If you pay attention to which companies are most often opened today, then without a doubt you can name jewelry, alcohol, automobile and furniture. Let's pay attention to the furniture. It consists of simple and lightweight materials, but with an interesting design it can be very expensive. Thus, furniture brings high income with minimal costs. As a result, equipment for the production of foam rubber is considered relevant for purchase.
The material is widely used in the manufacture of furniture, toys, and sporting goods. Foam rubber is a material consisting of polyurethane. It is very elastic and resilient, since 90% consists of cells filled with air.
Material used in manufacturing:
Issue volumes upholstered furniture V Russian Federation are increasing every year. The annual growth in this market segment is 10%. With the development of this industry, the demand for the materials needed also increases. The main one is foam rubber.
At the moment, there are two main methods that are used in the production of foam rubber: continuous and periodic. Small firms use the second technology because it is simple, and the costs of purchasing equipment and its maintenance are minimal. In addition, no specific education is required to make foam rubber; it is enough to take training courses offered by suppliers.
In order to start making foam rubber, you need to have:
In order to organize a full-fledged line, you should purchase additional devices: a waste crusher, a machine with which you can curl sheets, and a film packaging machine. The above types of equipment can be ordered separately, or you can purchase a complete line.
A set of equipment that produces 12 m 3 of material in one shift costs around 300 thousand rubles. If you order a line that includes all devices for producing foam rubber of various brands and is capable of producing up to 30 m 3 of foam rubber per shift, you will need 1.3 million rubles.
There is an option in which you can order a mini-factory in China. The production volume of such a line is at least 50 m 3 of finished material per shift. The issue price is 1.6-1.8 million rubles. This option is more profitable. To effectively build the process, you will need 7 employees who will work 8 hours per shift. Capital costs for organizing a line for the production of foam rubber will amount to approximately 1.78 million rubles.
Those who decide to engage in this activity need to register an individual entrepreneur. Find a suitable room where the workshop will be located with a total area of 200 m2. Find buyers among enterprises and firms that produce furniture and other goods that use foam rubber.
Line load is closely related to customer demand for upholstered furniture. The largest revenue will be generated during the peak time of furniture sales (autumn and from February to April). The rest of the time there will be a decrease in revenue due to seasonal customer demands. There are very few orders in January, this is primarily due to the holidays. This is the best time to spend maintenance equipment.
Revenue is best calculated assuming that the line is 50% loaded. When producing foam rubber with parameters of 20 mm thickness and density 25 kg/m3, the price for large orders will be 150 rubles/sheet, and the retail price will be 250-270 rubles. As a result, we can create the following table.
When producing a sheet of foam rubber, the cost will include the cost of raw materials for production and the energy used:
Thus, after making approximate calculations, you can see that even with a payback period of 12 months, you can regularly receive high income even with 50% line load. With 100% operation of the equipment, you will be able to recoup your costs within six months. Therefore, it is very important to take care of ways to sell products in advance.
The main activity of the company is batch production of sheet and block foam rubber. The produced foam rubber is used as padding material in the production of upholstered furniture, sports mats, children's modular products, medical mattresses, as well as for other purposes. Our company offers for sale not only the foam rubber we produce, but also a set production equipment with a full composition of chemical components for conducting this type of activity. Our specialists with many years of experience,will carry out full range of services for installation, commissioning,
training Your staff and release final products on the proposed equipment. If necessary, our company offers on favorable terms for you supply of chemicals including transportation.
We have been cooperating since 2003 with the following organizations:
- OOO " DAUIzolan" Vladimir
- OOO " Furniture-groups", G. Nizhny Novgorod
- OOO " NVP Vladipur", Vladimir
- OOO " Semi-products plant", Nizhny Novgorod
- OOO " Tempo NN", Nizhny Novgorod
- NPP LLC Elastoprom"Penza
The equipment is manufactured according to the design principles of imported (German) equipment, with the exception of complex expensive electronics; all critical components and assemblies are simplified and strengthened in accordance with domestic operating conditions.
Performance
Allows you to produce up to 60 cubic meters of foam rubber in an 8-hour shift.
Components
Mixing setup
Designed for the production of polyurethane foam blocks.
Overall dimensions 1400x1000x2730 mm.
- Supply voltage 3x380 V
- Maximum power consumption – 3 kW
- The mixer capacity allows the production of densities ranging from 16 kg/cub.m to 25 kg/cub.m
Form – mobile with floating lid
Cutting horizontal installation
- Designed for cutting polyurethane foam blocks into sheets of a given thickness (from 3 to 220 mm). Overall dimensions 4460x2500x2700 mm. Characteristics: - Supply voltage 3x380 V - Maximum power consumption – 5 kW
This type of activity uses six-component system. The main ones are: the polyester component and the isicianate component T-80. The apparent density of the resulting polyurethane foam depends on the amount of main components and water in the formulation. Surfactant and catalysts ensure a balanced process of foaming and hardening of foam rubber.
The process of producing polyurethane foam in batch plants consists of the following technological stages:
- preparation and tempering of raw materials
- preparation of the activator mixture and component A
- preparation of component C.
- dosage
- production of blocks and their aging
- cutting blocks into sheets of a given thickness
When producing elastic blocks PPU The room temperature must be maintained at a specific temperature. When ripening, PU foam blocks are placed on the floor at a distance of no closer than 0.2 m from each other. Resting takes place for at least 12 hours, then the finished blocks are sent for cutting. During the standing process, the processes of chemical transformation of starting substances into non-volatile polymer products are completely completed, reactive compounds are bound and the block is cooled.
Requirements for production premises
- The area of the molding shop (pouring) should be 30 – 35 sq.m, temperature range 20 – 28 C, ceiling height at least 3 m
- Availability of exhaust ventilation in the molding workshop. An umbrella measuring 1.2 m x 2.2 m is installed directly above the mold where foaming occurs. Fan motor at least 3 thousand rpm, air duct diameter 0.3 m
- The room for sawing and storage must have an area of at least 200 sq.m., regardless of temperature conditions
In total, the total area of premises required for the placement and operation of this production must be at least 230 sq.m.
Departure of specialists to organize the entire turnkey mini-production at the customer’s address.
- Installation and commissioning of equipment
- Project of premises for this type of activity
- Selection of all necessary attributes used in the production of polyurethane foam
- Technology training
- Delivery of chemical components
- Issue finished products
- All further consultations on customer issues
This production process must involve at least three people (technologist and two workers). When producing foam rubber of any density, from 15 to 30 blocks are produced in one work shift. For a month(24 working days) produced on average 500
blocks. Let us give a calculation of the cost of one block of foam rubber with a density of 22 kg/cub.m. According to the technology, the required amount of raw materials for the manufacture of one block is 50.17 kg. The cost of a six-component system for the production of foam rubber is $2.8 per 1 kg(1 kg contains all the necessary components in the required proportions). Therefore, the cost of one block for raw materials will be: 50.17 kg x $2.8 = $140.47. The block produced on this equipment has the following dimensions: width – 1000 mm, length – 2000 mm, height 1100 mm.
Thus, 110 cm of foam rubber (110 sheets measuring 10x1000x2000 mm) are available for sale. On average, as of January 2009, the cost of one sheet of foam rubber with a density of 22 kg/cub.m and a size of 10x1000x2000 mm is 2,1 $
, therefore 110 sheets x 2.1 $ = 231 $
. Let's determine the difference between the selling price and the cost of one block for raw materials: 2 31 $ - 140,47 $ = 90,53 $
. With an average employment of workers in the production process, up to 500
blocks per month with income 25 – 30 thousand $. Electricity costs are 2000 - 2500 kW per month at the above operating rates. Wages employees have piecework, on average it is 3 $
for the production of one block of polyurethane foam. Current expenses for needs production activities make up 400 – 500 $ per month. This equipment allows the production of up to 35 tons of foam rubber per month, subject to continuous operation of production
Today, foam rubber manufacturers operating in our country cannot fully satisfy the demand for this product, so it has to be imported from abroad. Delivery costs significantly increase the cost of products, so consumers prefer to buy material made by domestic manufacturers. The production of foam rubber in Russia brings great profits. We will figure out how to organize such a business in this article.
Modern foam rubber is significantly different from the material that was produced several decades ago.
Like any other material, foam rubber also has disadvantages. First of all, the production of such products is considered environmentally harmful, therefore high demands are placed on safety systems at enterprises producing them.
In addition, polyurethane foam is a flammable material. When ignited, it begins to release harmful substances that can lead to poisoning. To eliminate this drawback, manufacturers use special impregnations, but usually they do not provide the desired effect.
The simplest, periodic method. It is perfect for budding entrepreneurs. This technology for producing foam rubber does not require special knowledge or the use of complex equipment. All chemicals are mixed in a foaming machine, after which it is sent into a special mold. The material stays in it for no more than half an hour. Next, the finished product is cooled for 3 days and cut to size.
When making foam rubber, special attention should be paid to temperature conditions. In the production area, the temperature should not fall below +18 degrees. This requirement does not apply to warehouses, utility rooms and material cutting areas.
In addition, you need to correctly determine the dosage of the components. In this matter, the slightest errors cannot be allowed. The production process must be supervised by an experienced chemical technologist. Read more production process A video of foam rubber production will help you.
Scheme: making foam rubber
To make foam rubber, polyisocyanates and polyols are used, which are produced by petrochemical enterprises. To ensure uninterrupted operation of the production line, long-term contracts should be concluded for the supply of high-quality raw materials. In this case, your company will not stand idle without work and suffer losses.
In addition, you should allocate space for a warehouse for raw materials in order to have a reserve in case of force majeure situations. In addition, if you purchase material in large quantities, manufacturers can significantly reduce the price, which will allow you to save money and reduce production costs.
The finished line for the production of foam rubber can be used regardless of the method of organization of the enterprise.
To ensure waste-free production, you should also buy a crushing apparatus for processing edges and defective material. In addition, you will need a packaging device with which the foam is rolled into a roll and packed in polyethylene.
To operate the cutting and filling equipment you will need 2 people. You also need to hire 3 workers for loading and unloading.
To launch a foam rubber production plant, large capital investments will be required. Since the profitability of such a business is quite high, and the demand for foam rubber is constantly growing, the start-up capital will return in literally 5-6 months.
The purchase price of foam rubber production equipment is quite high. You will spend approximately 17 thousand dollars to purchase it. You will have to pay about another 7 thousand dollars for installation and personnel training.
Thanks to such additional investments, you can increase the productivity of the enterprise by 2.5 times, but only if you use the periodic method.
A fully automated line will cost 6.5 million rubles. This is the main equipment for the production of foam rubber, for which you will also have to purchase additional accessories:
According to preliminary calculations, the net income of such an enterprise is about 220 thousand rubles per month. According to experts, the profitability of such an enterprise is at least 15%.
Video on the topic Video on the topic
Furniture factories that use foam rubber as padding for upholstered furniture may become your regular customers. They are the main consumers of this material, since they purchase 70% of the total volume of products on the market.
In addition, foam rubber is used in construction for heat and sound insulation. Shoe manufacturers also purchase this material in small quantities. In the medical industry, foam rubber is used to make fixing splints and prostheses. The finished products can be sold to audio equipment manufacturers for the production of headphones, microphones and other devices.
Foam rubber can also be taken to hardware stores. Such goods are purchased by individuals in small quantities. Factories producing children's toys often use this material for stuffing various products, so you can try to enter into contracts with such enterprises.
Foam rubber has long been known as a durable material for the manufacture of elastic products. Existing enterprises in Russia are not able to fully satisfy the demand for this material domestic market goods. Opening a mini factory for the production of foam rubber in Russia will be quite beneficial both for those who are taking their first steps in entrepreneurship and for businessmen with significant experience and experience. Considering the fact that imported foam rubber costs much more than domestic foam, competition with manufacturers from other countries is not an acute problem. In addition, calculations show that the production and sale of foam rubber will not require large initial investments from the entrepreneur.
If we consider the production of foam rubber from the point of view of the technical equipment of production and the availability of raw materials, then a rather complicated picture emerges. The point is that every technological operation foam cycle is performed on its own separate equipment. And each stage of production requires careful monitoring of the product’s compliance with existing standards, only in this case the end result of the process will be high-quality commercial products.
The technology for producing foam rubber can be represented in the form of the following industrial algorithm:
An important role in obtaining high-quality material is played by exact adherence to the dosage in the reacting mixture of all components for foam rubber. There can be no errors here, everything must comply with the technical specifications down to the gram, and the weighing process must be carried out on scales with a very small error. Currently, only high-precision electronic scales can cope with this task.
It is known that every large enterprise for the production of foam rubber uses its own technological features, its own exact formulations and ratios of components. But the content of such substances as polyol and polyisocyanate in the initial mixture must remain unchanged everywhere. The difference in production methods lies only in the number of secondary components that make up the mixture.
Since in technological scheme Since the production of foam rubber involves the occurrence of complex chemical reactions, labor safety requirements for workers must be strictly observed. This also applies to an air temperature of 18˚C, and ventilation capable of removing all harmful gases from the operating area of the operating personnel. It is necessary to take a very responsible approach to the operation of the workshop’s treatment facilities, which must provide reliable protection of the atmosphere from significant pollution.
For the plant to operate with the production of only high-quality goods, it is necessary to include an experienced technologist in its staff who can monitor the correctness production cycle at all its stages. He will be required to monitor compliance with the recipe and control both the raw materials for foam rubber and the intermediate compositions of the working mixture. All these parameters are precisely regulated by state standards of the Russian Federation.
When purchasing equipment, the main decision is – a semi-automated complex or a fully automated one? Of course, the automatic line is advantageous in that its operation does not require numerous service personnel, and the quality of the manufactured product does not depend on the variable human factor. But, on the other hand, the cost of these types of equipment differs so much that sometimes a more profitable option is to install a semi-automatic complex at the enterprise and hire an increased staff. The final decision on choosing a foam rubber production line is made by the businessman himself, comparing his future expenses and income.
The cheapest package for purchasing equipment for the production of foam rubber should contain the following machines and units:
The last two positions are necessary in the case of organizing production on a large scale with the expectation of greater power of the purchased equipment.
The price of any equipment is largely determined by whether the machines will be purchased separately or as a complete production line. Entrepreneurs for the most part opt for a ready-made line of equipment, since here all the devices are prepared in advance for interaction, which allows them to avoid possible overloads and breakdowns during their operation.
Foam rubber machine with a production capacity of 12 cubic meters. meters of sheet material per working day is currently estimated by equipment suppliers at 600 thousand rubles. This is considered the minimum volume capital investments into production, but with such productivity the income of the enterprise will be quite modest. To buy a more productive line of equipment that can produce up to 30 cubic meters per work shift. meters of products, an amount of at least one and a half million rubles will be required. But it is precisely this kind of productivity that can be optimal for the enterprise to obtain high profits.
There are now enough more productive lines for the production of furniture foam rubber on the equipment market, but for starting a business with a product sales mechanism that has not yet been established, this option is not economically feasible.
We should not forget about the production of recycled foam rubber. Having skillfully organized waste collection, experienced entrepreneurs install equipment in their workshops for the production of secondary foam rubber. This allows you to obtain cheaper products, which play an important role in the struggle for the market for the product.
The process of organizing any production in our country is not very complicated. It is then more difficult to establish reliable sales of finished products by building relationships with representatives of the wholesale market. After all, it is wholesale buyers capable of generating large income for the company. All this leads to the right idea that sales channels for your product need to be thought through at the business design stage, and not when the warehouses are filled with finished products. Only operational work in sales of foam rubber is capable of the most short terms lead to a return on initial investment and significant net profit.
Potential buyers of foam sheets are:
Considering such a large number of industrial areas interested in purchasing foam rubber, there should be no downtime in the equipment of any newly organized workshop. It is only important that the prices and quality of products offered to customers are attractive to them in the market of competing enterprises of a similar profile.
By analyzing the product market and studying the capabilities of competitors, you will have to get involved in an active advertising company for the sale of foam rubber for upholstered furniture, which primarily includes high-quality foam rubber with an adhesive layer.
Speaking about the profitability of a business in the production of foam rubber, the main thing here is the competent organization of the business. With some effort and the ability to find the right contacts, the return on the initial investment in a business comes quite quickly. It is estimated that on average up to 2.5 million rubles are spent on registering a business, purchasing equipment and raw materials, renting premises - everything is spent on average up to 2.5 million rubles. This is an impressive cost figure, which can only be reduced by installing not new, but used equipment in the workshop.
But you shouldn’t save on raw materials. All raw materials must be supplied only from reliable customers; only this can allow the company to manufacture products high quality and maintain your customer base. Usually, after a year of active work, the initial investment in the production of foam rubber pays off, and the enterprise begins to give the desired profit to its founder. Namely, profit is main goal any business, any production.
Foam rubber (polyurethane foam) is a soft and elastic material that is used in furniture and clothing production, as well as in the manufacture of soft toys and for packaging fragile goods. The production of foam rubber in Russia is currently not able to fully satisfy the demand for products, so the niche is considered relatively free, which opens up opportunities for beginning entrepreneurs.
Brief business analysis:
Costs of setting up a business:from 20 thousand dollars
Relevant for cities with the population: without restrictions
Industry situation:average level of competition
Difficulty of organizing a business: 3/5
Payback: 8 – 18 months
Despite the fact that every year the volume of foam rubber production in Russia increases on average by 7%, in order to meet the demand of all consumer companies of this material it is necessary to import it from abroad. Considering the bulk of foam rubber and its relatively low weight, logistics costs often exceed the cost of the material itself. Taking these factors into account, each new mini-factory immediately acquires regular wholesale customers who want to save on components for their products.
Polyurethane foam is widely used in the production of the following goods:
In addition, during construction and repairs they use special sound-proofing foam, which has slightly different properties.
The production of polyurethane foam is considered harmful, so it is better to select production premises on the outskirts or outside the city - this will help avoid problems with supervisory authorities and save on rent. In addition, workers must strictly follow safety rules when using equipment. personal protection, such as respirators, goggles and gloves.
The main components used for the production of polyurethane foam are polyester, isocyanate and water. Polyester and isocyanate are complex chemical compounds, the production of which on our own will entail additional costs for equipment and qualified personnel; therefore, for a mini-plant, it is most advisable to order raw materials from specialized laboratories.
There are two main methods for producing foam rubber:
The process of producing polyurethane foam in a periodic manner is relatively simple: the components are mixed in mixers, poured into a mold and, due to the action of water on the polyester and isocyanate, within a few minutes the material rises, takes on shape and elasticity. The resulting block “arrives” in the mold for another 15-20 minutes, then is removed and transferred to the final formation room, where it remains for at least another day at a lower temperature. After this, the material is considered ready, it is cut into blocks of the desired shape and sent to the buyer.
With the continuous method, the mixture is poured onto a belt and rises as it moves. Upon reaching the end point of the conveyor, the material is already shaped, cut into blocks and moved to the final forming room.
Main feature production of secondary polyurethane foam - the presence of foam rubber chips among the components. Often, crumbs are formed during the production of ordinary foam rubber, and its use helps to create waste-free production and save on raw materials.
A mixture of crumbs and a polyurethane binder is pressed under a certain pressure, and the resulting material has increased rigidity and durability. Due to its technical properties, such material is used as rigid pads in the production of furniture, to protect the top layer of ordinary foam rubber from rapid abrasion and wear.
Acoustic polyurethane foam has the highest density, which ensures sound insulation of rooms. Often, foam rubber crumbs are used in its production.
Depending on the shape of the final product, there are relief and non-relief polyurethane foam. The first one is made with “wave” and “pyramid” profiles. The sound absorption coefficient of a material directly depends on the shape and thickness - for example, “pyramid” polyurethane foam with a thickness of 70 mm has a coefficient of 0.62.
For industrial production PPU will require the following types of equipment:
Beginning entrepreneurs are recommended to purchase a ready-made production line, since assembling the entire set yourself is difficult and often more expensive than ordering equipment from one supplier. A finished line for the production of polyurethane foam in a periodic manner will cost about 15-17 thousand dollars, with installation - about 20 thousand.
Also from current additional equipment It is worth noting a machine for twisting and packing sheets (this will help reduce the volume of products during transportation and, accordingly, reduce costs) and a waste crusher (needed for the production of recycled foam rubber).
To organize a mini-factory, a room of 200 square meters is enough. meters. It should be divided into several production workshops, and there should also be utility rooms for personnel. The ceiling height must be at least 3 m.
Considering the increased harmfulness of production, it is necessary to ensure high-quality ventilation of the room. It is also necessary to maintain a certain temperature regime - at the moment of pouring the working mixture into the mold, the temperature should not fall below +18°C, otherwise it will affect the technical properties of the finished material. To make it easier to maintain the temperature, it is recommended to isolate the pouring shop from other rooms. Other operations such as curing, cutting and storage can be carried out at lower temperatures.
For uninterrupted operation of electrical equipment, 380 V electrical wiring with “grounding” is required. To load finished products, as well as transport raw materials, there must be convenient access roads, as well as a turning area in front of the building.
To service the equipment and perform other work, you will need 8 workers and a chemical technologist with the appropriate education. Of these, 5 people are needed to service the machines, pour the mixture and cut the material, and another 2-3 for loading goods and other work.
The main difficulty on the path of a novice entrepreneur who has decided to start producing polyurethane foam may be the lack of money for equipment. However, if you have 20 thousand dollars, you can already launch a full-fledged production, the profitability of which is 15-20%, taking into account all expenses.
The advantage of the business is its versatility - clients of the mini-plant can be: construction companies, as well as manufacturers of furniture and car seats. In addition, with virtually no additional costs, you can organize the production of small finished products: sponges, rugs, window insulation and other household goods, with which you can go directly to the market.
