Technology for the production of screws and self-tapping screws. Semi-automatic equipment for the production of self-tapping screws at home What kind of wire are self-tapping screws made of
When we talk about a screw, does everyone know what it is? The word screw comes from the German Schraube. In fact, it is a screw that can easily be screwed into any soft material, forming a thread there “on its own”. A typical material of this kind is wood.
How can a screw penetrate soft materials? First of all, due to the thread, which covers a significant part of the screw shaft. This thread is different from the threads found on screws and bolts. It is not surprising, because the latter are not screwed into wood, but into metal. The thread applied to the screw is slightly higher. It has a significant cutting pitch and is applied to the threaded section of the screw in the form of a conical shape, which tapers towards the end of the screw. By the way, a screw thread can be cut both along its entire length, and only along its part.
Since the sizes of the screws are quite diverse, the natural question arises on what it depends. Screw sizes are closely related to their purpose. So for attaching nameplates to finished products, a very small screw, popularly called a “bug”, is widely used. Its dimensions: diameter - 4 mm., Length - 8 mm. Another screw, called a travel screw, is 170 mm long and 24 mm in diameter. And this is understandable, since with the help of it a railway rail is attached to the sleepers. The heads of such screws also have a different shape, determined by the installation conditions themselves, the appearance of the product and the requirements that apply to the structure being mounted.
Head shapes are shown in fig. one.
About types of heads and slots of screws
Among the types of heads, we distinguish: countersunk, countersunk double, countersunk truncated, countersunk type "horn", semicircular head, semicircular head with press washer, narrow cylindrical head, trapezoidal head, hex head, hex head with press washer.
The countersunk head is sunk into the material of the element to be fixed. At the same time, the surface of the material was and remains flat. The countersunk double head is a reinforced type of countersunk head. It is able to withstand significant loads, even with the impact method of installation in solid materials.
The countersunk truncated head makes it possible to press the fastened element against the base material with high efficiency. This is achieved due to the fact that the length of the thread of the fastener is increased, a lower platform is formed on the head, which is perpendicular to the pull-out load.
The countersunk head of the “horn” type is remarkable in that it very effectively provides high-quality drywall pressing to the base material. It is the specially convex shape of the head, which has the form of a “horn”, that provides optimal perception of the pull-out load. The semi-circular head, due to the wide bearing surface, effectively holds the element to be fixed. The use of such a head is justified when there is no special need to keep the surface of the element to be fixed even.
Another type of head - with a press washer is an increased bearing surface of the head and a reduced height. A head of this type, due to the extended bearing surface, is perfect for securely fastening sheet materials.
The narrow cylindrical head provides an important, in some cases, minimal bearing surface. During installation, this ensures its complete drowning in the fixed element. It is widely used in fasteners that are fixed, both in the base material and in the fastened element, with the help of a thread that performs the main function of fastening. The trapezoidal head has an increased bearing surface, and locking notches are located on its inner side.
One of the most famous and oldest types of fastener heads is the hex head. It is, as a rule, standardized for the available key sizes, and in order to mount it using a power tool, special hexagonal nozzles are used.
The functions of the hex head with press washer are the same as those of the simple hex head, but its bearing surface is still larger.
In order to mount the screw with tools, using a screwdriver or a hexagon, slots are preliminarily formed in the screw head, which can be: straight, cross-shaped, combined, in the form of a six-pointed star, in the form of a hexagon or in the form of an internal hexagon.
Traditionally, for the manufacture of screws, such material as steel ST 08 KP or ST 10 KP is used.
Screw technology
At the first stage of the manufacturing process, a blank or base for the screw is formed. At the same time, a device similar to a nail machine is used everywhere. Thanks to this device, the head of the screw is formed, its tip length. The diameter of the future screw is determined by the wire used.
At the second stage of manufacturing a screw, threading is performed on its shaft. And that process is carried out with the help of special machines. At the same time, the blanks of future screws are poured into the bunker, where, thanks to the vibration conveyor and the anchor mechanism, they arrive one by one in the area where the thread is cut. Screw blanks, at the same time, are strictly oriented in relation to the working elements, i.e. to flat dies, moved towards and parallel to each other, and perpendicular to the axis of the screw, which are tightly pressed against the screw shaft. Dies, at the same time, depending on where they are made, are produced based on the main parameters of the thread.
This scheme allows the production of screws with a diameter of 10-12 mm, but screws with large diameters are usually made using the hot stamping method. An example of such a product is a travel screw, the dimensions of which we talked about a little higher.
Self-tapping technology
As you know, a self-tapping screw has such a name because it is able to cut threads anywhere, both in wood, plastic, and in metal and concrete, etc. This is due to the fact that its surface has a powerful strength obtained by heat treatment, i.e. hardening. The end of the self-tapping screw is often performed in the form of a drill. Thus, its optimal screwing into the fastened structures is achieved, as well as drilling a hole of the required diameter.
At the first stage of manufacturing, even in the process of forming the blank, the formation of the drill is ensured.
At the second stage, similarly to the thread formed on the screw, the thread of the self-tapping screw is formed.
At the third stage, the finished self-tapping screw is subjected to surface hardening. This is perhaps the most important stage in the manufacture of a self-tapping screw, since it is important to strictly adhere to all technological methods to ensure that the necessary technical parameters are obtained.
At the fourth and final stage, self-tapping screws are protected from possible corrosion using methods such as phosphating, oxidation, galvanizing with yellow or white zinc.
Technology for the manufacture of screws and self-tapping screws
Composition of abrasive wheels
Abrasive materials for industrial use must be fixed or structurally made in the form of various tools and compositions, including in the form of abrasive cutting and grinding wheels.
Cutting wheel for metal made of electrocorundum* normal on a bakelite bond, which gives the cutting disc strength and prevents fragments from scattering when the disc is jammed or damaged.
Stainless steel cutting wheel differs from the usual cutting wheel for metal in its composition, iron, sulfur and chlorine are excluded from the alloy. This type of cutting discs eliminates contamination of the cut material during processing. Cutting wheels differ in outer diameter, blade thickness and bore diameter. The diameter of the cutting wheel affects the depth of cut, the thickness of the blade is selected depending on the thickness of the metal being cut. The cutting wheels are fixed on the cutting machine with a special nut and a mounting hole, which is pressed with a metal jacket - again, to increase the strength of the disc.
Cutting wheel for stone made of black silicon carbide** on a bakelite bond. The alloy used in the manufacture of a stone cutting wheel gives the wheel high hardness and strength when cutting concrete structures, refractory bricks, natural and artificial stone.
Grinding wheel consists of normal electrocorundum on a bakelite bond. The maximum speed of rotation of circles of this type is 80 m/s. Cleaning disc (grinding) is used when cleaning and peeling products from various types of steel. Prevents pollution of working surfaces of products and microcracking.
Bakelite bond - Bakelite is an artificial resin made from carbolic acid and formalin. The wheels on this bond are strong, elastic, allow high circumferential speeds of rotation, but are destroyed by the action of an alkaline coolant. To avoid this, it is recommended to impregnate the circle with paraffin. The disadvantages of the bakelite bond include the fact that it loses strength when heated above 180 C. To reduce the roughness of the treated surface, an abrasive tool on a bakelite bond is sometimes made with a graphite filler.
bakelite bond causes less heating of parts, provides high surface finish classes, has a higher strength compared to ceramic and the ability to increase the size under the action of a constant load.
*
Aluminum oxide or electrocorundum(Al2O3) is a crystalline alumina obtained from bauxite clays containing about 60% alumina. And it was called electrocorundum in connection with the technology of its production in electric arc furnaces.
The percentage of purity of aluminum oxide (94-99%) and its degree of hardness refers it to one of the varieties of grain from which grinding or cutting wheels or other abrasive tools for working wood or metals will be made.
** Silicon carbide (SiC)- this is the result of the synthesis of petroleum products with natural quartz sand in electric furnaces heated to a temperature of more than 2000 C. Under such conditions, the mixture crystallizes with the formation of silicon carbide. Silicon carbide has hard grains with an ordered crystal structure, which has a particularly high cutting ability, which makes it possible to effectively process varnishes and paints, fillers, ceramics and stone, cast iron and titanium, as well as rubber and various polymers.
How to choose the size of the cutting wheel for the grinder?
One of the main features of the cutting tool is the size of the circle, which should fit the grinder and the material with which the actions will take place. Most often, discs are used to work with metal, concrete, stone and wood.
The modern market provides a wide range of abrasive discs for angle grinders, which are well suited for working with various types of material.
Sizes of cutting wheels for grinder:
Basically, the outer diameter of the circle ranges from 115 mm - 230 mm.
Inner diameter (landing) 22.2 mm.
The thickness of the disc is from 0.8 mm - 2 mm.
The most popular are the following sizes: 115 and 125. These types are mainly used for household, not complex tasks. It is important to note that circles with a large diameter are already used for work at industrial facilities, which can be 280 mm. The use of such a disk requires, in turn, a professional tool. Such devices are distinguished by strong engine power.
Dimensions and characteristics of cutting wheels:
115mm is a small disc which is ideal for small jobs and material grinding. But it is not suitable for cutting, as it has a small depth of cut.
125 mm is one of the most popular sizes for an angle grinder. It allows you to work with different materials: metal, stone and others.
150 mm - well suited for work with strong products that require a significant load: concrete, large metal pipes.
180 mm is a suitable option for long-term construction work.
230 mm - this disc diameter is suitable for professional angle grinders.
It is used on industrial construction sites, and rarely for domestic needs.
Wheel Size Chart that are great for the indicated brands of grinders
In this table, we have indicated the opinion of experts on the selection and rating of grinders for the corresponding sizes of circles. There are a number of other popular brands that are also suitable for the necessary work. Each of the five types of grinders has its own peculiarity. If you are engaged in construction, then pay attention immediately to several types of angle grinders.
Technology for the production of screws and self-tapping screws
What wheel sizes are best for cutting metal, concrete and wood?
One of the most common and popular consumer tools is metal discs. They come in all the sizes above and are suitable for small and large angle grinders. If, when working with metal, you want to make a thin cut, then take a disc with 115 or 125 mm, since their thickness is from 1 mm - 2.5 mm. Suitable for cutting thin metal sheet. To work with steel, large materials, it is better to take larger diameter discs.
Rigid grinding discs are used for thorough cleaning of seams before welding. With their help, excess protrusions on the surface of the metal are cleaned of old paint, resulting in a flat surface.
Petals are also used to work with metal and wood. Best used with delicate tasks: lacquer coatings, thin curved metal surfaces.
Cutting wheels for stone are used for cutting tiles, bricks, slate, paving stones. There are two types of such discs: diamond and dry cutters. Diamond blades are long lasting and durable and are best suited for cutting red brick and concrete.
Diamond blades are divided into the following types: for dry cutting (segmented), wet and universal.
The disc for dry cutting has slots around the entire circumference, due to which they are able to cool. Dimensions that fit the grinder from 115 to 230 mm. When sawing stone, the disc has the ability to get very hot, so you need to take breaks every 1-2 minutes. With this use, it will last longer and the diamonds will not fly out. It works well with concrete and granite in this way.
The wet cutting blade features a smooth, slit-free design that allows you to cut without splinters. Often they work with them on special devices with water supply, where tiles are cut. If used with a grinder, then pre-moisten in water.
Universal fit for any kind of stone and can be used with wet or dry cutting.
Safety
The most important thing in the work: do not put larger discs on the grinder than indicated in the operation of the tool. Since in the process of using it can break. Remember that the larger the disk, the slower the rotation speed should be.
Self-tapping screws are extremely popular in construction. In the manufacture of self-tapping screws, the manufacturer immediately enters a wide market, as they are in demand among construction and repair companies. The manufacturer will be able to get a high profitability of sales from the first month of entering the market. However, it is worth sorting out the amount of initial investment, choosing the right equipment and raw materials. You can learn about all this from the article.
Machines for the production of self-tapping screws at home
The range of machines is quite wide. You can pick them up at an affordable price with little productivity. Or you can purchase equipment that will produce a large number of hardware per shift.
The cheapest equipment for the production of self-tapping screws
The most interesting home business machine is the Candid model AS3016. This is a semi-automatic machine for the production of hardware self-tapping screws screws. Its price starts from $3000. But in such cases, you will have to sacrifice productivity, which is only 25 pcs. per minute. Please note that the machine is semi-automatic, which means that some operations must be performed by the machine operator. But if you are new to this industry and just starting to explore the screw and self-tapping market, then you should consider purchasing a budget model such as the Hangzhou Candid AS3016.
Industrial business equipment retains its value very well. By investing in it, you save your capital for years - after all, it is an asset that brings money. Figuratively speaking, a machine for printing money. And when you have already established a sales market, you can cash out your assets and switch to more expensive machines with significantly higher productivity.
On the site: http://china-equipments.en.alibaba.com you can buy an inexpensive machine for the production of self-tapping screws at a price of $ 3000, there are many offers of this model.
Chinese machine tools and domestic
In the production of screws and bolts, the process is divided into two main operations:
Such equipment is produced in Ukraine, China and Taiwan. On the territory of the Russian Federation, there are only a few manufacturers producing such equipment. Therefore, the purchase of a machine is a rather expensive operation: you need to pay not only the purchase itself, but also the delivery.
The market leaders in the production of machine tools are:
- LianTeng (Taiwan);
- FOB (Taiwan);
- Candida (China);
- INNOR (China);
- KUPRA (Ukraine: PJSC "Odessa plant for the production of forging and pressing machines");
- SAMSTAL (Russia, Samara: SAMSTAL LLC).
These machines differ in the productivity of products per minute. The simplest machines produce about 60 parts per minute, while others have the ability to produce up to 250 parts per minute. Some models can be configured to produce other products. This is a significant plus, since you can expand your product range over time, and there is no need to spend money on the purchase of specialized equipment.
The price of the most inexpensive models of automatic machines with a productivity of more than 50pcs / min. starts from $13,000.
Wire for the production of self-tapping screws
For the manufacture of hardware in the form of self-tapping screws, wire from high-carbon and stainless steel or brass is used. Depending on the manufactured products and production volumes, an entrepreneur can purchase raw materials in the form of blanks or wire of a certain diameter.
There are many factories supplying this raw material. You shouldn't have any problems finding suppliers. When choosing a supplier, you should pay attention to the price of raw materials, their quality and proximity to your workshop. Having the supplier close to you will help reduce delivery times as well as transportation costs.
The first steps in the organization of home production
Having registered your enterprise and having decided on the productive capacity, you need to select a room and calculate the initial investment.
The calculation of the initial investment directly depends on:
- output volumes;
- the cost of the purchased equipment;
- purchase prices for raw materials.
Most of the investment amount will be directed to the purchase of equipment. Depending on the performance of the machine and its cost, the amount of investment capital may vary. The best options for machines at a price for the production of screws at home will be given below.
Home production shop
Next, you need to decide on the premises. If you have sufficient capital, and at the same time you have the opportunity to rent a good room where the full production cycle will take place, then this will be much more convenient for you. You can separate home and work. However, there is not always enough money for rent at the initial stages, so many people start making screws at home in the garage. These are quite suitable conditions for this business idea.
For the production of screws at home, a garage is suitable, which would have an area of at least 18 m2. It should be equipped with a good ventilation and heating system. The production room must be well organized, and the general environment must comply with all labor protection regulations.
Profitability of home hardware manufacturing business
Given all the features of this business, it should be noted that the profitability indicators are very high. The margin on manufactured products can reach up to 100%, depending on the level of competition in the market. The average profitability in the field of industrial and wholesale production of screws is about 50%. This means that for every ruble spent on production, the company can receive 50 kopecks.
A business built on the production of hardware has always been profitable. When starting homemade screws, you need to take into account all external factors that can affect the development of your enterprise. With an established sales market in a year, you will be able not only to recoup the invested funds, but to capitalize finances to expand your company.
Starting your own business is always risky. It is difficult to predict whether they will buy your products, whether you will be able to recoup your initial investment, and receive further profit. Of course, much depends on external factors: the economic condition, the oversaturation of the market and competing firms. You should carefully select the industry for business development.
The construction industry has always been and will be popular. And if the construction of large buildings becomes too costly due to crises, the usual renovation work of the premises takes place regardless of the economic situation in the country. Repair cannot take place without the use of building materials and finished products.
Price list for Chinese cold heading and thread rolling automatic machines
Estimated average prices on the Internet for automatic equipment for the production of self-tapping screws, screws, bolts and nuts. The price list contains brief technical characteristics.
| Manufactured product | Price in USD$ | Max workpiece diameter | Maximum workpiece length | |
| YH1552 | Screw, screw, bolt | 13500 | 5mm | 52mm |
| YH1564 | Screw, screw, bolt | 13500 | 5mm | 64mm |
| YH2038 | Screw, screw, bolt | 21400 | 6mm | 38mm |
| YH2076 | Screw, screw, bolt | 21800 | 6mm | 76mm |
| YH20102 | Screw, screw, bolt | 32000 | 6mm | 102mm |
| YH20165 | Screw, screw, bolt | 35900 | 6mm | 165mm |
| Name of cold heading machine | Manufactured product | Price in USD$ | Maximum dimensions | |
| 3 position | Bolt size M6 | 70000 | M6 x 50mm | 250 pieces min. |
| 3 position | Bolt size M8 | 88500 | M8 x 65mm | 210 pieces min. |
| 3 position | Bolt size M10 | 110000 | M10 x 75mm | 180 pieces min. |
| 3 position | Bolt size M12 | 150000 | M12 x 125mm | 150 pieces min. |
| Name of cold heading machine | Manufactured product | Price in USD$ | Maximum dimensions | Maximum performance |
| 5 position | Nut size M3-M6 | 36500 | - | 300-350 pcs min |
| 5 position | Nut size M6-M8 | 60000 | - | 200-250 pcs min. |
| 5 position | Nut size M6-M10 | 75000 | - | 220 pcs. min. |
| 5 position | Nut size M8-M12 | 107000 | - | 200 pcs. min. |
This type of business can be started with the production of small batches of self-tapping screws, for example, up to 1.5 million pieces of screws with a triangular thread per month. Today it is quite possible to purchase inexpensive modern equipment. Regardless of the scale of the enterprise, the manufacturing process of the product remains the same.
It is possible to expand the line for the production of self-tapping screws at any stage of commercial activity. It is enough to purchase high-performance machines for the manufacture of self-tapping screws of various formats, other metal fasteners. At the moment, this business orientation is recognized as profitable.
A competent approach to business, started with small costs, after a while will manifest itself from the commercial side. Mini production will begin to bring good profits:
Self-tapping screws are in demand just like nails. Not much more expensive, but have more extensive uses;
A wide range: universal self-tapping screws, roofing, for metal, drywall, wood, for sandwich panels and others;
Availability of raw materials;
There are machine-building capacities in the country, but these fasteners are not produced enough. Russia imports them in tens of thousands of tons annually;
Our construction market has hardly been affected by the economic crisis;
Private investors are happy to respond to a promising idea, subject to a professionally drafted business plan;
The main questions of the organization of industrial and commercial activities.
In the absence of own funds, it is necessary to apply to the bank for a loan. The bank will start considering your application only if you have a meaningful business plan, and will be able to issue a decent loan for organizing a business project. You can’t do without a detailed step-by-step description of the upcoming activity even if you already have the initial capital, and you just need to register a legal entity, it can be, for example, an individual entrepreneur (individual entrepreneur) or LLC.
The manufacturing technology of self-tapping screws is simple, but it should be carefully analyzed, carefully calculated in advance, before opening a company.
It resembles the production method of an ordinary nail. The difference between metal fasteners is that the rod has a head and an external thread.
Diagram of the cold stamping method:
- first, the raw material in the form of twisted wire is sawn across into small blanks of the required length;
- then a hat is formed and a thread is cut;
- obligatory procedure - hardening of the resulting self-tapping screws in the oven;
- products are thoroughly washed;
- a special anti-corrosion spraying easily falls on a clean surface.
For the organization of production, it is necessary to purchase equipment. The operating line for the production of screws is fully automated:
- The cold heading automatic machine provides a rhythmic drawing of a wire. Sliced semi-finished products are pushed into a large box;
- The thread rolling mechanism is equipped with special dies that grind threads of a certain size;
- Hardening of finished self-tapping screws takes place in a furnace, where the temperature is 880-950 ˚С;
- A special galvanizing line consists of several adjacent baths. The self-tapping screws move into a rotating drum, then they are immersed alternately in a bath with a degreasing agent, in a second container with phosphate, and in a third with oxides. At the final step, the parts are washed with running water. Now they are ready for zinc coating;
- The finished screws are dried with a hot air stream in a conventional centrifuge.
The choice of high-quality equipment is a guarantee of uninterrupted production and delivery of finished metal products to the consumer.
Experts recommend purchasing machine tools and other compact equipment from well-known Taiwanese companies FOB, LianTeng. Their line design is functionally complete (modular), allowing independent stand-alone layout and intermediate diagnostics after each next action. You can buy a machine that produces 50 parts per minute, you can also buy a more expensive machine that works at a speed of over 250 screws in the same time. The latest generations of CNC self-tapping machines are geared towards different workpiece lengths and different thread pitches. They have ample opportunities for cutting alternating protrusions and cavities, not only into ordinary screws and screws, even into dowels.
Cold heading machines of the YH1564, YH2076 brands with an average productivity of 120, 160 screws per minute have proven themselves well. Machines are easy to maintain, they give excellent product quality, have a short payback period.
Opening the production of self-tapping screws is also beneficial with Chinese semi-automatic machines INNOR, Candid.
In the Russian city of Samara, Samstal LLC produces affordable machines for self-tapping screws of the same name of good quality. CJSC "Monolith", Moscow. OOO "Auto", Kazan. Technoservice Krasnaya Zarya LLC, St. Petersburg. The list of foreign and Russian manufacturers of machine tools for the production of self-tapping screws can be continued for a long time. Many form an operating line from installations and mechanisms from different manufacturers.
When choosing raw materials, many parameters must be taken into account. This is both the type of products manufactured and the features of equipment for self-tapping screws. For example, roofing screws are best made from high carbon steel with a high hardness factor. Wooden elements are usually held together with stainless steel screws. Brass fasteners do not require additional drilling. They are used in construction when performing finishing work.
You can purchase the material in the form of a wire of a specified diameter or in the form of a blank.
There are many large metal-rolling plants in Russia now. There are no problems with the supply of raw materials for both small workshops and large enterprises. The fundamental points here can only be the cost of the material and the timing of its delivery.
Production room
The production site must comply with the conditions of fire safety, protection against injuries and all sanitary standards. It must be large enough to accommodate all the equipment for the production of self-tapping screws and provide easy access to the individual modules of the production line. Approximately you need a room of at least 500 - 600 square meters. meters.
The main requirements for the future mini-workshop include:
- location remote from the residential complex, best outside the city limits due to noise;
- the presence of an access road, gravel is allowed;
- the presence of a power supply network, since the power consumption of the operating line is up to several tens of kilowatts;
- communications are necessary: supply and exhaust ventilation, water, sewerage.
Many rent idle areas of production workshops at large enterprises.
Staff
Modern machines for the production of self-tapping screws are fully automated. All procedures are carried out using the control panel, which greatly facilitates the process. Fewer workers are required to maintain the system. Moreover, the qualifications of employees, and sometimes experience do not matter. The principle of operation of the machine is easy to master. Of course, in any situation, one cannot do without a chief technologist in order to fine-tune the installation as accurately as possible.
The tasks of selling products, purchasing raw materials, preparing financial statements, and organizational problems are solved by many entrepreneurs themselves, while others hire a specialist.
Sales of finished products
When a new generation of technology for the production of self-tapping screws is installed in the workshop, it is possible to start producing small batches of fasteners of various formats that differ from each other in the shape of the head, length, thread and slot. When selling goods, it is easy to determine the type that is most in demand in a particular region. Further, it remains only to increase the size of its production.
If you work hard on writing a business plan, you can come up with many sales opportunities:
- the ideal option is to negotiate with a large shopping center or with a construction company, you can conclude an agreement with a door manufacturing company, for example;
- you won’t get big profits in retail, it’s better to wholesale, however, this method of selling goods should not be discounted either;
- private contractors will be happy to cooperate with an opening company for the manufacture of self-tapping screws, subject to the most favorable conditions for them.
It is better to start your own business with low prices for products in order to attract customers.
About expenses and income
Articles of the business plan (expenses / income) will depend on many parameters. Here are examples of the main ones.
Fixed and variable costs / costs of opening a mini-factory of self-tapping screws:
- registration of an individual entrepreneur in state bodies, overhead costs, including the costs of opening a bank account - 3,000 rubles;
- organization of the workshop premises: cosmetic, possibly major repairs, setting up communications, ventilation - you can meet 500,000 rubles;
- purchase of equipment, examples: Chinese thread rolling machine CTR6HN for self-tapping screws, screws and bolts, the online store sells for $ 13,000, 150 - 330 pieces / min; A 3-position machine of the same brand with a capacity of 250 pcs/min costs much more than $70,000; a cold heading machine with a maximum workpiece length of 52 mm can also be bought here for $13,000, etc.;
- delivery, installation of equipment - 5% of its cost;
- the rent of the premises is paid monthly, depending on the size of the area;
- utility bills, communication and others;
- consumables (lubricant, chemicals);
- raw materials for production;
- employee salaries;
- tax deductions.
Equipment for production is better to select with knowledgeable people, see the existing mini-production. For our calculations, we will assume that the cost of the necessary equipment, including delivery and installation, is 3,000,000 rubles. To minimize costs, you can look at used equipment.
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Self-tapping screws come in lengths from 11 to 200 mm. The most popular colors are black. Consider the production of black wood screws 3.5 * 16. A suitable material for production will be wire according to GOST 5663-79, steel 10-20 of draft group 66. The costs must take into account the loss of wire up to 10% during production.
Let's assume that the maximum production volume is 150 items per minute. Then, with an 8-hour working day, 8 * 60 * 150 * 1.2 / 1000 = 86.4 kilograms of self-tapping screws will be produced. 1.2 grams - the weight of one self-tapping screw. The proceeds from the sale are received with a delay of 1 month, the first 3-4 months of work it is possible to conclude contracts for the supply of self-tapping screws only for 50% of the planned production, then reaching the planned volume.
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Based on the available data, we will calculate the net profit from the sale of self-tapping screws.
Our business planning horizon is 2 years. Payback 33 months. As the productivity of labor grows, the increase in the sale of the product, the cost of goods will begin to decline. It will become more attractive to customers. Income will go up.
A self-tapping screw is a product designed for fastening wooden and metal parts. The line for the production of self-tapping screws produces a product with a thread of a special triangular shape, which itself forms a hole. If such fasteners are used, then the need for additional tools is eliminated. By purchasing lines for the production of self-tapping screws and opening an enterprise, you can get a promising and stable business.
Business
In the Russian Federation, these products are manufactured not only for personal needs, but are imported to other countries. However, domestic demand is only 70% satisfied. Mechanical engineering in this area will continue to develop. A self-tapping screw is a universal fastener that has a fairly stable demand.
Experts characterize this business as profitable at the level of 55%. To start it, you need a line for the production of self-tapping screws, the price of which is about 650 thousand rubles. The power of equipment in this price range is enough to produce two million items per month.
The margin can be as high as 95%, because the annual turnover of a small plant, as a rule, is about 5 million rubles.
Production technology
As raw materials, stainless or carbon steel, as well as brass, are usually used. As a rule, this raw material is represented by a special cut round timber or a wire coil. It is easy to find suppliers of these materials. In Russia, a sufficient amount of rolled metal is produced. Therefore, it is possible to choose a plant that is territorially located closer to the workshop.
To understand what kind of lines for the production of self-tapping screws you need to purchase, you need to consider the production process of this product in stages. This technology is called cold stamping.
| Stage 1 | It is necessary to stretch the steel rod. Operations take place on drawing machines. The basis is rows of dies of different diameters. The metal rod that passes through them decreases gradually in diameter. The equipment is equipped with a cooling system. |
| Stage 2 | Cut blanks to the specified length. Forming hats on cold heading machines. |
| Stage 3 | The workpiece is transported to the machine for thread rolling. To do this, you need to use a special conveyor. They come with workpiece grips. |
| Stage 4 | The product is delivered to the furnace, where it is hardened at a temperature of 930 degrees. Thereafter, the temperature progressively decreases. This must be done to uniformly remove the metal tension plane. Further, the self-tapping screw enters the washing line. |
| Stage 5 | Needs to be galvanized. Use for this a small number of baths. In them, the preparation of surfaces and the direct application of anti-corrosion layers take place. A zinc anode is installed in the final bath. |
| stage 6 | Drying takes place in a special centrifuge. This is the penultimate stage of the industrial process. |
| Stage 7 | The final stage is the quality control of the product and its packaging. |
As practice shows, there are a lot of techniques for production. Buying one installation for the manufacture of self-tapping screws is unrealistic. This is a whole big technological line. To date, almost all processes in the lines are automated. Management of such equipment, possibly by one operator.
Equipment
In today's market, dealers offer Taiwan production lines. The leaders are LianTeng and FOB brands. The line consists of several devices. Thanks to them, you can control the production processes of each of the stages. You can freely combine the technique. The manufacturer of Taiwanese self-tapping screws notes that this technique is quite reliable. It almost does not fail with competent and skillful operation. 
FOB Brand Self Tapping Machine: Taiwan The Taiwan self-tapping screw production line, whose price depends on the production speed of products, makes it possible to produce 55 self-tapping screws per minute. The most expensive machine can produce 255 finished self-tapping screws per minute. The cost of the line is approximately 2,000 US dollars.
Also, the price of the line depends on the assortment produced on it. The range is determined by the length of the workpiece and the thread pitch. The more customization options a technique allows, the more expensive it is, respectively. There is equipment that, after reinstalling the settings, allows you to make a screw, screw and dowel. If in the future manufacturers plan to increase production and the list of finished products, then it is necessary to purchase modifications. For the future, it is best to buy new equipment. Used equipment can fail.
Top four brands of self-tapping screw production line:
| KONNAR | ID5 X 85 in conjunction with ID6 X 130 INNOR | YH2076 FOB | YH1564 LianTeng |
The price of YH2076 FOB is 23,000 USD, Z12-5 Сandid is 14,00 USD. In a minute, these two brands are able to produce 125-165 pieces of products, respectively.
Equipment for the production of Z12-5 Candid self-tapping screws The quality of the product complies with Russian standards. You can buy a line for the production of self-tapping screws in Taiwanese representative offices, while recouping the investment in a relatively short time. Of course, this will be possible, in conditions of full sales of manufactured products.
There are also European brands of this equipment. But their price is 3-4 times higher than their Taiwanese counterparts. You can also pay attention to Chinese equipment. Their performance and quality, as well as other special features, are not compromised by Taiwanese brands. The cost of Chinese equipment is about the same. As one of the options, you can consider Ukrainian-made equipment. Cold heading equipment ABO 215 is capable of producing 165 products in one minute. The price of this equipment is about 16,000 US dollars. The quality is no worse than Chinese and Taiwanese equipment.
Video: Thread rolling machine
Despite the economic crisis, the construction market is experiencing stable growth. Residents of our country are constantly building and repairing something, so fastening materials are very popular. Aspiring entrepreneurs who want to open the production of self-tapping screws as a business can be sure that such an activity will generate a high income.
Activity registration
To open the production of self-tapping screws in Russia, you must first draw up all the necessary documents. If you are planning to create a large enterprise that will produce a wide range of products in large volumes, you should form an LLC. This will allow you to sell products by bank transfer to legal entities, as well as enter into agreements with suppliers of raw materials.
This type of activity is not licensed, so you do not have to issue any permits. In order for your products to be competitive, it is desirable to be certified. For mini-production of self-tapping screws, it is enough to register as an individual entrepreneur.
Premises and location
The success of a business largely depends on where it is located. Some companies are more attractive to potential buyers because they are easy to get to. But not in our case.You should not rent a building in the city center for a factory for the production of self-tapping screws. After all, these are not buns that passers-by buy. Such products are purchased in tons, so sales volumes do not depend on where your company is located - in the center or on the outskirts. The most important thing is that good access roads lead to it. The buyer will pick up a quality product at an affordable price from anywhere, so when choosing a room, be guided by the cost of rent.
Choose an affordable, comfortable space that meets all your requirements. This may be a former garage for tractors or other special equipment. You will pay about 5 thousand per month for it. Agree that this is ridiculous money for a business, even a small one. Remove all rubbish from there, conduct electricity and you can start choosing a production line.
Equipment
In order for the product to be of high quality, you need to purchase machines for the production of self-tapping screws. Such equipment is offered by different manufacturers. The choice of certain models largely depends on the technology for the production of self-tapping screws that you are going to use in your enterprise.
Scheme: production of self-tapping screws
The technological process includes the following steps:
- Manufacturing of blanks;
- thread cutting;
- In order to expand the range of products in the line for the production of self-tapping screws, units for surface hardening and anti-corrosion treatment should be added.
The basic set of equipment for the production of self-tapping screws consists of the following units:
- Drawing machine;
- Unit for blank molding;
- Thread cutting machine.
If you are going to compete with large industrial enterprises, you should purchase an electroplating line, a spin dryer and a tempering furnace to improve the quality of products.
The cost of equipment fluctuates in a wide price range. It makes no sense to buy an expensive high-performance line until all marketing issues are resolved. If you are on a budget, you can buy used equipment.
You will have to spend a lot of money on equipping the enterprise, since all the machines are quite expensive. High-performance equipment pays for itself much faster. This should be taken into account when developing a business plan.
Technological process
A self-tapping screw is a fastener consisting of a rod with an external thread and a head. It should be noted that the technology and equipment for the production of nails and self-tapping screws is almost the same, but there are still some differences.The production process consists of the following steps:
- Cutting wire to size;
- Threading and cap shaping;
- hardening process;
- Washing;
- Anti-corrosion treatment.
As a raw material for the manufacture of self-tapping screws, a low-carbon wire that has undergone heat treatment is used. If you are interested in the production of self-tapping screws, a video on this topic can be found in this article.
Staff
Since the production line operates in automatic mode, it does not require many workers to maintain it. Operators look after pre-configured equipment, supply consumables and remove finished products. When compiling a business plan for the production of self-tapping screws, at the first stage, two workers can be provided. In addition to a salary of 15–20 thousand rubles, one should take into account the costs of their training. You also need to hire an accountant. The salary of such a specialist is in the range of 25-30 thousand rubles.
Business plan
To be profitable, you should not miss the following important points:
- Purchase of equipment;
- Choice of premises;
- Purchase of raw materials;
- Choice of assortment;
- Hiring employees;
- Search for sales markets.
Before starting work, prepare all the necessary documents.
Income and expenses
- Room rental - 5 thousand rubles;
- Salary - 40 thousand rubles;
- Raw materials - 15 thousand rubles;
- Electricity bills - 10 thousand rubles.
Raw material
With the purchase of raw materials, as a rule, there are no problems. Suppliers offer blanks or wire in reels at affordable prices. As a rule, they deliver raw materials directly to the enterprise, so you can save on transport costs. The choice of raw materials largely depends on the technology and equipment.
To reduce the cost of products, you can purchase raw materials directly from manufacturers at low wholesale prices. Steel or brass wire costs about 12.5 thousand rubles per 1 ton. 500 thousand self-tapping screws will be obtained from one reel.
Range
In order for your business to generate high income, you need to constantly expand the range of products. It will not be possible to achieve a great variety, since self-tapping screws can differ only in the type of head, length and thread.
Produce different models of fasteners in small quantities. Over time, you will be able to decide which screws are in demand in your area.
Production of self-tapping screws Production of self-tapping screws
Sales of products
To get a stable monthly income, you need to find potential buyers. The implementation of fasteners must be continuous. To achieve this, you need to produce a wide range of products. This may be the production of roofing screws, nails, anchors, and so on. Focus on the most popular types of products. In the future, your business can be adjusted depending on the season.
The best option is a contract for the supply of products with. For large-scale construction, large volumes of such products are purchased. Sometimes one object overlaps the monthly productivity of the enterprise. Also, take a look at . For example, a small furniture workshop consumes several tens of thousands of self-tapping screws per month.
First of all, try to establish contacts with building supermarkets, which will gladly expand their range. In any city there are markets or where you should start. To conclude contracts for large deliveries, you will have to work hard. To attract customers, you will have to slightly reduce the prices of products.
Conclusion
Now you know how self-tapping screws are made and make money from it. This is a simple, promising and quite profitable business. Since all equipment is automated, the main problems may arise only with the sale of products. But they are easily solved in the process of work. Read about others on our website.
