Crumb rubber is ordered from your state's crumb rubber operator based on our exacting specifications.  The raw material will have the consistency of coffee grounds and come in super sacks of up to 2,000lbs. 

Your state may negotiate "just in time" deliver schedules for the crumb and must provide storage for the raw material until it is utilized in the manufacturing process.

The Supersacks are placed into the staging rack by forklift.  The crumb is then emptied into the hopper and delivered by elevator to the holding bin at the top of the Mixer.   

The computer-controlled mixer blends the correct amount of crumb rubber material, resin, catalyst, water and pigment for the optimum consistency.  The material is blended within the mixing auger and distributed into fill tubs where it is weighed and poured into the appropriate mold. 

The rubber/resin compound from the mixer is weighed and placed into the proper mold.  Workers screed the material in the mold for uniformity before the mold cover is placed over the material. 

The mold is taken to the prepress station where even pressure is applied preparing it for the rolling press.

Upon leaving the prepress the molds enter the patented rolling press

Industrial rollers mounted to heavy-duty bearings put pressure on the molds, curing the rubber and resin compound inside.  The height of the rollers can be adjusted to accommodate a variety of products.

Within a short time, the molds emerge from the rolling press and are moved to the demolding station.

Finished products are removed from their molds at the demolding station.  A heavy metal base holds the base of the mold while a hydraulic lift removes the mold cover from the mold base.  

Tiles are visually inspected and randomly sampled for quality and consistency.  Strict quality controls ensure that products meet the appropriate specifications.  Playground tiles must meet stringent fall height requirements.

Molds are washed and stored on storage racks or seasoned and placed back into production for another run through the rolling press. 

Tiles are stacked on pallets for optimum airflow where they will continue the curing process.  Pallets with tiles weigh between 2,500 and 4,000 lbs.  Tiles are then packaged and shipped to the end customer.

An area needs to be set aside for cardboard cutting and binding where tiles are packaged for shipment.

Finished goods are packaged with cardboard and binding straps while on pallets. 

The bundled tiles are stored until such time as customers are ready for shipment.   Special consideration will have to be taken for the storage of several pallets either on-site of off-site. 

Customer Dock and forklift capabilities must be taken into account when scheduling the shipment and unloading of tiles.