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Pulverization of rubber crumb. Production line


LPUG-2 is used for spraying rubber crumb on various solid surfaces .

This line includes as follows

1. PTJ-100 Rubber crumb pulverizer 2. TPJ-2.5 spreader 3. JBJ-200 hydraulic skip mixer
Materials volume:100L.
Pulverizing yield: 12-15 kg/min
Power: 9.7 kWt 
Weight :  400 kg
Outer size(length x width x height):2150mm×1000mm×1100mm 

Spreading width: 2500 mm
Speed: 0.8-6m/min
Productivity of spreading : 100 -400m2/hr
Power: 8.6 kW
Weight 850 kg Outer size(length×width ×height):1800×3000×720mm

Volume of materials: 200l.
Power: 5.5kW
Weight 650 kg
Main shaft rotation speed - 40 rpm
Outer size(length×width ×height): 2300mm×980mm×1000mm

The set doesn't include trolleys.
Chinese hydraulics
Total power 23,8 kW
Number of workers - 6 persons
Production area: Any
Design productivity, - 300 m2/ hr
Working conditions, climate : Indoors and outdoors
One 40 ft. container is required for transportation
 
Rubber rubber crumb, 1-4 mm

Manufacturing technique:

1. Mixing of the components in the mixer
2. Delivery to pulverizer
3. Pulverizing
4. Levelling and slight pressing
5. The covering is to be solidified during 12-23 hrs  
 

Specifications of the products
:
Seamless coverings made of rubber crumbs, are layed as the whole carpet on solid or prepared ground (sportgrounds or playgrounds).
Thickness -  4 - 20mm (is set during lying)

 
Specification of the equipment

PTJ-100 rubber crumb pulverizer with PU based adhesive materials.


Operation principle
The pulverizer is intented for covering open and indoor grounds with tire and EPDM crumb. The mixture of glue and glranules is spayed via pulverizer's gun using high pressure, created by air compressor.
Main components and function.
1. Air compressor:high pressure, small losses, compact size, stable pressure level.
2. Hopper: welded metal hopper, anticorrosive coating, the  framework allows even and qualitative mixing of raw materials .
3. Pumps: it conveys glue and granules mixture, productivity is adjusted by rotation speed.
4. Chassis:metal welded structure, anticorrosive coating. There are two pairs of rubber wheels on chassis, with the drive on one couple. There are compressor, hopper, pump, machine's speed controller on the chassis, allowing fast movement using  control knob.
5. Pulverizer's gun. It  supplies the mixture of liquids, solids and compressed air on the sprayed surface.

Technical specifications
Air compressor
Pressure 1Mpa
Productivity: 0.65м3/min.
Power: 5.5kW

Pumps:
 Pressure 0.3mpa
Productivity: 0.0125 м3/min
Power: 2.2kW

Volume of materials (for effective productivity): 100l.
Spray output: 12 ~ 15 kg/min.
 Weight 400 gk
Size : (L*W*H) 2660*800*1100 mm
Thickness of the sprayed layer -  1  - 6 mm.
 
Application and products :
Upper layer on rubber coverings and other floor coverings. Spraying on
blocks (rubber, sand and concrete, polymer-impregnated sand);
Seamless rubber crumb coverings, made using cold method
As an independent floor covering or layer on solid base. Spraying on concrete, asphalt, wooden and metal floor, PVC, commercial linoleum
As sprayings on horizontal and vertical surfaces (other then floor coverings): metal, wood, concrete, asphalt, bitumen, glass, plastics, ceramics, etc
As sprayings on metal structures (vessel’s decks and hulls, fences, cranes, pipes).
As hydro-insulating and atmosphere resistant materials for insulation of cellars, foundations of buildings, roofing, the walls of residential and non-residential surfaces, wooden hulls of small self-floating vessels.
Spraying on parts of car bodies (bottom thresholds, body and baggage sections, bumpers and footboards).

Common features of the sprayed covering:
High wear resistance, rupture strength bend strength, twisting strength.
Excellent anti-slipping properties.
Shock load reducing ability, noise insulation
High adhesion.
Anti-corrosive properties.
Good air resistance
Good salt, alkali and acid resistance.
These coverings can get rid off snow cover and ice crust several times as faster as compared to ordinary coverings.
Weight of 1 m2 of covering of thickness of 1.5-3 mm is 1.3 kg, the material yield from the pulverize is 9-10 m2/ min.
 
General process description : 
1.The materials (crumbs and binding materials) and equipment (pulverizer and mixer) are brought to the spot of laying.
2. The surface is prepared by removing dirt, dust and moisture
3. The materials and equipment are properly placed.
4. The mixer is used to make a mixture of crumbs and binding materials (glue), so the crumbs and glue should be stored near the mixer. For proper dosage of binding materials the scale is required. Glue/crumb ratio should = 1/1, it depends on the crumb’s fraction, air humidity, and brand of the binding materials. After mixing of the constituents the resultant mixture is placed to the trolley, transported to the laying spot and fed to the pulverizer’s neck. For mixings and transportation one person is required. The covering is sprayed via the pulverizer’s gun to make the layer of required thickness. Spraying radius is adjustable.
5. Drying time is 12-20 hrs, it depends on temperature, moisture, the brand of binding materials.
6. Marking or drawing can be patterned as required.
7.Marking or drawing can be patterned as required.
-The surface on which the materials are applied should be dry and clean.
It is forbidden to operate under negative temperatures and atmospheric precipitations.
-The used crumbs must be dry, their fraction is 1-4 mm.
-Weight of covering of 1 m2, thickness 1,5-3 mm – 1,3 kg
Its time of service is at least 15 years

 Specifications for the equipment set
1.PTJ-100 pulverizer- 1 unit 
2. JQ-3500 vertical load mixer- 1 unit
3.Trolley, capacity 50-100 kg,-1 unit

TPJ-2500 Spreader
The advantage of using special machinery is evident.
The machine is easy to operate and maintain, and it can be adjusted to avoid misallocation of components and to manufacture the products of the preset thickness and quality.
This machine allows to reduce the staff (in average, 3-5 persons are required, including 2 operators and 1-3 shift men for making the mixture). And labor productivity is several times higher than that of unpowered brigade (at least 1000 m2/day.)

Technical specifications:
1. Width of spreading: 2500 mm
2. 2. Speed of motion :0.8-6 m./min.
3. Productivity of spreading : 100-400m/hr
4. Power: 8 kW
5. Weight 850 kg
6. Size: (L*W*H) 1800*3000*720 mm
 
Description of the machine
1. Operating part: it has even steel surface with anti-corrosive coating and can operate in under severe working conditions.
2. Front scrubber: Steel structure, the ground distance can be adjusted manually using screw, this allows to set the thickness of the covering. Upper limiter allows to adjust the width.
3.Control and traversing device: it is based on chain transmission. It has speed controller, forward, backward and curve line motions are possible.
4. Motion device: wheeled mover. For manually operated movement hydraulic drum lifts the operating surface from the crawlers.
has 4 functions, namely: setting of height, setting of corners, setting of temperature and vibration. Plastic and rubber materials are made even by the plate following the vibration, pressing and smoothing.
For proper consolidation of the material the vibropsreading is required, whereas heating to 80 C provides quick setting and solidification of the surface and improves the quality of the materials.

Applications and products
This equipment manufactures seamless coverings made of rubber crumbs. The coverings are laid as whole carpet on solid or preliminary prepared non solid surface. Mainly, the coverings are laid on playgrounds and sports grounds.
There are coverings as follows
• Colored ;
• Double layered (thin colored upper layer and thick black layer). In this case black layer is first to be laid, followed, after its drying, by colored layer (using spreader or PTJ-120 pulverizer ). To make colored layer either black crumbs or colored granules made of EPDM synthetic rubber can be used;
• Black. PTJ-120 crumb and glue pulverizer can be used as supplementary equipment. Spraying on seamless black layer can result in 2 types of surface, namely water permeable and water resistant surface. It depends on crumbs/glue ratio and the crumbs fraction. Laying of upper colored layer using spreader results in water permeable, drainable surface, where no puddles are formed even in the rain

In winter any type of the above surfaces can serve as skating ring, and in frost-free season it will be a sport ground or playing ground again. Any color variations are possible, including homochromous or heterochromous coverings.
It is possible to apply different variations of marking or drawing on the sport grounds and playgrounds.
The thickness of covering -4-20 mm (it is set before laying).

General process description
1. The materials (crumbs and binding materials) and equipment (pulverizer and mixer) are brought to the spot of laying.
2.The surface is prepared. If it is levelcrete, the dirt an dust must be removed 3. The surface is coated by thin glue layer which is used for cold laying. Glue consumption varies from 100 to 300 gr/m2 depending on the surface relief
4. The materials end equipment are properly placed.
5. The mixer is used to make a mixture of crumbs and binding materials (glue), so the crumbs and glue should be stored near the mixer. For proper dosage of binding materials the scale is required. Glue/crumb ratio should 16/100-20/100 , it depends on the crumb’s fraction, air humidity, and brand of the binding materials. After mixing of the constituents the resultant mixture is placed to the trolley, transported to the laying spot and dropped on the operation surface of the spreader . Mixings and transportation are performed by 1-3 persons depending on the productivity required.
6. The scattered mass is smoothed by the spreader, the joints with preliminary laid layer are smoothed manually by an operator of the spreader using special trowels. All possible roughs of the surface are filled with materials and smoothed.
7. Drying time is 8-14 hrs, it depends on temperature, moisture, the brand of binding materials. After that upper colored layers can be sprayed or laid. The second layer is laid without preliminary coating
8. Marking or drawing can be patterned as required. .The glue is mixed with the dyer of required color and the resultant mixture is brushed on preliminary lined marking. Other variant is also possible; the required drawing, logo or inscription can be cut from rolled rubber materials and laid on the glue on the first black layer. Then it is covered by protective covering, and the second colored layer is applied over it. After drying the protective material is removed and we have the covering with drawing, inscription or logo
-the surface on which the materials are applied should be dry and clean.
It is forbidden to operate under negative temperatures and atmospheric precipitations.
-The used crumbs must be dry, their fraction is 1-4 mm.
Weight of covering of 1 m2, of thickness 10 mm – 7-8 kg
Its time of service is at least 10 years

Specifications for the equipment set:
1. Spreader - 1 unit .
2. JQ-3500 vertical load mixer, productivity 150 kg/5-8 min – 1-3 unit (depending on the required productivity )
3. Trolley, capacity 150 kg,-1 unit.
 
 

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