Foam rubber production technology at home. Production of foam rubber in Russia as a business. Purchase of technological equipment

To date, foam rubber manufacturers operating in our country cannot fully satisfy the demand for this product, so it has to be imported from abroad. Shipping costs significantly increase the cost of products, so consumers prefer to buy material made domestic producers. Production of foam rubber in Russia brings big profit. How to organize such a business, we will understand in this article.

Business features

Modern foam rubber is significantly different from the material that was produced several decades ago.

Among its advantages I would like to highlight:

• High moisture resistance;
• Mold resistant;
• High degree of heat and sound insulation;
• Elasticity.
• The most important advantage of the product lies in its low cost.

Like any other material, foam rubber also has disadvantages. First of all, the production of such products is considered environmentally harmful, therefore, high requirements are placed on security systems at enterprises for its production.

In addition, polyurethane foam is a combustible 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.

Manufacturing technology

For the production of foam rubber, one of two methods can be used:

1. Continuous;
2. Periodic.

The simplest, periodic method. It is perfect for aspiring entrepreneurs. This foam rubber production technology does not require special knowledge and use. complex equipment. All chemicals are mixed in a foaming machine, after which it is sent to a special form. In it, the material is no more than half an hour. Further, the finished product is cooled for 3 days and cut to size.

Particular attention in the manufacture of foam rubber should be given to the temperature regime. In the production room, the temperature should not fall below +18 degrees. This requirement does not apply to the warehouse, utility rooms and cutting area.

In addition, you need to correctly determine the dosage of the components. There is no room for error in this matter. The production process must be controlled by an experienced chemical technologist. A video of foam rubber production will help you to get acquainted with the production process in more detail.

Scheme: foam rubber production

Raw material

For the manufacture of foam rubber, polyisocyanates and polyols are used, which are produced by petrochemical enterprises. To ensure the smooth operation of the production line, it is necessary to conclude long-term contracts for the supply of quality raw materials. In this case, your company will not be idle without work and suffer losses.

In addition, a room should be allocated for a warehouse for raw materials in order to have a reserve in case of force majeure situations. In addition, if you buy material in large quantities, manufacturers can significantly reduce the price, which will allow you to save money and reduce the cost of production.

Range

Consider the main types of foam rubber:

• Increased rigidity. For the manufacture of this material, special polyols are used, which give it increased strength. Such foam rubber is used for the manufacture of seats and mattresses;
• Latex highly elastic foam rubber. This type of product is presented in a wide range. It is much more elastic than other types of polyurethane foam. Material with such properties is used in the furniture industry for the manufacture of pillows, mattresses and other products. It is durable and resistant to dents;
• Material for molding various elements. To achieve an orthopedic effect, many manufacturers use spring blocks with multilayer filling in the manufacture of upholstered furniture. Synthetic flooring materials, for example, block elastic polyurethane foam, can significantly reduce the cost of products;
• Foam rubber. This material is made from rubber. It is produced in the form of molded elements or sheets. Foam rubber has excellent sound and heat insulation properties, as well as durability and high hygiene.

Equipment

The finished foam rubber production line can be used regardless of the method of organization of the enterprise.

It consists of the following units:

• foaming machine;
• Thermal camera;
• Device for cutting material;
• dispenser;
• Form block.

To make production waste-free, you should also buy a crusher for processing edges and defective material. In addition, you will need a packaging device, with which the foam is rolled up and packed in polyethylene.

Staff

It is not necessary to hire to work in the enterprise qualified personnel. It is enough to find one experienced chemist-technologist. Other employees may receive special training. Usually such courses are offered free of charge by equipment suppliers.

2 people are required to service the cutting and pouring equipment. You also need to hire 3 workers for loading and unloading.

Financial calculations

To start a plant for the production of foam rubber will require large capital investments. Since the profitability of such a business is quite high, and the demand for foam rubber is constantly growing, start-up capital will be back in 5-6 months.

The purchase price of foam rubber production equipment is quite high. You will spend approximately 17 thousand dollars to purchase it. For installation and staff training, you will have to pay another $7,000.

To improve performance, you must also purchase:

• Thermal camera - 6 thousand dollars;
• A set of dosing devices - 6.5 thousand dollars;
• Band saw machine - 5 thousand dollars.

With this additional investment, you can increase the productivity of the plant by 2.5 times, but only if the periodic method is applied.

A fully automated line will cost 6.5 million rubles. This is the main equipment for the production of foam rubber, to which you will also have to purchase additional accessories:

• Packing machine - 7 thousand dollars;
• Crusher for foam rubber crusts - 2 thousand dollars;
• Equipment for waste processing - 9 thousand dollars.

To the cost of equipping the workshop should be added:

• Payment for the rent of the premises;
• Employee salaries;
• Purchase of components for the production of foam rubber;
• Fare;
• Payment of utility bills.

According to preliminary calculations, the net income of such an enterprise is about 220 thousand rubles a month. According to experts, the profitability of such an enterprise is at least 15%.

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Sales of finished products

Furniture factories that use foam rubber as padding for upholstered furniture can 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 buy 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 manufacturers of audio equipment for the manufacture of headphones, microphones and other devices.

Foam rubber can also be taken to construction stores. Such goods are bought by individuals in small batches. Factories for the production of children's toys often use this material for stuffing various products, so you can try to conclude contracts with such enterprises.

The main activity of the company is production of sheet and block foam rubber in a periodic way. Produced foam rubber is used as stuffing material in the production of upholstered furniture, sports mats, children's modular products, medical mattresses, as well as for other purposes. Our company offers for sale not only the produced foam rubber, but also a set production equipment with full team chemical components to carry out this type of activity. Our specialists with many years of experience,will hold the whole range of services for installation, commissioning, learning Your staff and the release of final products on the proposed equipment. If necessary, our company offers on favorable terms for you supply of chemicals including transportation.
We have been cooperating since 2003 with the following organizations:
- OOO " DAUIzolan"Vladimir
- OOO " Furniture groups", G. Nizhny Novgorod
- OOO " NVP Vladipur", Vladimir
- OOO " Semi-product plant", Nizhny Novgorod
- OOO " HH pace", Nizhny Novgorod
- LLC NPP " Elastoprom"Penza

Equipment

The equipment is manufactured according to the design principles of imported (German) equipment, with the exception of complex expensive electronics, all critical components and assemblies are simplified and strengthened in accordance with domestic working conditions.
Performance
Allows you to produce up to 60 cubic meters of foam rubber for an 8-hour work shift.
Components
Blend setting
Designed for the manufacture of PPU blocks.
Overall dimensions 1400x1000x2730 mm.
- Supply voltage 3x380 V
- Maximum power consumption - 3 kW
- Mixer capacity allows to produce a range of densities from 16 kg/cu.m. to 25 kg/cu.m.
Form - mobile with floating lid
Cutting horizontal installation
- Designed for cutting PPU blocks into sheets of a given thickness (from 3 to 220 mm). Overall dimensions 4460x2500x2700 mm. Characteristics: - Supply voltage 3x380 V - Maximum power consumption - 5 kW

Technology and Components

This activity uses six-component system. The main ones are: polyester component and isocyanate component T-80. The apparent density of the resulting foam depends on the amount of basic components and water in the formulation. Surfactants and catalysts provide a balanced foaming and curing process.
The process of obtaining PU foam at batch plants consists of the following technological stages:
- preparation and tempering of raw materials
- preparation of the activator mixture and component A
- preparation of component C.
- dosage
- production of blocks and their aging
- cutting blocks into sheets of a given thickness
In the manufacture of blocks of elastic PPU the room temperature must be maintained at a particular temperature. When aging, PPU blocks are installed on the floor at a distance of no closer than 0.2 m from each other. Standing takes place for at least 12 hours, then the finished blocks are sent for cutting. In the process of maturation, the processes of chemical transformation of the starting materials into non-volatile polymeric products are completely completed, reactive compounds are bound, and the block is cooled.
Requirements for production facilities
- The area of ​​the molding shop (pouring) should be 30 - 35 sq.m, the temperature regime is 20 - 28 C, the ceiling height is at least 3 m
- Availability of exhaust ventilation in the molding shop. An umbrella measuring 1.2 mx 2.2 m is installed directly above the mold where foaming takes place. Fan motor at least 3 thousand revolutions per minute, air duct diameter 0.3 m
- The room for sawing and storage must have an area of ​​at least 200 sq.m, without reference to the temperature regime
In total, the total area of ​​the premises required for the placement and operation of this production should be at least 230 sq.m.

Services

Departure of specialists for the organization of the entire turnkey mini-production to the address of the customer.
- Installation and commissioning of equipment
- Project of the premises under this species activities
- Selection of all the necessary attributes used in the production of PPU
- Technology training
- Delivery of chemical components
- Release of finished products
- All further consultations on customer issues

Profitability

In this manufacturing process at least three people (technologist and two workers) must be involved. In the manufacture of foam rubber of any density, from 15 to 30 blocks are produced in one shift. Per month(24 working days) produced on average 500 blocks. Let us calculate the cost of one block of foam rubber with a density of 22 kg/cu.m. By technology required amount raw materials for the manufacture of one block is 50.17 kg. The cost of a six-component system for the production of foam rubber is 2.8 $ per 1 kg(1 kg contains all the necessary components in the required proportions). Therefore, the cost of one block for raw materials will be: 50.17 kg x $2.8 = $140.47. The block obtained on this equipment has the following dimensions: width - 1000 mm, length - 2000 mm, height 1100 mm.
Thus, 110 cm of foam rubber (110 sheets of 10x1000x2000 mm in size) are for sale. On average, in January 2009, the cost of one sheet of foam rubber with a density of 22 kg / m 3 10x1000x2000 mm in size is 2,1 $ , therefore 110 sheets x 2.1 $ = 231 $ . Let's determine the difference between the sale price and the cost of one block for raw materials: 2 31 $ - 140,47 $ = 90,53 $ . With an average employment of working personnel in the production process, up to 500 blocks per month with income 25 - 30 thousand $. Electricity costs are 2000 - 2500 kW per month at the above rates of work. Wage employees have a piece rate, on average it is 3 $ for the production of one block of PPU. Current expenses for needs production activities constitute 400 - 500 $ per month. This equipment allows to produce up to 35 tons of foam rubber per month, subject to the continuous operation of production

If you pay attention to which companies are most often opened today, then here you can undoubtedly name jewelry, alcohol, automotive and furniture. Let's take a look at the furniture. It consists of simple and light materials, but with an interesting design, it can be very expensive. Thus, furniture brings a high income with minimal cost. As a result, equipment for the production of foam rubber is considered relevant for the acquisition.

• Equipment for the production of foam rubber
• Necessary costs for the production of foam rubber
• How much can you earn in the production of foam rubber
• Step by Step Plan to Start a Foam Rubber Business
• What is the OKVED for the foam rubber business
• What documents are needed to open
• What taxation system to choose for a foam rubber business
• Do I need permission to open
• foam production technology

The material is widely used in the manufacture of furniture, toys, sporting goods. Foam rubber is a material consisting of polyurethane. It is very elastic and resilient, as 90% consists of cells filled with air.

The material is used in the manufacture of:

• various furniture;
• soft toys;
• car seats;
• sports and household goods.

Production volumes of upholstered furniture in Russian Federation increase every year. The annual growth in this market segment is 10%. With the development of this industry, the demand for materials that are needed also increases. The main one is foam rubber.

At the moment, there are two main methods that are used in the manufacture of foam rubber: continuous and periodic. Small firms use the second technology, as it is simple, and the cost of buying equipment and maintaining it is minimal. In addition, no specific education is required to make foam rubber, it is enough to take training courses offered by suppliers.

Equipment for the production of foam rubber

In order to start making foam rubber, you need to have:

• machine (automatic) for foaming;
• thermal chamber;
• machine for cutting blanks;
• dosing device;
• configuration block (forms);
• related materials (couplings, hoses, etc.).

In order to organize a full-fledged line, you should purchase additional devices: a waste crusher, a machine with which you can twist sheets and a film wrapping machine. Higher listed species equipment can be ordered separately, or you can purchase a complete line.

Necessary costs for the production of foam rubber

A set of equipment that produces 12 m 3 of material in one shift costs around 300 thousand rubles. If you order a line that includes all devices for the production of foam rubber of various brands and is capable of producing up to 30 m 3 of foam rubber per shift, 1.3 million rubles will be required.

There is an option where you can order a mini-factory in China. The output of such a line is not less than 50 m 3 of finished material per shift. Issue price 1.6-1.8 million rubles. This option is more profitable. For effective building The process will require 7 employees who will work 8 hours per shift. Capital costs for the organization of the line for the production of foam rubber will amount to approximately 1.78 million rubles.

Those who decide to engage in this activity must issue an IP. Find a suitable room where the work shop with a total area of ​​200 m 2 will be located. Find buyers among enterprises and firms that are engaged in the production of furniture and other goods where foam rubber is used.

The loading of the line is closely related to the demand of buyers for upholstered furniture. It will be possible to receive the largest revenue during the peak time of furniture sales (autumn and from February to April). The rest of the time there will be a decrease in revenue associated with seasonal customer requests. There are very few orders in January, this is primarily due to the holidays. This is the best time to spend Maintenance equipment.

How much can you earn in the production of foam rubber

Revenue is best calculated with the condition that the line will be loaded by 50%. In the manufacture of foam rubber with parameters of 20 mm, thickness and density of 25 kg / m3, the price of large orders will be 150 rubles / sheet, and retail 250-270 rubles. As a result, we can create the following table.

In the manufacture of foam rubber sheet, the cost will include the cost of raw materials for production and the energy used:

Thus, after making approximate calculations, you can see that even with a payback period of 12 months, you can regularly receive high income even with 50% line load. With 100% operation of the equipment, it will be possible to return your costs in six months. Therefore, it is very important to take care of the ways of selling products in advance.

Foam rubber is currently one of the “long-lived” materials: for the first time, polyurethane foam (or PPU for short) was developed back in the 1930s, and received in the 1940s. It is a proven and reliable softening and support material used to give elasticity to products (for example, upholstered furniture) and thermal insulation.

However, its production in Russia is far from covering the needs, so foam rubber is often imported from abroad. Therefore, the production of foam rubber can be enough profitable business, given the fact that foreign manufacturers will not be able to compete with domestic for the simple reason that the transportation of this material, especially to long distance often costs more than the transported material itself - after all, foam rubber takes up a large volume with low weight, even if transported in a special compressive package.

In addition, the production of foam rubber (in relatively small volumes) does not require significant equipment costs and large production areas, and therefore is perfect for a novice entrepreneur.

However, this moment can also become a significant obstacle for a local manufacturer: the same territorial restrictions are imposed on it as on foreign manufacturers - the production of foam rubber is actually a very customer-oriented production, the sales market for which is relatively small and quite specific.

The main sales niche is occupied by those industries that produce fragile and mechanically affected goods, for example, electronics ( e-books, GPS navigators, etc.) that need a soft pad to protect them from breaking.

Such industries willingly purchase large enough batches of foam rubber as a packaging, or rather, cushioning, material. In second place are manufacturers of upholstered furniture, which use foam rubber as stuffing in inexpensive and medium-priced products that make up the bulk of such products in a medium-sized enterprise: armchairs, sofas, etc., as well as construction firms, sometimes using foam rubber as sound, heat and vibration insulation.

Approximately in equal (relatively small) volumes, foam rubber is purchased by shoe manufacturers, who use it as one of the components of the insole for shoes, and manufacturers of audio equipment - microphones, headphones and some types of audio speakers.

A very small volume of foam rubber sales is made up of other customers, among which it is worth noting the manufacturers of some medical products, such as fixing splints (for example, a collar splint), some prostheses, etc. products. Of course, we should not forget also about the distribution network for individuals: supermarkets and building materials stores can also buy a certain amount of products.

So when you open own production of foam rubber should be correlated with the estimated production volume with the same estimated sales volume, taking into account all potential buyers in the region and not taking into account the possibility of sending the manufactured goods outside the zone, which does not imply a competitive cost of transported foam rubber plus transportation costs with analogues from other manufacturers.

foam production technology

The production of foam rubber is considered environmentally hazardous and in some cases harmful to health. The fact is that for its manufacture polyol, aromatic diisocyanates are used - mainly toluene diisocyanate (toluene diisocyanate) or methylene diphenyl diisocyanate (diphenylmethane diisocyanate), some catalysts and foam stabilizers.

Some of these components are toxic when evaporated, but they decompose into non-hazardous ingredients under the influence of moisture and air - which is why manufacturing facility should be provided with running water and well ventilated, and workers should have respirators.

The actual production of foam rubber, as well as any other polyurethane foam, can be classified into two categories: volume, i.e. capacity of the plant and the method of production used - continuous or batch.

In fact, both categories are related: as a rule, the continuous method is used for large production volumes (over 2000 tons per year), although some medium-sized (500-2000 tons per year) enterprises also use it; the periodic method uses part of the medium (with a capacity of 500-2000 tons per year) and all small (up to 500 tons per year) enterprises.

The very same process of production of foam rubber is as follows. Liquid chemical reagents - a composition for producing foam rubber - are dosed into a mixer of a certain volume, then quickly mixed in a foaming machine (in accordance with the mixing modes, on which the main characteristics of the foam rubber depend - density, compressive stress, relative residual deformation during compression, breaking stress, relative elongation at break) and poured into a mobile mold with hinged walls.

After mixing the reagents, a chemical reaction takes place in the mold, which leads to the formation of foam and its rise to the top edge of the mold. The block of foam rubber obtained in this way is kept for the time allotted by the technology (approximately 15-20 minutes) in the form, then the form is disassembled, and the block is moved to the room for final formation (cooling the blocks and completing chemical reactions in them).

After 1-3 days, the finished foam rubber is cut into sheets of the required thickness (usually from 5 to 150 mm) on a horizontal band saw. Sheet foam is sold.

The foam rubber production methods differ in the following point: with the continuous method, the pouring machine delivers a measured amount of components to the mixer, from where the mixed composition is poured not into a mold, but into a special moving conveyor, where foaming occurs. A continuous layer of material is cut into blocks of the required length. After exposure, the blocks are cut into sheets of the required thickness.

Equipment for the production of foam rubber

Equipment for the production of foam rubber according to the continuous and periodic method does not differ fundamentally and consists of a foaming machine, a mold (for batch), a conveyor (for continuous), a horizontal or vertical band saw and a set of kits for dosing components, servicing machines, pumps, etc. Only the power of the equipment is different, i.e. its performance.

A ready-made production line for low capacity (from 100-140 to 500 tons per year) with the possibility of expansion will cost $ 16,700, which in terms of rubles at the current exchange rate is about 510 thousand rubles, and taking into account installation and staff training - in 24,700 dollars (about 755 thousand rubles).

Further expansion of production will require: thermal camera for tempering raw materials, accelerating the process of final formation - 6,000 dollars, or about 180 thousand rubles; an additional automatic set of dosing devices and containers - $ 6,200, or about 190 thousand rubles; as well as an additional vertical band saw - $ 5,000, or about 153 thousand rubles. After these investments, the production of foam rubber will increase approximately 2-2.5 times, but it should be remembered that the production method will remain the same, i.e. periodic.

A fully automated set of equipment for the production of foam rubber in a continuous way will cost a little more - 6200 thousand rubles. However, in addition to the main one, there is also optional equipment, which is worth acquiring as soon as possible if it is not possible to purchase it immediately.

Such machines include, for example, a machine for rolling and wrapping sheets in polyethylene film or paper worth $7,000, or about 214,000 rubles; a crusher for processing foam rubber crusts into crumbs, which is used for stuffing relief products in the production of upholstered furniture, and is also used in the production of "secondary foam rubber" worth $ 2,000 or about 61 thousand rubles, as well as the actual set of equipment for processing foam rubber waste and obtaining recycled foam rubber worth $ 9,000, or 275 thousand rubles.

The premises and personnel required for the production of foam rubber

Basic requirements for production premises reduced only to the height of the ceilings (which should be at least 3 m) and maintaining temperature regime at a level not lower than 18°C: if the air temperature at the block pouring area drops below 18°C, then the production of foam rubber is impossible.

The temperature limitation applies only to the block pouring area (30-50 sq.m.), which can be separated from the rest of the workshop in a separate room for ease of maintaining the desired temperature. Further exposure of the blocks can be carried out in a room with a lower temperature, and cutting and storage of finished products can be carried out at any temperature.

The total area of ​​the foam rubber production shop is 200-250 sq.m., including a utility room for production workers and a small office for a technologist. The presence of electrical wiring for 380V with a "ground" loop is mandatory, as well as properly installed ventilation. In addition, band saws require a light foundation.

Convenient access roads should lead to the workshop, and the area in front of it should provide an opportunity for unloading barrels of raw materials (200-250 kg).

The production of foam sheets requires a person who is either trained as a chemist-technologist or has received the appropriate training, which is often provided by manufacturers of foam rubber production lines. In principle, the presence of a chemical education is a desirable, although not a mandatory criterion in the selection of personnel.

In addition, to service the machines, 3 people are needed for the filling and 2 people for the cutting machine, and 2-3 handymen are needed for loading and unloading goods and raw materials and other work. The qualifications and education of production workers are of little importance.

Prospects for the development of the foam rubber business

The main direction of development of the foam rubber business is the production of molded products. Such products are now used mainly for seats and backs of car seats, as well as in the furniture industry - in the segment of expensive upholstered furniture.

In addition, the production of rugs, sponges, window insulation strips, children's toys, coat hangers, etc. is a practically cost-free option. household goods.

Do not forget about the introduction of new technologies: in the West, instead of foam rubber, non-combustible polyurethane foams (which are produced by introducing special additives) have become widespread.

Video about the production of foam rubber

Foam rubber has long been known as durable material for the manufacture of elastic products. Existing enterprises in Russia are not able to fully meet the demand for this material on the domestic market of goods. Opening a mini foam rubber production plant in Russia will be quite beneficial for both those who are taking their first steps in entrepreneurship and businessmen with significant experience and seniority. Considering the fact that imported foam is much more expensive than domestic, 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.

Technology and equipment of foam production

If we consider the manufacture 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 is built. The fact is that each technological operation of the foam cycle is performed on its own separate equipment. And each stage of production requires careful monitoring of product compliance with existing standards, only in this case end result process will be of high quality marketable products.

The foam rubber production technology can be represented as the following industrial algorithm:

• creation of a raw composition and loading it into the hopper of the foaming machine with continuous mixing;
• filling the resulting solution with special folding forms;
• providing a chemical reaction of the interaction of the components of the mixture before filling the foaming composition of the forms to the upper edge;
• cooling of the material at a given temperature for 3 days;
• cutting foam rubber in the form of sheet material into specified formats;
• innings finished goods to the warehouse.

An important role in obtaining high-quality material is played by the exact observance of the dosage in the reacting mixture of all components for foam rubber. There can be no errors here, everything must correspond terms of reference up to a gram, and the weighing process should be carried out on a scale with a very small error. At present, only electronic balance high class of accuracy.

It is known that each large enterprise for the production of foam rubber uses its technological features, its exact recipes and ratios of components. But the content of such substances as polyol and polyisocyanate in the initial mixture should be unchanged everywhere. The difference in production methods lies only in the number of secondary components that make up the mixture.

Since in technological scheme production of foam rubber provides for the flow of complex chemical reactions, then labor protection requirements for workers must be strictly observed there. This also applies to the air temperature of 18 ˚C, and ventilation capable of removing all harmful gases from the operating personnel area. It is necessary to take a very responsible approach to the work of the workshop's treatment facilities, which should provide reliable protection of the atmosphere from significant pollution.

To operate a plant with the manufacture of only high-quality goods, it is necessary to include an experienced technologist in the staff of its employees, who will be able to monitor the correctness of the production cycle at all its stages. He will be required to monitor compliance with the recipe and control both the feedstock for the foam rubber and the intermediate compositions of the working mixture. All these parameters are precisely regulated state standards RF.

When buying equipment, the main decision is a semi-automated complex or a fully automated one? Of course, the automatic line is advantageous in that it does not require numerous service staff, and the quality of the manufactured goods does not depend on the variable human factor. But, on the other hand, the cost of these types of equipment is so different 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 the choice of a foam rubber production line is made by the businessman himself, comparing his future expenses and income.

The cheapest completeness of the purchase of equipment for the production of foam rubber should contain the following machines and units:

• equipment for dosing mixture components;
• foaming apparatus;
• thermal chamber;
• block forms;
• foam rubber cutting machine;
• apparatus for grinding primary production waste;
• packaging machine.

The last two positions are necessary in the case of organizing production on a large scale, with the expectation of a large capacity 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. For the most part, entrepreneurs opt for a ready-made line of equipment, since here all 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 cu. meters of sheet material per working day is currently estimated by equipment suppliers at 600 thousand rubles. This is considered the minimum amount of capital investment in production, but with such productivity, the income of the enterprise will be quite modest. To buy a more productive line of equipment that is capable of producing up to 30 cubic meters per shift. meters of production, an amount of at least one and a half million rubles will be required. But it is precisely this performance that can be optimal for obtaining high profits by the enterprise.

There are now enough more productive lines for the production of furniture foam rubber on the equipment market, but for starting a business with an undeveloped mechanism for marketing products, 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 for the production of secondary foam rubber in their workshops. This makes it possible to obtain cheaper products, which play an important role in the struggle for the commodity market.

About product sales and profitability

The very process of organizing any production in our country is not very complicated. It is more difficult then to establish reliable sales of finished products by building relationships with representatives of the wholesale market. After all, it is wholesale buyers who are able to bring a large income to the enterprise. This all suggests the right idea that the distribution channels for your product need to be thought out at the stage of business design, and not when the warehouses are full finished products. Only operational work on the sale of foam rubber is capable of the most short time lead to a return on initial investment and to a significant net profit.

Potential buyers of sheet foam rubber are:

• furniture enterprises;
• companies and retail chains building profile;
• toy factories;
• manufacturers of high quality audio equipment;
• footwear industry.

Considering such a large number of industries 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 offered to customers and the quality of products are attractive to them in the market of competing enterprises of a similar profile.

Making an analysis of the product sales market and studying the capabilities of competitors, you will have to get involved in an active advertising company sales of foam rubber for upholstered furniture, which primarily includes high-quality foam rubber with an adhesive layer.

Speaking about the profitability of the 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 payback of starting investments in the business comes quite quickly. It is estimated that the registration of entrepreneurship, the purchase of equipment and raw materials, the rental of premises - everything takes on average up to 2.5 million rubles. This is an impressive figure of expenses, which can be reduced only by installing not new, but used equipment in the workshop.

But you should not save on raw materials. All raw material supplies must be made only from reliable customers, only this can allow the company to manufacture products High Quality and keep your client base. Usually after a year active work the initial investment in the production of foam rubber pays off, and the company begins to give the desired profit to its founder. Namely, profit is the main goal of any business, any production.