Polymer-sand products are products made using polymer wastes (plastic bags and PET bottles).
Is it profitable to engage in this production and how quickly it will 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;
ease - polymer-sand products are two times lighter than cement-sand analogues;
not the spread of flame and electricity;
resistance to environmental influences - they withstand temperature extremes 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, wash well, do not accumulate snow, and up to 30 years old retain their original color.
In Europe, it is ANDERA polymer-sand tile, which has 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 consist of polymer sand and dye. The ratio for tiles is 24/75/1, for paving tiles - 5/94/1.
For work, you will need soft (bags, plastic film) and hard (polystyrene, polypropylene, PET bottles) polymers. Their ratio is 50/50. Do not use rubber and refractory polymers - polycarbonate, fluoroplastic.
Raw materials for business can be found at a regular landfill or recycling points. You can buy sorted and treated waste, but it will cost much more, and there is no great need for it, because paper and food waste burn out and will not have any effect on product quality.
1 ton of untreated waste on average in Russia - 3 thousand rubles.
Sand is used as a filler for the finished product. The moisture content of the sand should be no more than 10%, and the clay content not more than 20%. Permissible fraction - up to 3 mm.
1 ton of sifted dry sand costs on average in Russia - 300 rubles.
The third component is the Bayerferrox dye (Bayer company). 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 process:
Crushing of polymer waste. We use the device - PT polymer crusher 2018.08.2019 (productivity 900 kg / h).
The resulting mass is placed in an extrusion machine (PT Extrusion Machine 08.08.2019 with a productivity 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 the crusher to obtain an already fine homogeneous fraction up to 10 mm.
The resulting polymer mass, the prepared sand and dye are mixed and poured into the melting and heating unit (АПН ПТ 08/08/2019 with a capacity of 250 kg / h). This stage is the most critical; here, mixing, heating of the mass and enveloping of each sand particle with polymer takes place. This is achieved by a peculiar shaft design, the blades of which advance the mass at different speeds in the three heating zones, and this leads to high-quality mixing of the mass.
The resulting mass of consistency of tight dumplings is placed in a molding press, where the mass is put in the molds, and under pressure (250 tons) it is cooled. To obtain paving slabs, the mass is cooled evenly. To obtain shingles, to give it shine, the lower part of the mold cools faster than the upper.
The average productivity of such a production line is 100 square meters. m per day (two work shifts of 8 hours).
For production you will need a room with an area of 150 square meters. m with fresh air ventilation. Ceiling height - 4 m. Renting such a room will cost you an average of 15 thousand rubles / month.
Since products and equipment are original and non-standard, certificates and licenses for production are not required.
Calculations per 100 m2 of products:
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 for 8000 p. = 64, 000 rubles per month: 30 = 2133 rubles
water supply - 100 rubles per day
rental of premises - 15000: 30 = 500 rubles per day
transportation costs - 300 rubles per day (calculated individually).
Total cost of 100 m2 of finished products will be 7037 rubles.
The cost of finished products for different manufacturers is 250-400 rubles per 1 sq. Km. m. To establish itself and enter the market you need to take the lower price - 250 rubles per 1 sq.m. Consequently, 100 sq.m. we will sell for 25 thousand rubles. Net income net of cost - 17, 963 rubles. per day.
The average cost of the production line of polymer-sand materials (for 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 get a complete set of drawings with all modifications of 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 acquired drawings at any tool plant or machine-building plant in your city. The production time of the entire line depends on the capacity of the plant 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.
Calculate the payback: (200, 000 + 20, 000 for the drawings): 17963 = 12.2 slaves. of the day.
That is, the payback period when choosing this method of obtaining equipment will decrease by almost five times.
Thus, it is extremely profitable to produce polymer-sand materials and starting a business is quite simple. In addition, the production of polymer-sand products is an effective solution to the problem of plastic waste.
Good luck in creating your own business!
Based on materials from an article by Serik Ainurov for the project www.polimercherepisa.narod.ru
* The article is more than 8 years old. May contain outdated data