Total: 4 units, 2 suppliers, prices from 154,400 to 5,000,000 rubles.
An overview of the foam manufacturing technology required for this equipment and a step-by-step description of the production process.
For the production of foam plastic, the following equipment is required:
The equipment can be purchased as part of one production line or purchased separately for each unit.
You will also need:
Styrofoam Raw Material: expandable styrene foam is a product of the chemical industry. The characteristics of the resulting foam plastic depend on its quality and shelf life. The older the raw material and the longer it has been stored, the more difficult it is to foam the granules.
The density of the resulting foam directly depends on the size of the original polystyrene granules: the smaller they are, the greater the density of the foam. Conversely, larger granules can produce less dense foam.
For the production of foam used in construction, a flame retardant, a substance that prevents combustion, is also added to the composition of the raw materials.
The foam production process begins with the production of water vapor, with a pressure of 0.7 to 6 atmospheres and a temperature of 110 to 170 C. A steam generator is used for its production. Depending on the availability of energy resources, the steam generator can be electric, diesel or gas. To obtain the maximum volume of steam, a steam accumulator is used.
The amount of feedstock required for a certain brand of foam plastic is loaded into the pre-expander, and then steam is supplied.
Under the influence of steam, the original polystyrene granules foam, increasing in volume by 20-50 times. On average, to obtain one cubic meter of foamed raw materials, 15 kg of the original polystyrene is needed.
The foaming process lasts 5-7 minutes. After foaming, the granules enter the drying plant, where excess moisture absorbed during steaming is removed from them.
In the dryer, the granules are treated with warm air currents, freeing themselves from excess water while maintaining their volume. Streams of warm air are fed from below, constantly mixing the granules.
At the same time, wet granules go down, while dry ones, on the contrary, rise up and are moved to the aging bunkers with the help of a pneumatic transport system.
As a rule, the drying process lasts from 5 to 10 minutes.
In the aging bunkers, the final stabilization of the granules takes place. The duration of this process depends on the volume of the pellets and the ambient temperature. The number of aging bunkers depends on the productivity of the plant, and their height and volume are determined by the height of the ceilings in the room.
In this case, polystyrene of various grades should be stored in separate bins. As a rule, the duration of aging can be from 4 to 12 hours. The stabilized granules are then subjected to sintering.
Through a special loading opening, the block form is completely filled with ready-made granules, which are supplied using air flows generated by the compressor.
The sintering process is carried out with the help of steam supplied from the steam accumulator. The quality of sintering directly depends on the temperature and pressure of the steam, as well as the time of its supply.
Then the foam is cooled using a vacuum unit and takes the desired shape. The whole process, depending on the baked brand, lasts from 5 to 12 minutes.
After its completion, the installation door opens and the block is pushed out by a pneumatic pusher onto the receiving table. Finished blocks are stacked vertically and aged for several hours or days. At this time, they give off excess moisture and undergo a stabilization process.
Then, using a horizontal cutting machine, the foam blocks are cut into slabs of the desired thickness. Grooves and protrusions can be made on them. The resulting scraps are recyclable.
Finished slabs are packed and sold.
Styrofoam is a building material, which is a gas-filled cellular mass. Today it is massively in demand in the construction, repair and reconstruction of buildings and facades. It is mainly used for sound and heat insulation of internal walls and facades for room insulation.
As practice shows, such a finish fully pays off later, thanks to a reduction in the cost of air conditioning and heating. That is why the demand for the production of foam sheets is growing every year, and the market for this building material is still far from being saturated.
To organize the production of foam, you should realistically assess the consumer opportunities in your region and the financial costs of opening and launching the process. This can be done using the following algorithm.
Who is a potential consumer? The lion's share of the foam plastic market, of course, belongs to the construction industry (about 85%).
The remaining 15% is the production of packaging, fishing tackle, life jackets, fillers in boats, etc.
But it is not easy to find access to such sales areas, and not every region has it, so you need to focus on mass consumption.
An analysis of consumer demand should give an answer to the question of which type of trade you prefer to choose.
Retail trade involves the supply of its products to construction stores in the region for subsequent sale to the final consumer.
The estimated sales volume of one outlet per month is about 30 cubic meters of foam, while you do not need to spend money on renting the premises of your own store, sellers, or advertising.
But you should consider the disadvantages of retail:
In wholesale trade, sales can be carried out directly from the warehouse of the workshop, allocating a small room for the exhibition of product samples and buying a cash register. Of course, no one will go to the warehouse for one or two sheets of foam.
This sale is for a wholesale buyer. For example, for the insulation of the facade of one house with an area of 150 m2, about 30 cubic meters of foam will be required.
Of course, it is more profitable to purchase such a volume from the manufacturer, without the 25-30% trade margin of a hardware store.
However, it is possible to combine wholesale and retail trade, having its own profit from each industry, gaining a client base of large suppliers and construction companies.
First of all, you should pay attention to the competition.
The ideal option is when there is not a single manufacturer within a radius of 100-150 km (the presence of foam plastic in construction stores is not an indicator, since products can be brought from anywhere).
So, we evaluate manufacturers, types and quality of products, prices (wholesale and retail), discounts for large volumes, availability of additional services (departure of a master for measurements, free delivery in the region, etc.).
Before buying equipment, you need to decide on the volumes, since productivity is one of the most important indicators that determines the cost of a technological line and the quantity of manufactured products.
For example, a turnkey line for the production of sheet foam in a minimum configuration with a capacity of 20 cubic meters per shift will cost about 400,000 rubles, 40 cubic meters.
/ shift - 810,000 rubles, 100 cubic meters / shift - 1,350,000 rubles.
The cost of such equipment includes a pre-expander for primary processing, a aging bunker, a molding compartment, a cutting machine, bags for bunkers.
For calculations, we take a line with maximum automation and a complete set for the production of 40 m3 / shift (Price - 1.2 million rubles). It includes all the equipment necessary to start production (except for the steam generator, which is purchased separately):
For this line, the water consumption per shift will be about 1000 liters, electricity - depends on the type of steam generator.
), a special hood for equipment (35,000 rubles), pipes for pneumatic transport (45,000 rubles).
Separately, it is necessary to purchase a steam generator (about 250,000 rubles) - diesel, electric, wood, gas, with a capacity of at least 200 kg of steam / hour.
Approximate fuel consumption: diesel (10-12 l/h), electricity (200 kW), gas (12 m3/h).
The premises for the production workshop should be with high ceilings (from 5 m) and a total area of at least 150 m2 (with a production line of 40 m3/shift). Primary requirements: good ventilation, water supply for technical needs (up to 3 m3 / day), electricity, heating (not less than +15 C).
For the warehouse of finished products, 50-60 m2 of space will be required, isolated from the workshop by fire-resistant structures (foam plastic can be stored under a canopy, with mandatory protection from the sun and precipitation).
Materials and resources needed in the production of foam:
Foam production can be waste-free, "non-standard" is crushed and added again to the raw material before being formed into a monolithic block.
The raw material (expandable polystyrene) has the form of translucent glass beads, with a diameter of 0.2 to 3.5 mm, divided into fractions (screenings) for the production of foam of the corresponding type.
For example, for the manufacture of foam 50, screening No. 1 is used (the smallest granules), and for grade 15, the largest (No. 4).
When choosing a domestic manufacturer, the cost of raw materials will be lower, imported - higher productivity (almost 10% due to better opening of granules).
That is why most of the workshops for the manufacture of foam plastic work on Chinese raw materials.
The granules of PSV (finished raw materials) enter the pre-expander chamber, where they are “inflated”, taking the form of balls. The number of foaming times depends on the type of product being manufactured.
For example, for foam with a weight above 12 kg, one time will be enough.
And for the production of light material of low density (weighing less than 12 kg), it is necessary to repeatedly “visit” the pre-expander chamber, and before each granule it will be necessary to “lie down” in a special bunker.
After the foaming process, the raw material is fed into the aging bunker with the help of pneumatic transport. Here they are at least 12 hours (up to 24 hours).
This time is necessary for good drying (the granules come out wet after the pre-expander) and for stabilization of the internal pressure.
After aging, the granules are sent again for foaming, or further - for molding.
From the aging bunker, the granules enter the block mold. Here, under the influence of steam from the steam generator, a foam block is formed. The granules expand in a closed space and stick together to form a monolithic mass.
After demolding, the block must be cured for at least 24 hours. During this time, the monolith has time to dry out, and the risk of getting torn or uneven edges when cutting is minimal. After drying, the block is cut horizontally and vertically into sheets of a given thickness and size.
Cost calculation 1 m3 of foam plastic grade 25 (weighing 16 kg) - the most popular and sought-after material in the construction and insulation of house facades.
Raw material consumption- 16 kg per 1 m3 (on average, 1 kg of raw material is used to prepare 1 kg of finished foam plastic).
Approximate cost of production 1 m3 - 150 rubles. It is formed on the basis of the cost of water, electricity and the wages of workers (for a small enterprise, we take into account 2 workers with a payment of 600 rubles per day or 30 rubles per 1 m3 for each).
The cost of raw materials with delivery- 73 rubles / 1 kg. The cost of raw materials needed for the production of 1 m3 = 75 rubles. x 16 kg = 1200 rubles
Total: production of 1 m3 = 1200 rubles. + 150 rub. = 1350 rubles.
Profit from 1 m3 of foam - will be 300-500 rubles.(depends on the selling price and conditions - wholesale, retail)
The cost of equipment (including installation, delivery and training of personnel) is 1.6 million rubles.
In order to "recapture" the cost of equipment, it is necessary to produce (and sell!) 3200 - 5500 m3 of finished products.
That is, with one-shift work and 23 working days per month, the payback period will be from 4 to 7 months.
With an average equipment life of 10 years, we can conclude that such an investment is very profitable (the initial capital will increase by almost twenty times during operation).
Of course, it all depends on the sales rate and the season. After all, during high demand (construction season), production can work in 2-3 shifts.
In addition, the monthly expenses must be added:
As can be seen from the calculations, the business is profitable and, with the right organization, pays off quickly, further bringing net profit.
In addition, all calculations were made for small businesses with a fairly low entry threshold.
The monthly production volume of such a line will be about 1000 m3, with an average monthly income of 250 thousand rubles.
The scope of foam is very diverse:
Business planning should begin with an assessment of the product sales market. According to experts, in order to successfully start a business, it is necessary to have a guaranteed demand.
Despite the fact that the volume of construction is increasing, which naturally increases the demand for thermal insulation materials (by ~ 10% per year), competition among foam plastic manufacturers is quite serious.
In addition to the vast number of small and medium-sized enterprises in Russia, the volume of foam plastic exports from China is growing from year to year.
However, the market is still far from saturation and favors the entry of new players. Entry barriers are not so high, and the total investment for the creation of a small line (40 m3 per shift) is about 800 thousand - 1.5 million rubles.
To create a mini-enterprise for the production of foam, you will need to purchase:
The main raw material for the production of polystyrene foam is expanded polystyrene PSV-S in granules. Much depends on the quality of raw materials and their shelf life. So, the older the polystyrene, the longer the foaming process and the more difficult it is to achieve the required density of foamed granules.
The most popular brand of foam is PSBS 25F, which has a longer exposure time than other brands (PSB-S15, PSB-S25, PSB-S50, etc.). The use of this brand allows you to achieve a more even surface with a fine granule, on which plaster and paint easily fall.
About 15 kg of polystyrene is required to produce 1 m3 of polystyrene. The cost of 1 kg of polystyrene depends on the region of delivery and the manufacturer. For example, the price of an average quality Chinese raw material is 60-70 rubles/kg.
Accordingly, the cost of raw materials for the production of 1 m3 of foam plastic is: 70 rubles. * 15 kg = 1050 rubles. To ensure the operation of one 8-hour shift with a capacity of 40 m3 of foam, about 42,000 rubles will be required.
These are serious initial expenses at opening of the enterprise with small start-up capital. We must not forget this when planning a business.
The foam plastic production technology includes such stages as: primary and secondary foaming, drying, aging in air, molding and cutting of finished products.
In detail, the production process is as follows: First, the pre-expander is turned on and the required amount of polystyrene granules is loaded.
Then steam is supplied to the pre-expander and when the granules reach the required level of foaming, the steam supply stops. The foamed granules are unloaded and transported to the dryer. After the dryer, the granules are fed into the bunker, where they are aged for 12 hours.
Then, with the help of a pneumatic pusher, the finished block is unloaded through the wall of the block mold. The division of finished foam sheets is carried out on a special machine for horizontal cutting.
The resulting cuttings after dividing the sheets are placed in a crushing plant, crushed to the required fraction, loaded into a bunker, where they are mixed with primary foamed granules in a ratio of 1:8 and reused.
To open a workshop for the production of foam, you will need a room with an area of at least 250m2, including storage facilities.
The ceiling height must be at least 5m, the room must have good ventilation (due to the harmfulness of production), water supply, electricity connection (380 W) and heating (at least + 15 gr.).
At least 50m2 of space is allocated for the warehouse of finished products, with mandatory insulation from the production workshop with fire-resistant structures.
The warehouse must have a canopy that protects the foam from direct sunlight and precipitation. Monthly rent of a room of this size, depending on the region, will cost 50-100 thousand rubles.
The required number of workers is calculated based on the productivity of the line - one person per 6 m3 of foam per hour. Two workers are required to work in two shifts.
The remuneration of workers is piecework-bonus, that is, it depends on the number of blocks manufactured per shift, on average - 50 rubles / m3. In addition to the production staff, at least one handyman is required (10 thousand rubles.
), an accountant (10 thousand rubles) and a sales manager (15-20 thousand rubles).
The organizational form of the enterprise is an individual entrepreneur or LLC (legal entity). Individual entrepreneurship is easier and cheaper to register than a legal entity.
However, large wholesale firms prefer to work more with organizations than with individual entrepreneurs.
Much also depends on production volumes - with small volumes, IP is enough, then with an increase in production volumes and sales markets, it is definitely necessary to register an LLC.
A legal entity can create branches and representative offices in other cities, and it is even safer from a legal point of view - an LLC is liable for obligations only with property belonging to this organization, while an individual entrepreneur is liable with all property belonging to an individual (apartment, car, etc.) .).
The cost of purchasing equipment depends on the configuration, productivity of the line, and taking into account delivery and installation, they amount to at least 800 thousand rubles (for a used one it is somewhat cheaper).
The most expensive components of the kit: steam generator - from 150 thousand rubles. and block form - from 100 thousand rubles.
The cost of a full-fledged automated line with a capacity of over 100 m3 of foam per shift is estimated at several million rubles.
Let us calculate the economic efficiency of an enterprise for the production of foam plastic with a capacity of 80 m3 per shift.
Initial data:
Capital expenditures: Acquisition of a line for the production of foam plastic worth 1.5 million rubles.
The kit includes: a steam generator, a dryer, a BF 0.5 block, a pre-expander, a receiving hopper with a control panel, tables for cutting blocks, an automatic pellet feed system, a waste crusher, a packaging machine, and industrial scales. The costs include delivery and installation of equipment at the customer's site.
Raw material cost: Expandable polystyrene PSV-S in granules will be used for the production of foam plastic. The price for 1 kg is 65 rubles. For the production of 1 m3 of PSB-25 foam plastic, 15 kg of polystyrene is needed. The total cost of raw materials is: 15 * 65 = 975 rubles / m3.
Let's move on to calculating the total cost of foam production per month, per shift and per unit of production.
According to the above calculations, the cost of production of 1 m3 of foam plastic is 1285.3 rubles.
Let's proceed to the calculation of indicators of economic efficiency of an enterprise for the production of foam:
The net profit of the enterprise for the production of foam plastic is 160,595.6 rubles per month.
The profitability of production with such indicators is 14.2%, and the payback period for equipment is 9 months.
It should be noted that the indicators were calculated on the basis of 100% sales of all manufactured products, which is 880 m3 of foam plastic per month.
Since polystyrene refers to foamed plastic, according to the all-Russian classifier of types of economic activity, when registering, we indicate 25.21, which refers to the production of plastic products (plates, pipes, strips, profiles).
To open the production of polystyrene foam, the following package of documents will be required:
prepare internal documentation:
No permit will be required to open a Styrofoam business, with the exception of the Fire Inspectorate. There is no need to go to a sanitation station, since this type of activity is considered practically harmless
ATTENTION!!! Since 2015, instead of GOST 15588-86, GOST 15588-2014 has been introduced.
According to the new GOST, the foam is divided into the following grades: PPS-10, 12, 13, 14, 15F, 16F, 17, 20, 20F, 23, 25, 30, 35, 40, 45.
The abbreviation of foam plastic "PSB" (according to the old GOST) is no longer used.
Styrofoam grades according to the old GOST PSB 15, 25, 35, 50 are no longer used.
Any designation of polystyrene with marking according to the old GOST - this is a consumer deception if there is a link to GOST. If the foam is not made according to GOST, but according to TU, then you can write anything you like. But at the same time, it must be clearly indicated that the foam is marked not according to GOST, but according to TU.
The main difference of the new GOST is the minimum weight of 1 m3 of foam plastic. In the old GOST, the PSB-15 foam grade could weigh from 0 to 15 kg.
That is, it was possible to produce polystyrene with a weight of 7 - 8 kg per cube, and it was polystyrene that fell into GOST. In the new GOST, the lightest grade of PPS-10 foam must weigh at least 10 kg.
If the foam weighs less than 10 kg per cube, such a foam does not comply with GOST.
The above does not mean that it is now forbidden to make foam with a weight below 10 kg per cubic meter. Not at all. Styrofoam with a weight below 10 kg per cube can be made, but not according to GOST, but according to TU. What you need to inform the consumer in advance.
The Delo1 company does not call for work only in accordance with GOST or vice versa. We simply consider it our duty to convey to you all the necessary information related to the production of foam.
The most important indicator of any business plan is the cost of the products received. Based on the cost, an entrepreneur can calculate the profitability of doing business.
The cost of production of one cubic meter of foam plastic consists of the cost of raw materials consumed per 1 cubic meter and the sum of the costs for the production of one cubic meter.
The cost of producing one cubic meter of polystyrene consists of energy costs (approximately 20 kW per 1 cubic meter) and the cost of workers' salaries.
Additionally, you need to add on the overhead costs of doing business as a whole: premises, taxes, employees not directly involved in production, etc. etc.
Calculation of the cost of 1 m3 of PPS-10 foam plastic. Calculation of the payback of the line for the production of foam.
Polyfoam PPS-10 is the most popular in retail. This is due to the fact that it is the cheapest. And the end user in most cases focuses not on the properties of the material, but on its cost.
In the total volume of production, if you focus on retail, PPS-10 brand foam plastic will be 70 - 90%. Let's consider the payback of the line using his example.
We are considering PPS-10 foam produced in accordance with GOST, and not according to TU.
| Name | Unit measurements | Price | Quantity | Sum |
| PSV-s | kg | 110 rub. | 10 | 1100 rub. |
| Electricity | kW | 5 rubles | 1 | 5 rub. |
| Steam | Steam on electricity. On gas, steam will cost 10 times less. * Calculation of the cost of steam for the production of 1 m3 of foam. | 80 rub. | ||
| Salary | rub. | 60 | 60 rub. | |
| other expenses | rub. | 10 | 10 rub. | |
| TOTAL cost | 1255 rub. | |||
| Selling price in Voronezh: wholesale / retail (wholesale from 100m3) data for January 2017 | 1500/ 2000 rub. | |||
| Profit from the sale of 1m3 | 245/745 rub. | |||
| Average profit if 70% wholesale and 30% retail | 395 rub. from 1 m3 | |||
| The average cost of launching a TOP-selling line is no more than 1.8 million rubles. with a steam generator. Payback of the line at 100% of the implementation of the entire volume, when working in one shift | about 5 months |
Of course, the calculation above is made for an ideal situation. As many years of experience show, 100% sales can be achieved within 6 - 12 months after opening a business.
Thus, the real payback period of the foam production line should be considered twice as long as indicated in the table. That is about 10 months.
The cost of some other brands of foam:
Styrofoam is one of the most necessary materials in construction, so the production of foam can become a profitable and sought-after business. In this article, we will talk in detail about how to open a foam plastic business and what is needed for this.
Basically, foam is used in the construction industry - about 85%. The remaining 15% goes to the production of packaging material, special life jackets, etc.
An analysis of the consumer market will make it possible to decide how profitable it is to open a mini foam plant. The presence of competing enterprises is important.
It is desirable that there are no competing enterprises at least within a radius of 100 km.
However, the presence of polystyrene in stores cannot be considered as an indicator, since the goods can be imported from anywhere.
The business plan should include all costs associated with production, organizational issues, as well as the profit that is expected to be received over a certain period. A business plan will allow you to understand how to build a business with minimal investment, but with maximum benefit.
Today, entrepreneurs can purchase lines for the production of a particular product, the complex of which includes all the necessary and relatively inexpensive equipment.
The styrofoam production line is a complex equipment designed for streaming production of products. The price of the equipment is assigned based on the possible volumes of the goods produced.
For example, a line with a complete set (40 m³ per shift) and a cost of $ 15,000 includes the following equipment:
Polyfoam is made of polystyrene PSV-S, produced in granules. The production time depends on the quality of the raw material, since the “older” the raw material, the slower the foaming process is and the more difficult it is to achieve the required density.
The diameter of polystyrene granules is not more than three millimeters.
Now, during the technological process of producing raw materials, a fire retardant is usually added to the composition, which prevents ignition.
However, the presence of this component must be checked with the supplier, since not all manufacturers add antiprene to the raw materials.
The process of creating finished foam sheets consists of the following steps:
The foam plastic manufacturing technology begins with the fact that raw materials (finished PSV granules) are placed in a chamber where foaming takes place. The number of such procedures directly depends on the type of product that is planned to be received.
For example, if it is planned to release foam weighing more than 12 kg, then one procedure will be enough. If it is planned to produce light sheets weighing less than 12 kg, then several foaming procedures are necessary.
At the same time, the processed raw materials after each procedure must hold out for a certain time in the bunker.
After foaming, the treated raw material is transferred to a special tank (bunker). There, the raw material is aged from 12 to 24 hours, since it must dry well.
Also, during the aging procedure, the level of internal pressure stabilizes. After that, the raw material goes through the foaming procedure again, and then you can start molding.
In a block form, the prepared raw material under the influence of steam takes on a certain shape. During the molding process, the structure of the raw material expands, due to which the mass is glued together.
After removing the foam from the mold, the blocks must be aged for about 24 hours. When the material dries, the blocks are cut into sheets.
It is possible to organize the production of foam plastic without waste, in which damaged products or goods that do not meet any parameters are added to the raw materials at the block formation stage. This method of work will reduce the cost of raw materials.
Under the workshop for the production of foam, you need a room with high ceilings (about 5 m), as well as an area of about 150 m2.
Also a prerequisite is the presence of good ventilation, plumbing, necessary for technical needs.
Also needed are heating (at least +15 degrees) and electricity (380 W).
The storage area should be approximately 60 m2. The warehouse is insulated with special constructions made of fire-resistant materials. It is possible to place a warehouse under a canopy, with mandatory protection from direct sunlight and precipitation.
Before starting production, it is necessary to collect a set of documentation that allows this or that activity. Here we will talk in detail about what documents are needed to organize the production of polystyrene foam.
Many entrepreneurs first register as individual entrepreneurs, paying a single tax.
This is the best solution, since initially it is quite difficult to pay tax contributions in full.
However, at any time you can expand production by re-registering it as an LLC, according to a simplified taxation system.
You need to collect the necessary documents, as well as pay the state fee. At the same time, a tax system is selected from five possible ones.
Then the code is defined OKVED. In this case, production corresponds code 22.21"Production of plastic products (pipes, blocks, plates, sheets, profiles, etc.)". After that, you can start collecting documents.
All documentation is submitted to the tax office. A few days later (from 3 to 7), the entrepreneur will need to appear to receive documentation, as well as a record sheet on the start of work as an individual entrepreneur.
In addition, a bank account must be opened. It is also necessary to obtain permission to operate from the fire inspectorate, conclude agreements with organizations for servicing production (utilization and waste disposal).
In addition, it is necessary to prepare a set of internal documentation:
One shift can work from 2 to 4 employees. When planning large volumes of production, it is possible to conclude an employment contract with a large number of people.
The production of polystyrene occurs with the work of the following specialists:
Accounting can be outsourced, which will help to focus on production activities, as well as on the sale of goods, avoiding unnecessary hassle.
Styrofoam production as a business is a fairly profitable enterprise, since polystyrene is one of the most sought-after building materials.
Cost price Styrofoam is quite high, since the market value of one m³ of this material is about $ 20, and the cost of production is about $ 10 (electricity, steam, raw materials).
For example, if a plant produces about 40 cubic meters daily, then the profit per month (when working 24 days a month) will be about $ 20,000. However, about half of this amount (about $ 9,000 must be spent on monthly expenses). Net profit - 9000 - 10000 thousand rubles
Profitability Styrofoam production depends on how much product is made, how fast sales are made, etc.
Here is an approximate calculation of costs and income in order to create such a business from scratch:
Based on this, we can say that the profitability of this type of production is about 22%, the payback will be 5-6 months.
The production of building materials has always brought a good income. This also applies to foam. Today, this material is in great demand in the domestic market. If you decide to open your own business and make a good fortune, pay attention to the business plan for the production of foam. To implement this idea, you will not need a large start-up capital, as, for example, in the case of, so any novice entrepreneur can do this business.
It will not work to quietly open a workshop in a large room and install rather bulky equipment in it. The production of polystyrene foam at home should be legalized in any case. This will allow you to sell goods by bank transfer in large quantities. And this is a significant advantage.
At the start, you can register an individual entrepreneur and pay a single tax. Opening a full-fledged company and paying taxes in full at the stage of formation is too expensive. This could lead your business to bankruptcy. When the company begins to expand, you can open an LLC and work on a simplified taxation system.
To choose the right geographical location of the enterprise, it is necessary to conduct a thorough market research. The most favorable for doing business are those regions in which the supply of this product does not fully cover the demand. In such a place, you can safely launch your commercial project.
Do not forget to clearly work out and include in the business plan the ways of selling the finished material. This is a very important point, on which the profitability of your enterprise largely depends. In addition, the seasonality of the business should be taken into account. In a period when demand for products is falling, you can switch to the production of foam products. This will allow you to provide a stable year-round income.
The main consumer of foam -. Each of them is already cooperating with other manufacturers. You need to attract their attention to your product with low prices, but at the same time with good quality. To ensure stable sales of products, it is necessary to find regular wholesale buyers, for example, and conclude contracts with them.
The building in which the equipment for the production of foam plastic will be located has special requirements. The mini-factory should consist of three rooms, which are isolated from each other by special fire-resistant shields:
The workshop should be supplied with water and electricity. The height of the ceilings in this room should not be less than 5 meters.
As for the location of the workshop, it is best to find a room outside the city. Renting there will be much cheaper, which will significantly affect the payback time of the business.
Scheme: equipment for the production of foam
This equipment does not require any special maintenance. You can install it yourself. But, as in any other business, there are some nuances here, which in the future can negatively affect the cost of the product. Therefore, it is better to entrust the installation of equipment to specialists.
One block mold for the production of foam will not be able to provide high productivity. It is advisable to purchase two units at once. If you plan to produce in high volumes, buy a cutting table equipped with an electric cutter.
Don't think that a modern styrofoam machine won't need an attendant. To ensure the continuous operation of the enterprise, it is necessary to form a staff.
To work in one shift, you will need 1 technologist and 4 workers. In addition, the staff should have a person who cleans the premises. To resolve issues related to taxation and accounting, you need to hire a competent specialist.
One of the most important steps in drawing up a business plan for mini foam production is to calculate the costs:
If your company will work in two shifts 5 days a week, the initial costs will pay off in just 3-5 months. This applies only to the purchase of equipment and raw materials. The cost of renting the premises and salaries of employees will be monthly.
The profitability of such a business reaches 20%. These are excellent indicators that are difficult to achieve in any other direction of entrepreneurial activity. If you are looking for a profitable business idea, foam plastic production is an ideal option for starting your own profitable business.
Polystyrene foam is made from special expandable polystyrene foam. Its cost largely depends on the manufacturer and fraction. The price of raw materials for the production of foam plastic ranges from $ 2 per 25 kg.
When purchasing polystyrene foam, pay special attention to its quality. Domestic raw materials can be bought at a low price, but this may adversely affect the quality of the finished product. Imported polystyrene foam allows you to get high-quality material with a small amount of marriage. Recently, the main raw materials are purchased from China.
Pay attention to the quality of polystyrene, as well as the duration of its storage. The older the raw material, the longer the foaming process will take and the more difficult it is to achieve the density of the foamed granules.
When the feed material enters the pre-expander, the granules inflate and turn into balls. If necessary, this process is repeated. After foaming, the granules increase in volume. This foam production technology is used for the manufacture of material of low strength.
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At the next stage, the foamed granules are fed into the hopper. They are kept there for 24 hours. During this time, the semi-finished product dries out and the pressure inside the granules normalizes. After that, it is poured into a block mold and formed by acting on the granules with steam. If you are interested in the production of foam, the video of the process will help you understand it in more detail.
Foam production: 10 material properties + composition + foam classification + marking + 4 areas of application + 9 stages of production organization + features of the production cycle + calculation and profit.
Styrofoam first appeared in Germany in the 50s of the twentieth century under the name styrofoam. Since then, this versatile material has become widely used in almost all branches of human life.
Many companies are engaged in the manufacture of foam plastic today, because. styropor only as a heat-insulating product occupies more than 10% on the market. It is not worth talking about the expediency of foam plastic production from the point of view of profitability, even despite the competition.
Therefore, in this article we will look at the important steps through which legal entities can start the production of foam, increase their competitiveness and get their “piece of the pie”.
Each manufacturer, before organizing the production process of a particular product, studies its technological features and scope. We will first consider the properties of the foam.
Styrofoam is characterized by:
However, polystyrene has some negative factors:
As you can see, the advantages prevail over the disadvantages, which leads to a high demand for the production of foam. What gives the material such useful properties? To answer the question, you need to know its composition.
Plastic mass is mainly composed of gas. The initial raw materials are vinylbenzene polymerization products. Due to the filling of the main volume with gas, the finished product is significantly lower in density than the polymer substance.
To be precise, only 2% is polystyrene. The remaining 98% is air. The material has a rigid porous structure, odorless, white.
Now let's deal with the range of goods that you will manufacture. Styropor can be produced in different classes, differing in durability and strength. It all depends on the technology you choose, the recipe.
So, distinguish press foam and the one whose production is carried out non-press method.
The second is done at high temperatures to bake the granular substances. This is the type of foam we see most often. This is a material that has a spherical structure.
But pressable styrofoam lends itself to high temperature, it is mixed, but during its production it is still necessary to add a foaming solution. This type of foam wins with high strength indicators. It is practical and hard to break.
Material marking has its own characteristics. For example, the production of domestic foam plastic entails the mark PS. In the case of non-press production technology, the designation PSB should be put. The PSB-S-15 brand has the maximum density. Also on store shelves there are brands with a numerical value: 25, 35, 50.
There are 3 more types of styrofoam according to the production method:
Polyurethane (PPU) or foam rubber.
It is characterized by: elasticity, porosity. Due to the fact that such material passes air well, it is used in construction and furniture production.
However, the smoke from a PPU fire is poisonous. And the sun's rays lead to its yellowing, durability "limps".
The second type of material is polyethylene (PPE).
It is also very flexible and is most often used for protective wrapping of fragile items when moving.
Styrofoam comes to retail outlets in sheets of different sizes. Unlike polyurethane material, it is environmentally friendly and has a long service life.
You can also set up the production of polyvinyl chloride foam (PVC).
Its characteristics do not differ in many respects from the previous type. PVC does not ignite when not in contact with fire.
But when ignited, this foam poses a threat, because it releases hydrogen chloride into the environment, which, when combined with the liquid, forms strong hydrochloric acid.
Foam production is beneficial for the following industries:
Construction.
Polyfoam has found its application as a finishing, structural material for shaping, making decorative elements. Often it fills compartments where there is no heating (for example, on small boats).
Styropor allows you to save on thermal energy, reduce material and time costs for installation and construction. Due to the fact that polystyrene foam plates reduce the thickness of the walls, in parallel with this, the area of \u200b\u200bthe building itself increases.
Foamed polystyrene is the basis of ceiling tiles, skirting boards. He has proven himself well as a heat-insulating material for the floor.
Remarkably, when cutting and other work with polymer, it is not necessary to wear protective clothing, use special devices, because. it does not form dust, does not cause irritation of the skin. However, some safety rules must be observed. So, it is necessary to work with the material in well-ventilated workshops.
Fishing, sea.
Polyfoam is used in the production of life jackets, fishing gear.
Medical.
Styropor serves as an auxiliary substance in the manufacture of pharmaceutical and medical containers.
Foam production benefits people who use the product as packaging. It is also needed as a heat insulator in household appliances.
Styrofoam is also used in the production of metal products, allowing you to form a sample, a mold on which casting takes place. Styropor is also in demand in the manufacture of disposable tableware and children's toys.
Due to its wide application in various areas of the national economy, environmental safety, good technical characteristics, versatility, low cost, ease of production, the demand for foam increases¸ and the manufacturing process becomes cost-effective.
To organize the production of polystyrene, an entrepreneur must follow a certain algorithm. It is carried out in 9 stages.
Let's take a closer look at each specific stage.
First you need to give a real assessment of consumer opportunities in the place of the future presence of the plant for the production of foam. For this, the market conditions, aspects of sales, demand, and competition are studied.
These factors will affect the success of the business. If there are many competitive foam manufacturers in your area, and supply exceeds demand, it is better to abandon the idea.
Potential consumers of styropor are usually builders and construction companies. They own 85% of the market. 15% falls on the production of gear, packaging materials, aggregates, etc. You have to target mass consumption. Studying these questions will help you decide on the type of trade.
In the case of retail sales, foam plastic will have to be supplied to hardware stores, to end consumers. As a rule, one outlet orders approximately 30 cubic meters per month. m of foam. The retail type of trade will save you from renting a room for a store, hiring sellers and advertising costs.
However, there are also disadvantages here:
Wholesale can be carried out directly from the warehouse. To organize it, you need to purchase and install a cash register, allocate some space for demonstrating product samples.
In this case, your customers will be wholesale buyers. Suppose a person wants to insulate the facade of a house with an area of 150 sq.m. To do this, he will need 25-30 cubic meters. m of material. It is more profitable for him to contact an entrepreneur engaged in the production of foam plastic and purchase goods without extra charge. Some legal entities are trying to combine both types of trade.
When analyzing competitors, take into account their presence within a radius of 100-200 km, the quality and types of their products, wholesale / retail cost. It is important to pay attention to the promotion tools used by competitors: the provision / non-provision of additional services, the effect of discounts, promotions.
Interesting fact ! In Europe, as a building material, polystyrene is very popular. So, in Italy there are 400 enterprises for the production of foam.
In the developed countries of Western Europe, up to 5-7 kg of polystyrene foam per citizen. Recently, there have been trends towards the production of "black foam" containing graphite filler.
A clear drafting of the project is the basis for the production of any product. Therefore, you must write a detailed business plan that reflects the results of the research and analysis from the first paragraph.
In addition, the following information should be included in the document:
A business plan for the production of polystyrene foam products is especially necessary if you do not have your own, and it is planned to attract investors, receive bank loans, and subsidies from the state.
Before establishing the production of polystyrene, the entrepreneur must legalize it. Even if you intend to manufacture at home, this does not relieve you of this responsibility.
Many are registered as individual entrepreneurs and pay a single tax. At the stage of formation of production, it will be unprofitable to make tax contributions in full. When the company expands, you can at any time re-register the production of polystyrene foam into an LLC, and then work according to a simplified tax system.
The opening of an individual entrepreneur is accompanied by paperwork and the payment of state duty in the range of 800 rubles. If you do not have the opportunity to personally provide the necessary list of documents to the regulatory authorities, you will have to resort to the services of a notary who must certify each paper. It takes up to 1.5 thousand rubles.
When submitting an application, a tax system is selected from the five current ones. It is recommended for the production of polystyrene to pay attention to UTII or USN. Thanks to them, bookkeeping is simplified, the tax burden is reduced, because they are intended for small businesses.
After that, you need to determine the type of activity according to the OKVED-2 directory, since the selected code is indicated during registration. The production of expanded polystyrene corresponds to 25.21.
25.21 - production of plastic products (pipes, blocks, plates, sheets, profiles, etc.).
Then you can start collecting documents.
You will need:
The documentation is transferred either to the tax office (look for the address here - https://service.nalog.ru/addrno.do) or through the MFC (list of branches here - https://mfc.rf/mfc/index/regions). After 3-7 days, you will have to appear to receive documents and a record sheet for registering the production of foam plastic as an individual entrepreneur.
Also, it should. Also, the production and sale of polystyrene is impossible without obtaining permits and coordination with the fire inspection, concluding agreements with service organizations that will remove and dispose of waste.
In addition, internal documentation is being prepared:
Polystyrene granules are taken as raw materials for the production of polystyrene, which are classified as plastics. Some order imported ones, because. they are of better quality than domestic ones. The difference is not only in cost, but also in their chemical parameters.
On average, the price for 1 kg of polystyrene granules is 2-3 dollars. Medium-quality granulated PSV-S polystyrene costs 60-70 rubles. It resembles beads measuring 0.02-0.35 cm (in diameter). For each type of foam, appropriate granules are selected.
For example, in the production of PSB-S-50 foam plastic, polystyrene number 1 is used, i.e. the smallest. The production of PSB-S-15 brand implies the use of polystyrene No. 4. The most popular brand is PSB-S-25F.
To achieve the production of 1 cu. m of foam, you need to have 15-50 kg of raw materials available. The consumption rate is determined by the brand of foam. Many are trying to establish production even at home, since the technology is simple.
The production technology can be described as follows:
This production process takes 4 minutes. The treated polystyrene is then discharged from the tank. If the specific gravity of the foam is 12 kg, one procedure is enough.
For lighter products, it is necessary to repeat the task several times, moreover, after the aging of the granules.
Removing excess moisture by drying.
From below, hot air enters PSV-S polystyrene, however, they can be shaken. At the end of such actions, the granules through pneumatic transport fall into a special bunker.
After 4 min. you can proceed to the next stage of foam production.
Curing of foamed raw materials.
Depending on the size of the substances, room temperature, the granules lie down for 4-12 hours.
Forming (sintering).
To do this, the foam is placed in certain forms, then it is exposed to hot steam under high pressure.
The result should be a monolithic structure due to gluing, acquiring an adjacent shape, sintering. This procedure in production lasts up to 12 minutes.
Sorting and warehousing.
Styrofoam should rest after removal from the block mold for at least a day. Finished blocks during this time should lose moisture residues.
Block cutting.
At this stage of production, polystyrene is cut with a special machine into a certain thickness of the plate (2-100 cm). Standard sizes: 100x50, 100x100, 200x100 cm.
Recycling of residues (in non-waste production).
The remaining layers of material, allowances at the edges, "crumbs" can be processed and mixed in subsequent production, observing a ratio of 1:8.
To find out what kind of foam you need, you need to decide on the volume of output that you are counting on. This indicator is of decisive importance for the choice of technical equipment and affects its cost.
For example, for the production of 20 cubic meters. m of foam for an 8-hour work shift, a set of equipment is suitable, the price of which is at least 500 thousand rubles.
In order to double productivity, it will require the cost of purchasing units in the amount of 800 thousand rubles. and higher. For the production of 100 cu. m of products, it is better to buy a complete production line, the cost of which exceeds 1.4 million rubles.
This line will be:
Maximum automation is provided by a complete set of:
In some cases, the steam generator for the production of the product is purchased separately.
Such equipment consumes at least 1 thousand liters of water per shift, the electricity consumption depends on the steam generator.
To simplify the production and release of foam, many people buy additionally:
The price of a steam generator varies depending on the fuel and performance. Focus on 250 thousand rubles. In terms of consumption, buying an electric one is not profitable. However, it does not need to obtain the appropriate permissions and is safe to use.
The production equipment does not require special maintenance. Installation and launch is within the power of everyone. However, in order to avoid a negative impact on the cost of foam, it is better to contact specialists.
The foam production workshop must have high ceilings (at least 5 m). It is necessary to choose a room with an area of 200 sq.m.
It must meet the following requirements:
The temperature regime cannot be lower than +15°С. The water supply must satisfy the minimum needs (about 3 cubic meters per shift).
A separate room of 60-70 square meters is also required. m used as a warehouse. The warehouse is surrounded by fire-resistant structures. It is desirable that it be closed. Although, if necessary, expanded polystyrene foam can also be stored under a canopy so that no precipitation or ultraviolet rays have a negative effect.
Another unit is a warehouse for raw materials. For this room, 10 square meters is enough. m area.
It is advisable to rent a mini-factory for the production of polystyrene outside the city (it's cheaper).
Having finished with the material and technical base, proceed to the selection of personnel. The staff involved in the production of products is recruited without special requirements. It is not necessary to look for employees with higher education, but experience is welcome.
Technological equipment is quite simple. The equipment supplier explains the operating rules upon delivery, so training of personnel will not cause difficulties. 2-4 people are enough for one shift. If necessary, you can conclude an employment contract with a large number of employees.
The composition of the staff is affected by the performance of the equipment. Thanks to the efforts of one worker, a production of 6 cubic meters can be expected. m of foam. And for other organizational issues, people with other qualifications will already be required.
In the production of any brand of foam, personnel are needed:
Production personnel are paid piecework-bonus. Under such conditions, workers will be motivated to increase productivity.
It is not enough just to care about the production of quality products. It is important to establish its marketing. To do this, they go the classical way, that is, they place advertisements in various sources: print media, on television and radio, and on the Internet.
If at the expense of the first methods you can doubt, then the opportunities provided by the World Wide Web should not be neglected. If you want - create a corporate website, if you want - buy places on advertising platforms for your ads. An additional way to make yourself known will be the distribution of booklets with your contact details, an image of the products you are engaged in.
Be aware that competitors can poach your customers. To avoid this, try to conclude profitable contracts for the wholesale supply of foam, and as early as possible. Competently compose a commercial offer so that it is beneficial for both you and the buyers. If there are difficulties with finding large customers, the best option is to supply polystyrene foam to construction markets or sell it from a warehouse.
Polyfoam production technology.
What are the advantages of this business idea? Tips for
organization of production.
The cost of production of polystyrene of the running 25th brand depends on the cost of raw materials and utilities, the purchase of equipment.
One block of material weighing 16 kg (per 1 cubic meter) requires 1 kg of raw material. If we take into account the costs of electricity and water, the salary of 2 workers (600 rubles per person per shift or for the production of 30 cubic meters of foam for each), the approximate cost will be 150 rubles. For the purchase and delivery of raw materials (1 kg), you will have to pay about 70-75 rubles. Multiplying this number by 16 kg, we get 1.2 thousand rubles.
It turns out that the cost of production of 1 cu. m of foam are: 1.2 thousand rubles. + 150 rub. = 1350 rubles. Cheaper raw materials will cost 975-1000 rubles.
Profit from this amount of material will be formed depending on the type of trade and the sale value. This is approximately 250-400 rubles. In general, it is impossible to designate a figure, because. you will have your own volumes of production and sale of foam.
Payback of equipment for the production of products can reach 7-12 months. If sales rates are good, taking into account seasonality, investments will return in a shorter time.
The cost of the mechanism depends on its configuration. An automated line will cost 1.3-1.5 million rubles. By purchasing equipment separately, you can meet 500 thousand rubles.
Styrofoam production entails monthly costs:
Approximately 100-150 thousand rubles will have to be allocated for wages. Lease payments start from 60 thousand rubles. Tax deductions - 26.7 thousand rubles. It is not worth launching a large advertising campaign, 10 thousand rubles. enough for her.
In total, transport costs, utilities and other expenses can give 90-100 thousand rubles. and more.
If the cost of production is 1285-1350 rubles, 1 cu. m of foam can be sold at a price of 1.5 thousand rubles.
Here is another example of calculated data for the actual production of foam plastic:
Necessary capital investments, taking into account the purchase of a technological line and other costs within 2.5-2.7 million rubles.
Styrofoam production, judging by the indicators of profitability, payback, simplicity of technology, demand for products - a very promising and profitable idea. The main thing is to make all the calculations correctly, take into account the peculiarities of the market and draw up a business plan.
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It is difficult to find a modern material that would be used as widely as foam. The range of its application is so wide that listing only the industries where it is used would take several pages.
To understand the versatility of foam, here are a few of the industries where it is most commonly used:
As you can see, polystyrene is used in almost all areas of modern life. It is this fact that makes its production one of the most profitable and cost-effective today.
Styrofoam- the collective name for the class of materials, which is a foamed (cellular) plastics. The main useful property of foams is their low specific gravity and low density (the main volume of the foam is gas, so it is not much - only 9 to 29 times - heavier than air).
This fact, coupled with cellularity, determines the main advantages of foam plastics: high heat-insulating (convection flows are practically impossible in a single cell) and sound-proofing (thin elastic cell partitions are a poor conductor of sound vibrations) properties.
Foams are derived from many of the most widely used plastics (polymers). The best known materials are polyurethane, polyvinyl chloride (PVC), phenol-formaldehyde, urea-formaldehyde and polystyrene foam.
All these types are distinguished by density, mechanical strength and resistance to various types of impact. The choice of a specific type of foam for use in certain conditions and purposes is determined by the composition of the raw material and the technology of its processing.
In our and many other countries, the most common polystyrene foam, or expanded polystyrene, is made in accordance with GOST 15588-86.
Expanded polystyrene is a white homogeneous substance, having a structure of balls glued together, elastic to the touch. Has no smell.
Expanded polystyrene is an environmentally friendly, non-toxic, heat and sound insulating material. It has been used in construction for half a century and has established itself as the most economical and convenient to use.
Polystyrene foam is a neutral material that does not emit substances harmful to humans. It is not susceptible to degradation by microorganisms and has no limited shelf life. Moisture does not affect the properties of this material and does not cause the formation of bacteria and mold in it. The physical and chemical properties of expanded polystyrene are not adversely affected by the ambient temperature.
In addition, this type of foam tolerates the presence of asphalt emulsions, asphalt-coated roofing material, artificial fertilizers, caustic soda, ammonium, liquid fertilizers, paint foams, soaps and softening solutions, cement, gypsum, lime, salt solutions, water and all kinds of ground water. .
The only negative (destructive) factor for polystyrene is prolonged ultraviolet irradiation, or, simply speaking, exposure to direct sunlight. This factor increases the fragility of expanded polystyrene and its susceptibility to erosion from wind, rain and other weather events. Therefore, during storage, it is necessary to cover the plates from the sun.
The raw material for the manufacture of polystyrene foam (expanded polystyrene) is a special expandable polystyrene (PSV).
The foam production technology is divided into several stages.
On the first of them, foaming of the starting material is performed (single or multiple). Polystyrene granules, getting into the pre-expander chamber, foam (inflate) turning into small balls.
If required, the process can be repeated: during repeated foaming, the already foamed granules are re-fed into the pre-expander chamber, where they increase in size (inflate) even more.
This technology is used to produce low density foam. The density of the foam is measured in kilograms per cubic meter and is called the actual weight. That is, if we talk about expanded polystyrene with an actual weight of 10 kg, it means that 1 cubic meter of such expanded polystyrene will weigh 10 kg.
A single foaming results in a foam with an actual weight of 12 kg and more. With double-triple foaming, foamed polystyrene will be obtained with an actual weight of less than 12 kg.
The second stage of production is curing. Foamed granules are fed pneumatically through a special bunker, where they are kept from half a day to a day. This process is necessary to dry the semi-finished foam and stabilize the pressure inside the granules.
It is important to repeat the aging with each re-frothing, i.e. to obtain polystyrene foam with an actual weight below 12 kg, several stages of curing will be required.
After aging, an amorphous mass of foam plastic is molded. The granules that have dried and reached the condition are poured into a special block mold, in which, under the action of steam, a foam plastic block is formed.
The process takes place in a closed space and the foam balls-granules expand, interlocking with each other and forming a monolithic block.
This block is aged for at least a day, and then it is cut, where it is given the desired shape. The second exposure is necessary again for drying. If you try to cut wet foam, the cut will be uneven or torn.
The styrofoam production line is easy to assemble and operate, and quite low cost. It consists of several nodes and assemblies, the minimum set of which is given in the table below.
|
equipment identification |
Number of units, pcs. |
Unit cost, rub. |
Total, rub. |
|
steam generator |
|||
|
pre-foamer |
|||
|
Secondary Foaming Device |
|||
|
Receiving hopper |
|||
|
block form |
|||
|
steam accumulator |
|||
|
crusher with fan |
|||
|
Fan for aging bunkers |
|||
|
Cutting table with transformer |
|||
|
Trimmer with a transformer |
|||
|
Bunker bag |
|||
|
TOTAL |
Consider the table in more detail and make some additions and clarifications. The production of foam plastic does not require any material costs, except for the cost of foaming suspension polystyrene. But besides this, utilities are also required - the supply of cold water and electricity. In addition, some steam generators use natural gas as fuel.
However, this table shows the price of a more economical steam generator - for liquid (diesel fuel) and solid (wood, as well as peat and coal briquettes) fuel.
In addition, for only 155 thousand rubles. it is possible to purchase a steam boiler with an afterburner (utilizer) of various waste - sawdust, tyrsa, husks from seeds, shavings, bark, lumpy waste and other combustible materials.
The use of such equipment will allow not only to organize waste-free and environmentally friendly production, but also to increase the productivity of steam boilers by 2-2.5 times at the same fuel consumption and thus save on expensive fuel. The difference in cost between a conventional steam generator and a steam generator with an afterburner pays off within a few months due to fuel savings.
However, despite the obvious advantages of a boiler of this type - a cheap type of fuel, low cost and ease of maintenance, there are two significant drawbacks: the need for constant monitoring of the boiler and its maintenance (fuel filling), which requires hiring at least one full-time unit - a stoker - a stoker, as well as a fire-fighting requirement, placing the steam generator in a separate room, which is not always possible for architectural reasons.
Therefore, if it is not possible to use an oil-fired steam boiler, electric boilers are used. Their cost is also low - from 56,700 rubles. up to 80,000 rubles, respectively, depending on the capacity, but the resource they use (electricity) can significantly affect the cost of production.
The pre-foaming plant is operated by one person and has a capacity of 6-7 cubic meters. m per hour (with primary foaming) up to 10-12 cu. m per hour (with secondary foaming).
It is necessary to take into account the fact that the performance of the block mold is designed for once foamed material, and therefore also does not exceed 6-7 cubic meters. If an enterprise specializes specifically in the production of expanded polystyrene with an actual weight below 12 kg, it is advisable to purchase a second block mold, the price of which in this case (i.e. with a separate purchase and installation of additional devices that are not included in the line indicated in the table) will be 109- 135 thousand rubles, depending on the desired size of the resulting block: 2000x1000x550 mm or 2440x1230x650 mm. The block form is served by 1-2 people. In the second option, that is, when using two block forms, you will also have to purchase a steam accumulator with a volume of 1.65 cubic meters. m for 85 thousand rubles. instead of a 0.7 cu. m, which is enough for the production of 6-7 cubic meters. meters of foam per hour.
With large volumes of production, as an option, you can use an electric table for cutting blocks worth 250,000 rubles.
The number of liners for the holding bin for foamed granules (2 pcs.) is the minimum. In fact, the number of bags should be at least equal to the number of types of products produced per shift and depend on its volume.
For example, with a production volume of 6-7 cubic meters. m (i.e. ordinary polystyrene foam) per hour, the liner bag is completely filled in 3 hours of work, and in the production of low-density polystyrene foam - in 2 hours. Therefore, the first shift will require 3 bags, and the second - 4.
The crusher with a fan indicated in the table at a cost of 35 thousand rubles. is an apparatus in which industrial waste (cuttings, etc.) of foam plastic is placed. Styrofoam production is waste-free: all substandard material is crushed and added to pre-foamed polystyrene granulate before molding it into foam blocks in an amount of 5-10% of fresh raw materials.
As already mentioned, the production of any foam requires only a special expandable polystyrene. At the same time, it should be taken into account that these raw materials differ in a number of technical characteristics, the most important of which is their price, which depends on the fraction (the size of the initial granule), and, of course, the manufacturer.
On average, for manufacturers and fractions of granules, the normal price for foaming polystyrene is 51-61 rubles. for a 25 kg package. The arithmetic mean between the two given figures is 56 rubles. and take it as a calculated value.
Further, the production of expanded polystyrene from polystyrene is correlated as 1:1 by weight, taking into account waste-free production. For ease of calculation, we will assume that the mini-factory operates 8 hours a day, 24 days a month and daily produces 52 cubic meters (average between 5 and 6 cubic meters of hourly output) of foam plastic daily, and 1248 cubic meters of foam plastic per month.
Let's say that the plant produces foam of the same type: the actual weight is exactly 12 kg. Then it turns out that the daily output of the plant is 624 kg, and the monthly output is 14976 kg. Thus, it turns out that the cost of materials will be equal to 24.96 packages of expandable polystyrene daily, and 599.04 packages per month.
For accuracy, we will add a certain number for shrinkage, shrinkage and other irreversible material losses inevitable during manual labor and round the resulting figures to 25 and 600 packs per day and month, respectively. So, the daily cost of the material is only 1,400 rubles, and the monthly cost is 33,600 rubles.
To calculate the material cost of expanded polystyrene, you should get the quotient from the cost of material and production. With a daily cost of 1,400 rubles divided by a daily output (52 cubic meters), an amount of 26.92 rubles is obtained, which is the cost of production of 1 cubic meter. m.
The next step is to study the price of finished products. As you might guess, it depends on the density of the foam - the denser the material and has a higher specific gravity, the more expensive it is.
For our "ideal" polystyrene, we will have to calculate some average, statistical price. For example, the price of 1 cubic meter of polystyrene with an actual weight of 10.5-11 is 1050 rubles. And the price of 1 cubic meter of polystyrene with an actual weight of 13-14.5 kg is 1250 rubles. We calculate the average price between two items: 1150 rubles. for 1 cu. meter.
Thus, the net material profit from 1 cubic meter of expanded polystyrene is 1123.08 rubles. Daily net profit will be 58400.00 rubles, and monthly - 1401600.00 rubles. If we take utility bills and wages for employees as 40% of net material profit, then the business owner gets at least 840,960.00 rubles. net income monthly.
As you can see, all the equipment indicated in the table pays off in the first month and is even much lower than the first revenue: 483,500 rubles. to 840960 rubles. The payback is 57.49% in the first month. Accordingly, 42.51% of revenue, or 357,460.00 rubles. remain in the hands of the business owner.
On the example of the above descriptions, you can see that the production of foam from any material - whether polystyrene, polyurethane, polyvinyl chloride, or other polymers - is one of the most cost-effective today.
In fact, such high profitability figures of 4271.43% are almost impossible to find in any other industry. This is explained by the ratio of material costs to the trade margin, which is 1: 41.71 (or 2.34% to 97.66%). But such a significant ratio is not accidental - it fully characterizes the ratio of supply and demand for foam plastics in the Russian market. As you can see, the demand is very high, which is reflected in the profits of an organization that is engaged in the production of foam plastics in general and expanded polystyrene in particular.
Video about foam production
