How Rubber Flooring Made?
There are two types of rubber flooring resin-made and vulcanized. Here are the processes of manufacturing these two types:
Resin-made Rubber Flooring.
Vulcanized Rubber Flooring.
Resin-made Rubber Flooring:
Resin-made rubber flooring is manufactured by bonding rubber granules with a polyurethane (PU) binder. This process is commonly used for recycled rubber flooring rolls, gym mats, and playground tiles because it is cost-effective, environmentally friendly, and highly customizable.
A. Tire Recycling & Rubber Preparation
Scrap tires are cut into manageable pieces.
Steel wires are removed using magnetic separators.
Nylon fibers are removed using air classifiers.
Rubber is crushed into granules or crumb rubber.
Vibrating screens separate the crumb into different mesh sizes for specific flooring applications.
B. Mixing
Rubber granules are weighed according to the production formula.
Polyurethane resin binder is added.
Pigments are introduced if colored flooring is being produced.
The mixer coats every rubber particle evenly to ensure consistent strength and appearance.
C. Forming
The mixed material is evenly distributed onto a production belt or inside molds.
Hydraulic pressure compresses the material to the required thickness while eliminating trapped air.
D. Curing
Heat activates the polyurethane resin.
The resin permanently bonds the rubber granules together.
Temperature and curing time determine the final hardness and flexibility.
E. Cooling
The flooring is cooled gradually to stabilize its dimensions before finishing.
F. Peeling & Winding
After curing, the rubber sheet is peeled from the steel conveyor belt.
The continuous sheet is wound into large rolls while maintaining consistent tension.
G. Cutting & Packaging
Finished products are cut into rolls, mats, or tiles before inspection and packaging.