Elastic polyurethane foam, better known as foam rubber, has practically no analogues on the market in terms of price and consumer qualities. The material is characterized by high wear resistance, good elasticity, moisture resistance, tightness, excellent noise and heat insulation, safety (does not cause allergies), and long service life.
The technology for producing elastic polyurethane foam is based on foaming polymers, during which air cells are formed, which make up 90% of the finished product. There are two methods - block and continuous.
With each of them, the raw material for producing polyurethane is poured into a mixer, where it is foamed until the required volume is obtained. Depending on the mixing modes, foam rubber with different physical properties is obtained.
At in a continuous way the prepared foam at a temperature of 20-21°C is fed to a conveyor with high sides, where in the process of movement (5-7 m) it foams to a height of 1-1.3 m.
Over the next 25 m of movement of the belt, the raw material collects the necessary physical properties As a result of the polymerization process, 32 m after the start of the conveyor movement, the resulting material can be cut off with a special guillotine. In this way, it is possible to obtain a long block up to 64 m long.
The material is then transported to a special workshop where it is finally formed upon completion chemical processes and gradual cooling. The polyurethane foam obtained in this way is of higher quality.
Depending on the operational purpose, foam rubber is produced according to different technological maps. This allows you to obtain the following types of polyurethane foam (in terms of hardness):
All of these types of polyurethane foam are used in production upholstered furniture. Various types of foam rubber are used to make mattresses and mats, padding for sports equipment, upholstered furniture, and car seats.
Foam rubber is also widely used in the automotive, medical, clothing and construction industries. Manufacturers of workwear, soft toys, household appliances, sound recording equipment. All industries that require packaging of fragile products need foam rubber.
The company "Santex" LLC deals, including to order.
Many years of experience in this field, as well as modern equipment, careful control at all stages of production allow us to guarantee high quality products.
If you are interested in purchasing foam rubber, call us or place your order online. Information on how to receive goods and prices will be provided to you as quickly as possible. Our consultants will help you choose the type and configuration of foam rubber; we work with both large and small wholesale.
Production of foam rubber: analysis of the sales market + technology for the production of foam rubber of 3 types + purchase of equipment + search for production premises and employees + preparation of documentation + calculation of expenses and income of the enterprise.
Foam rubber is a softener that gives elasticity to some products, such as upholstered furniture or toys. It is also used for thermal insulation, it is durable and very light.
For the first time, the development of polyurethane foam (the scientific name for foam rubber) began in the last century, in the 30-40s. Despite the long history of the existence of such auxiliary material, its production in Russia does not yet cover all the needs of the population.
Often, material for furniture or thermal insulation is imported from abroad. This is associated with an inflated cost of the material, and as a result, a considerable final price for sofas, armchairs, etc.
The production of foam rubber can be an excellent business start, especially since competition is still at a fairly low level.
Production costs are relatively small; a novice entrepreneur can handle them. However, it is worth starting a business by producing foam rubber in small batches until you find regular customers and are able to fully sell the product.
We would like to immediately make a reservation that polyurethane foam is not an essential product. The sales market for such products is small and quite specific. It will not be possible to sell foam rubber to an ordinary consumer, because he simply does not need it.
Who can sell the product to:
The sales niche is really not very broad, and if in your region there are no organizations of this kind to which you can supply foam rubber, then it will be difficult to develop a business.
There is no need to spend money on advertising; you need to personally negotiate the supply of foam rubber to large customers. The only thing worth spending money on is purchasing a website and promoting it. This way you can tell the whole of Russia about yourself and attract new customers.
You can buy a website for about 5-7 thousand rubles. Additionally, you will have to pay for services to promote the portal in search engines, and this is another 10,000 rubles every month.
Workers must also be provided with special uniforms, goggles, rubber gloves and respirators so that they inhale harmful impurities as little as possible.
So, to create polyurethane foam, you will need 3 components:
All components must be purchased, because producing them on your own will entail additional costs.
Now let's look at the production process of different types of foam rubber:
| Periodic foam rubber | All ingredients must be mixed with a production mixer and poured into a special form. Within a few minutes, the material will begin to rise and take its shape due to the action of water on chemicals. The material should remain in the mold for 15-20 minutes. Then it must be removed and transferred to a room with a low temperature (10-15 degrees) for final shaping for 24 hours. The finished foam rubber is cut into pieces and sent to the consumer. |
| Recycled foam | Polyurethane binders and foam crumbs, which remain after the production of periodic foam rubber, are the basis of secondary production. This material is much tougher and has high durability. Recycled foam rubber is used in furniture factories as a top layer to protect primary foam rubber from wear. |
| Acoustic foam | To soundproof a room, you need to use dense foam rubber, which is made from foam rubber chips. Acoustic foam rubber comes in two types: textured (wave or pyramid) and non-relief, which also differs in thickness. The sound absorption coefficient depends on the thickness of the foam rubber. |
The minimum documents you will need are a passport, INN, a receipt for payment of the state duty (800 rubles), an application in form No. P21001, an application for switching to the simplified tax system.
Please note! In the application for opening individual entrepreneur status, you must indicate the code OKVED activities 22.23 — “Production of plastic products used in construction.”
Documents confirming will be ready in 5 days.
In addition to the Tax Inspectorate, you must obtain permission from the Fire Inspectorate, which will check the safety of the building and the presence of a fire protection system. The SES will also check the premises for compliance with the standards and requirements of SanPiN.
Don’t forget about Rospotrebnadzor, which must certify that foam rubber does not contain harmful impurities and is suitable for use in the production of furniture, toys, etc.
No licenses are needed to operate, but it is important to constantly monitor all documentation from suppliers of raw materials, tenants, and buyers of goods.
Payment in such industries is carried out by bank transfer, so take care of opening a bank account and order a stamp.
Legal registration of a business will not require such large expenses from the entrepreneur - about 10,000 rubles.
The equipment set consists of the following elements:
Ready-made equipment for the production of foam rubber consists mainly of the above elements. It’s also worth thinking about buying a crusher to also produce recycled foam rubber.
If you have enough money, then buy a rolling and packaging machine. Packaged foam takes up less space, so you will save money during transportation.
You will have to pay separately for the delivery of the equipment and its installation in the workshop, which is another 200,000 rubles.
| № | Equipment | Quantity | Price (RUB) |
|---|---|---|---|
| TOTAL: | 1,248,000 rubles | ||
| 1. | Foam rubber production line (32 m3)
| 1 | 720 000 |
| 2. | Crusher | 1 | 68 000 |
| 3. | Foam cutting machine | 1 | 340 000 |
| 4. | Packing press | 1 | 120 000 |
A separate expense item is the purchase of uniforms for workers, equipment of the technologist’s office (desktop, computer, test tubes for testing raw materials) and changing rooms for ordinary personnel. Depending on the selected furniture, shape and equipment, you will need about 60,000 rubles for this.
Special requirements are put forward for the workshop where the equipment will be located and the process of producing foam rubber will take place - the temperature should not fall below 18 ° C, otherwise pouring foam rubber into blocks will be impossible, and you will simply spoil the raw materials. In all other rooms there are no special requirements for temperature indicators.
A foam rubber production plant must also have workshops for cutting foam rubber and packaging it, as well as storing finished products. Take care of a room for workers and an office for the technologist.
Pay great attention to ventilation and electrical wiring of at least 380 V with a grounded circuit. The workshop needs to be accessible for trucks that will bring raw materials and unload finished products.
The cost of renting a workshop for 1 month with an area of 200 m2 - from 150,000 rubles + payment of utility costs - from 20,000 rubles.
Among the personnel, you will definitely need a specialist in the field of chemistry who will occupy the position of technologist and control the production process. Also hire ordinary workers for the enterprise who will stand behind the machines. You can't do without loaders, and the cleaner can work part-time.
Only the technologist should have qualifications and special skills; all other people can be taught how to operate the equipment from scratch. The production manager himself can control the flow of money and look for sales points
The workshop will operate in one shift, 5-6 days a week. If demand increases, more people can be hired and the plant can be operated in two shifts.
Foam rubber production as a business idea.
What equipment is needed to implement the idea?
All calculations are approximate. We did not take into account that the goods may not be sold out, or the equipment may suddenly break down. Every business is full of pitfalls, and foam rubber production is no exception.
The enterprise can pay for itself in a year of successful operation if the founder makes an effort and is able to find regular buyers of foam rubber.
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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 on the domestic goods market. 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 the technological scheme for the production of foam rubber provides for the occurrence of complex chemical reactions, the labor protection 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 initial 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 enterprise’s income 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 an 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.
When 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.
Among the promising areas entrepreneurial activity The production of foam rubber has recently attracted steady interest among novice businessmen, as well as among their more experienced colleagues. This trend can be explained very simply: domestic enterprises, working in this industry, are not able to satisfy the steadily growing demand for foam rubber, and buying these products abroad, firstly, is very expensive (especially after the rise in the dollar exchange rate), and secondly, normal trade is hampered by political instability in relations with supplier countries.
Therefore, domestic businessmen need to take advantage of the current situation and actively organize enterprises that will produce foam rubber, and this article will be an excellent assistant in this difficult matter. The reader will be able to study not only the technical nuances of the production process, but will also find out what is needed to draw up a business plan, what organizational and legal form is suitable for this activity, where to start a business, and what starting capital is needed to open a company for the production of foam rubber.
Despite the development modern technologies and a huge number of discoveries in the field of inorganic chemistry, foam rubber continues to be in demand, as in the 40-50s of the last century. Elastic, soft, but quite durable material is indispensable for clothing and furniture production. In addition, it is used to make excellent children's toys, and is also used as packaging material for fragile products and in enterprises for the production of modern computer equipment. In everyday life, foam rubber, like 50 years ago, is an irreplaceable thing. In a word, the demand for this material in our country will be stable and high for at least the next ten years.
Let's move on to the disadvantages of this material. Its production is harmful to the health of company workers and the environment. You will have to buy powerful fans, obtain the appropriate permits from regulatory authorities, and also allocate money for measures to reduce negative influence on ecology. Prepare for constant “courtesy visits” from fire inspectors, as well as representatives of sanitary and environmental services. In addition, equipment for the production of foam rubber is not cheap, which means that to open an enterprise you need a large start-up capital.
Today, even schoolchildren know that to open a business it is necessary to register a company with the tax office and special funds. For the production of synthetic materials, an LLC is best suited. Registration legal entity will cost more than processing documents for an individual entrepreneur, but this will help you quickly obtain all the necessary permits; suppliers of specific raw materials often refuse to work with individual entrepreneurs, and many large buyers of foam rubber sign cooperation agreements only with legal entities.
There are exceptions when you can limit yourself to registering an individual entrepreneur. For example, you create your business specifically for the work of several large companies(2-3 furniture factories). In this case, you have preliminary agreements before starting your business, you know exactly how many materials need to be produced, and buyers agree to cooperate with the individual entrepreneur.
Complete package necessary documents(permits from the fire inspectorate, environmentalists, SES, certificates for finished products, etc.) You will receive only after preparing the premises and concluding agreements with suppliers of raw materials. That is, when everything is ready for you to start production, you will be able to resolve all issues related to obtaining permits.
Almost every foam rubber manufacturer in Russia focuses on its own circle of buyers of finished products and does not violate the borders of its territory. You must carry out thorough marketing research and determine how much foam rubber you can sell over a certain period of time.
Representatives of the target audience of this area of activity are:
You need to conduct preliminary negotiations with all enterprises in your region on the specified list and, ideally, agree on cooperation, as well as clarify what volume of finished products they will buy. This parameter will allow you to create the most accurate business plan. Knowing it, you will be able to choose the appropriate equipment, estimate what kind of staff is needed to produce foam rubber, and calculate the cost of production of the finished product and the profit margin.
When choosing a room in which foam rubber production will be carried out, you must adhere to the following criteria:
Entrepreneurs experienced in such matters recommend looking for premises on the outskirts of the city. It is easier to comply with environmental safety standards here, and renting production space costs significantly less than in areas close to the center.
To operate your enterprise, you need to purchase a foaming apparatus, molds, a belt machine, dosing tanks, automatic machines for grinding raw materials and waste, a thermal chamber and a packaging machine. It is better to buy a ready-made production line, which will be set up and your specialists will be trained to operate it. It makes sense to look for a company operating under a leasing agreement. This is especially important for businessmen who do not have enough personal funds to open a plant. Some entrepreneurs, in order to save money, buy used equipment, but it all depends on your personal luck. If you decide to buy used equipment, do it only with a highly qualified specialist, so as not to buy a bunch of scrap metal for a lot of money.
To work at your enterprise, you definitely need a technologist, preferably with the appropriate education, 3-6 workers in the workshop, 2-4 general workers and a fitter. As for administrative personnel, this issue depends on individual factors.
Definitely needed chief accountant (good specialist will save you 2-3 of your salaries), a manager, as well as a manager for working with suppliers and customers. But if you take part in the work of the enterprise, then the list of administrative personnel may have a completely different look.
When considering the production of foam rubber as a business, it is necessary to pay attention directly technological process. Without this, your knowledge of a production organizer will be incomplete. As was already said at the beginning of the article, the production of foam rubber is a very harmful process for human health, therefore all workers must have respirators, and fans must be installed in the workshop.
Technologists distinguish two methods for producing this material: periodic and continuous. The latter is used in large factories where more than 2 thousand tons of finished products are produced per year, and the former is used in small and medium-sized enterprises. But fundamental differences There is no difference between these methods, the only question is performance. The process itself is carried out as follows: the necessary reagents enter into a chemical reaction in a special mixer, and then are poured into a collapsible form, where the interaction of the ingredients continues. The result is a block of foam rubber, which is released from the mold and placed in a prepared room for a couple of days, where the reaction ends and the foam rubber we are accustomed to is obtained. The final stage is cutting the finished product on a band saw to obtain sheets of the required size.
To start the presented business you need to: register an enterprise, rent a premises, make repairs in it if necessary, buy equipment, obtain all the necessary permits. To do this, you need an initial capital (we take averages, focusing on real data) of about 90 thousand dollars.
Monthly expenses necessary for the normal functioning of the company include:
General monthly expenses are 38 thousand dollars. This enterprise has a net profit of about 8 thousand dollars every month, and the calculations include the manager’s salary, which can be received by both the owner of the enterprise and the hired manager. Based on the indicated indicators, it can be calculated that within a year, maximum one and a half, all the money invested in the development of the enterprise will be returned to investors. To summarize, we can conclude: in modern economic conditions It is quite difficult to find a business such as the production and sale of foam rubber that allows you to earn big money without fear of competitors or other unforeseen circumstances.
Polyurethane foam, or foam rubber, is a very common material that is successfully used in construction, furniture manufacturing and other areas of life. To choose the right equipment for the production of polyurethane foam, you must understand what materials are needed for the job and what type of product you will be making.
So, the presented material can be divided into 2 types:
It should be noted that foam rubber can also be used when packing fragile items: dishes, electronics.
Before purchasing equipment for the production of polyurethane foam, you must understand the advantages of the presented product. Among them are the following:
Naturally, now you will have to choose equipment for the production of polyurethane foam. Try to buy it at certified points of sale. Of course, the equipment must be of very high quality. Therefore, give preference only to those manufacturers who have already proven themselves on the positive side in the equipment market. Naturally, try to carefully examine technical condition devices at the time of purchase.
Standard equipment for the production of polyurethane foam includes the following machines:
The most important apparatus is the foam generator, in which all the necessary components (polyol and isocyanate) are mixed.
In addition, such equipment can be divided into low and high pressure devices. In the first case, you will not need to spend a large amount of money. In the second, the equipment is equipped with various sensors and automatic control.
Naturally, for the manufacturing process you will need not only equipment, but also, in fact, the material from which you will make the final product. That is, you will need to purchase the following raw materials for the production of polyurethane foam:
In principle, such components are not too difficult to find.
The presented material is produced continuously or periodically. The second method is most suitable for those companies that have just opened and have not yet expanded their capacity. In addition, periodic production of the product allows you to constantly monitor the market and sell it quickly enough so that it does not sit in the warehouse.
During the manufacture of polyurethane foam, you must be extremely careful, since the chemical reaction uses an extremely dangerous substance - polyol, as well as some catalysts and foam formers. However, they subsequently decompose and become non-toxic. Therefore, the final product will not cause any harm to health.
The manufacturing technology of the product itself is very simple. The installation for the production of polyurethane foam is filled with all the necessary ingredients: this is where the reaction takes place. It should be noted that the initial raw material is in a liquid state. Naturally, it is necessary to strictly dose the amount of components. After the foam forms and sits in the mold for some time, it is sent to another block where it is cooled.
The polyurethane foam is cut after 24-72 hours using a special band saw. Then the finished product can be sent to the customer. If necessary, foam rubber can be stored and stored for a long time. That's all the features of making polyurethane foam. Good luck! 
The domestic market for the production of foam rubber cannot fully satisfy the needs of the population. Most often, this material is purchased abroad. Therefore, the production of foam rubber is a good idea for starting your own business. Thanks to the large sales market, convenient transportation, and the fact that this business does not require large initial capital, with the right choice of equipment you can make it successful.
The production of foam rubber is quite harmful, because the fumes generated during the production of this material can cause significant damage to the human body. They are released into the environment in large quantities. However, after this, the harmful substances completely disintegrate into safe chemical elements that do no harm.
Therefore, it is very important that the production is equipped with a modern ventilation system and water supply. In addition, production floor employees must have respirators and other protective equipment.
The choice of equipment for the production of foam rubber depends on the required power and volume of finished products, as well as on the method of manufacturing the products, which can be periodic or continuous.
To make foam rubber, the necessary chemicals are mixed in a foaming machine. After this, the finished mixture dries out after some time, and it is cut into sheets of the required thickness.
To set up a workshop for the production of foam rubber, you will need the following equipment:
This equipment can be purchased separately, or in the form of production line, which will include all the necessary elements for organizing the work of the production workshop.
However, what should you focus on when purchasing equipment so that your business can generate maximum income?
The choice of equipment for the production of foam rubber should primarily be based on the initial capital that you are willing to invest in it, as well as on the required productivity. In addition, you should decide whether you will buy a finished production line or equipment separately. The production line is much more convenient. The fact is that all the elements in it are perfectly selected. Thus, malfunctions occur much less frequently.
In the event that large capital investments are not possible, it is worth considering purchasing a machine whose capacity is about 10 cubic meters per shift. A foam production line will cost two to three times more, but its capacity is about 25 cubic meters per shift. If the sales of products are well established, then it makes sense to purchase even more powerful equipment, otherwise it will be impractical.
If your financial capabilities are small, you should take a closer look at new domestic machines. You can buy them very cheaply, but you will have to spend a little more to return them to working condition. Thus, it will be possible to purchase more expensive raw materials for the production of foam rubber so that the quality of the finished product meets all indicators.
If you have the opportunity, it is better to purchase imported equipment. It is more durable and of higher quality.
The most necessary equipment, without which no production can do, is:
Of course, for the normal operation of the production workshop it will be necessary to additional equipment. However, it can be purchased gradually. To start production, the main thing is the presence of the three machines listed above.
The choice of equipment for the production of foam rubber will be more successful if you first consult with the owners of existing production facilities. If you can conduct your own research on this issue, then you will definitely not make the mistakes made by others.
There are several ways you can find out this information.
When choosing the direction of your future business, it is better to give preference to the production of those products that are in high consumer demand - regardless of the season and the state of the economy in the country. This includes the production of foam rubber. Investments in starting an enterprise will be impressive, but with the right approach, the investment will pay off very quickly. Study the issue thoroughly to take into account all the nuances.
How to open a foam rubber production plant in Russia?
Our business assessment:
- Starting investments - from 1,000,000 rubles.
- Market saturation is low.
- The difficulty of starting a business is 6/10.
Foam rubber (polyurethane foam) has been used in everyday life and for industrial purposes for many decades. Despite the appearance on the market of fundamentally new materials with similar properties, foam rubber does not lose its popularity among consumers. This will be the main advantage for a businessman - wholesale customers can always be found!
Foam rubber is a soft, elastic material used in furniture and clothing production. But the application is not limited to these areas - the production of soft toys, the transportation of fragile goods.
The production and sale of foam rubber in Russia is not very developed, which gives future entrepreneurs a good chance of a quick payback on the project. If you supply quality products to the market, you can defeat any competition.
As for the disadvantages, the main one is difficulties with the equipment of the room. The production of foam rubber is considered harmful, so workshops must have a powerful ventilation equipment which will entail financial costs. You will need to obtain regulatory approval to operate. The enterprise must strictly observe working conditions and control the amount of harmful emissions into the atmosphere - frequent inspections by sanitary, environmental and fire services cannot be avoided.
It is better to start a mini plant in early spring. It is during this period that all furniture factories “activate” - active procurement of raw materials begins. This way you will quickly find buyers for your products.
It will take at least 3 months to collect all documents and permits to register an enterprise. Everything can be handled much faster with the help of a lawyer.
For the enterprise being opened, OKVED: 24.70 (Production of artificial and synthetic fibers) is suitable.
It is better to formalize the industrial production of foam rubber in the form of an LLC - it is easier to find buyers of finished products and suppliers of raw materials. You will receive permission to conduct activities only after the premises have been found and prepared, contracts have been concluded with suppliers of raw materials, and quality certificates for the finished products have been received.
Place the production of furniture foam rubber in a free space on the outskirts of the city. Firstly, renting real estate here is cheaper, and secondly, environmental safety requirements will not be so high. This will greatly facilitate the process of starting a business.
To organize a production workshop, storage facilities and service rooms will require at least 200 m 2. If you are planning a large-capacity plant, look for a larger building.
In addition to ensuring good ventilation in the workshop and the presence of treatment facilities, other requirements are imposed on the found premises:
If free space does not allow, the company’s office can be located in another place - where it will be convenient for clients to get to. But these are extra expenses for organizing activities.
The raw materials for foam rubber are polyol and diisocyanates. If the technology is not followed, these substances can be harmful to the human body. But if the workshop has good ventilation and only high-quality “ingredients” are processed, there will be no chemical poisoning of personnel and no harmful emissions into the atmosphere. The specific ratio of components will depend on the type of foam rubber produced. There are a few of them:
There are also special brands of foam rubber, which are subsequently used to make dishwashing sponges and self-adhesive insulating strips. There is foam rubber that has soundproofing properties. Product prices in this case will be slightly higher.
It is better to immediately agree with suppliers on wholesale supplies of raw materials - this will ensure uninterrupted operation of production equipment.
The technology for producing foam rubber depends on the method - continuous and periodic. To select the appropriate option, it is necessary to evaluate the planned capacity of the plant and the raw materials used. It is advisable for small enterprises to introduce a periodic method in production. "Average" technological scheme making foam rubber looks like this:
During the manufacturing process of finished material, waste is generated. They can either be sold to consumers (the same furniture factories, for example), or you can plan the production of recycled foam rubber. The technology involves foaming foam crumbs and scraps with special glue and then pressing the mass under pressure. The finished product has excellent quality characteristics - increased strength, sound insulation, durability. It is in this way that acoustic foam rubber and mats for gyms are produced. This way you will find more buyers interested in your products.
Secondary foam rubber is produced in several grades - BB-60, BB-80, BB-100, BB-120, BB-140, BB-160. Materials differ in properties and physical and chemical parameters.
The simplest line for the production of foam rubber
The foam rubber production line is the most expensive item in the budget. For manufacturing you will need the following machines:
It is difficult to assemble a line from individual devices. For novice entrepreneurs, it makes sense to buy a line that is ready to work.
The price of equipment for the production of foam rubber will depend on the power of the machines. The mini-workshop can be equipped with a low-productivity line that produces up to 12 cm 3 of finished products per shift. This one will cost 400,000 rubles. But you can buy equipment for foam rubber of higher capacity (up to 50 m3) by spending at least 2,000,000 rubles. To the costs of purchasing devices, add the seller’s services for their commissioning. All manipulations for setting up the line can be done on your own, but you need to know well the specifics of its operation.
You can save money if you purchase used equipment. The price of used machines is significantly lower. And if you find a reliable seller, the purchased line will last a long time.
All costs for a foam rubber machine will begin to pay off when contracts are concluded with regular customers of finished products. Depending on what type of material is produced within the walls of the workshop, offer the product:
By offering consumers special types of products, for example, foam rubber with an adhesive layer, you can attract more customers. If this cannot be done in the early stages of establishing an enterprise, be sure to think about business development. It is important to constantly improve production methods.
Payback periods depend on initial costs. If we count at the minimum, then it will take 1,000,000 rubles to organize a workshop. This will include funds to buy a machine for cutting foam rubber and other equipment, prepare the premises for work, and register the enterprise. You will open a high-performance plant if you have at least 3,000,000 rubles.
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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 production premises 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%.
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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. Finished products can be sold to audio equipment manufacturers to make 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.
As you can see, polyurethane foam of various types is in great demand, so problems with its sales usually do not arise.
A foam rubber production enterprise is enough promising business. This is especially true for the production of molded products. This material is used for padding furniture, as well as backs and seats in car seats. From waste you can organize the production of rugs, insulation or sponges for washing dishes. This will allow you to receive good additional profit.
