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Innovation of the mixture preparation process for the production of rubber recyclate products

To innovate the process of preparing material mixtures for the production of pressed boards made of recycled rubber granulate obtained by crushing used tyres.

The rubber granulate mixture generated by recycling the used tyres and polyurethane binding agents and paints based on diphenylmethanediisocyanate have progressively been used in more and more fields of industry and they have been replacing standard materials such as concrete, wood, sand, plastic materials, etc. They have excellent mechanical properties, keeping their flexibility for a long time, and also have stability in terms of size and service life. They show high compressive loadability values and structure-borne dampening. They are used as safety materials to reduce the impacts of potential falls as well as anti-slip multipurpose sports surfaces and floors for stables, protection of locomotive organs or as products dampening noise and vibrations. In gardening, the rubber recyclate is starting to be used as a replacement for mulching bark given its long service life, high soakability values and long-term stable characteristics. The objective of the project is to innovate the process of preparing material mixtures for the production of pressed boards made of recycled rubber granulate obtained by crushing the used tyres and its introduction in European processing plants. This process will be based on automated dosing, mixing and preparation of the mixture. The processing plants will benefit from a substantial improvement of the ecological parameters of the production, improved conditions of hygiene at work and reduced waste production compared to the existing systems of mixture preparation. The equipment will be developed in order to achieve the following results: 1. Innovation of the technology of the whole process of preparing the mixture will improve our market chances when selling know-how, and thus our profits will increase. 2. Increased labour productivity by approximately 80% by automating the process. 3. Reduced waste production by eliminating manual handling of the individual components, and by eliminating the human factor and reducing the defect rate. 4. Improved working conditions for the production workers by eliminating manual transport. 5. Increased profitability of the companies and related wage increase for the production workers through a significant increase in the labour productivity. Overview of the main stages of the solution with milestones and decisive outputs expected during the project implementation. Stage 1 (01/2008 - 09/2008) - Conducting the market analysis abroad as well as in the Czech Republic; - Determining the ideal capacity of all the equipment given the market requirements and price/efficiency ratio; - Evaluating the most advantageous method of automated mixture mixing. Stage 2 (10/2008 - 12/2009) - Design of equipment that was not found on the market; - Production of prototypes of the equipment as per the design documentation; - Material tests to determine the optimal mode of all equipment functioning; - Modifications of the design documentation on the basis of conducted tests. Stage 3 (01/2010 - 12/2010) - Draft comprehensive technological process of the whole line (transport and weighing of the individual components, mixture mixing, mixture dosing in moulds, pressing); - Long-term capacity and quality tests of the mixing equipment. Stage 4 (01/2011 - 12/2011) - Construction of a prototype of the automated line; - Long-term operating tests of the line and potential modifications. Keywords: tyre, recycling, technology.
Acronym: 
INPROGUM
Project ID: 
4 064
Start date: 
01-01-2008
Project Duration: 
48months
Project costs: 
1 120 000.00€
Technological Area: 
Recycling, Recovery
Market Area: 
Other manufacturing (not elsewhere classified)

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.