulcanised 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. Reclaiming is essentially depolymerisation and misnomerically called "devulcanisation" although combined sulphur is not removed. By this depolymerisation, the reclaimed rubber shows decreased resistance to deformation at ordinary temperature; thus loosing its elastic nature and become less resistant to compression, stretching or swelling. Reclaimed rubber was born because a secondary source of rubber was urgently needed. Entire rubber industry was growing so fast in the early days and there was no enough crude rubber to substantiate the demand. Reclaim rubber soon become indispensable. Apart from this, tire pose a disposal problem and therefore utilized as basic raw material in the form of ground vulcanised waste (Crumb rubber) or converted to reusable state-reclaimed rubber.

Because of short break-down and mixing time, the power consumption during break-down and mixing, low temperature required in calendering and extrusion, non-critical calendering temperature penetration to fabric, tack improvement, minimising sulphur bloom, forming of uncurved stock, low swelling and shrinkage on extrusion and calendering, low thermoplasticity, high rate of cure and cheaper rubber/filler are important considerations in the mind of the compounder in deciding upon regular use of reclaim for low cost, energy, conservation and efficient processing steps even with new generation polymers to achieve desired optimum properties. Reclaimed rubber is primarily used in the manufacture of cycle tyres, Rickshaw tyres, Battery Boxes, Automobile tyres and other moulded rubber goods.

COST ESTIMATION

Plant Capacity            10 MT/Day

Land & Building (2000 sq.mt.)    Rs. 57.75 Lac

Plant & Machinery                    Rs. 3.00 Cr

Working Capital for 1 Month    Rs. 96.73 Lac

Total Capital Investment          Rs. 4.69 Cr

Rate of Return                          70%

Break Even Point                      37%

CONTENTS

INTRODUCTION

WHAT HAPPENS DURING RECLAIMING

USES APPLICATION AND ADVANTAGES

RAW MATERIALS

BIS SPECIFICATIONS

MARKET SURVEY FOR RECLAIM RUBBER

SO WHAT EXACTLY IS RECLAIM?

ADVANTAGE OF RECLAIM OR RECYCLE RUBBER

INVESTMENT, MAINTAINCE AND YIELD FOR CRUMB RUBBER PRODUCTION

EXTRACTION OF RUBBER SCRAPS FROM WASTE TYRE

SOME FORMULATIONS FOR RUBBER RECLAIMED

RECLAIMED RUBBER

MANUFACTURING PROCESS OF RECLAIMED RUBBER

FLOW DIAGRAM FOR PRODUCTION OF RECLAIMED RUBBER

TESTING & EVALUATION OF RECLAIMED RUBBER

TYRE REUSE AND RECOVERY IN DEVELOPING COUNTRIES

PLANT LAYOUT

COMPLETE PLANT AND MACHINERY SUPPLIER FOR TYRE RECYCLING

& CRUMB RUBBER

DETAILS OF TYRE RECYCLING MACHINERY

RUBBER REFINER MILL

COMPLETE PLANT AND MACHINERY SUPPLIERS FOR TYRE RECYCLING

SUPPLIERS OF RAW MATERIALS

BUYER’S ADDRESSES OF CRUMB RUBBER

BUYERS OF RECLAIM RUBBER

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

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)