Open a sole trader for the production of liquid glass. Business in the production and processing of plastic bottles. How much can you earn from waste disposal?

It's hard to imagine life modern people without plastic bottles as they are the most widespread and demanded type of packing. Entrepreneurial people have long learned to benefit by building their business on the production of such products. In this article, we will introduce you to the features of the production of plastic bottles, equipment for the production of plastic bottles, and also tell you how to start such a promising and profitable business from scratch.

Business features

Today, the production of plastic bottles in Russia is considered one of the most profitable areas. entrepreneurial activity. Literally 20 years ago, no one could even imagine that PET containers would sell carbonated drinks, water, milk, juices, beer, and so on. Today, plastic containers are used in a variety of industries, so such products are always in demand in the market. But one cannot count on an easy start in such a business, since the level of competition in this segment is constantly growing.

It should be noted that the equipment for the production of plastic bottles, the price of which is quite high, is characterized by high energy consumption. For example, an automatic machine that makes 3,000 bottles per hour consumes an average of 25 kW per hour. This will require a powerful compressor with a pressure of at least 40 bar. If you want to go into this business, be prepared to shell out a lot of money to buy equipment and pay electricity bills.

One more important point is the mass of the workpiece for the production of plastic bottles. This largely depends on the cost. finished products. The highest quality equipment that can make liter PET bottles from a preform weighing no more than 35 grams.

Advantages and disadvantages

Pros:

• The low production cost of plastic bottles allows them to successfully replace their glass counterparts. This container is not afraid of shocks and is easy to transport. Many juice and carbonated drink manufacturers no longer buy PET bottles from middlemen, as they make their own bottles. They gradually expand their production in order to sell the surplus and meet their expenses from the profit;
• The production of plastic bottles will flourish, because a better and more environmentally friendly material has not yet been invented. This means that any novice businessman can open a fairly profitable and promising business;
• Inexpensive raw materials. If you want to reduce the cost of finished products, you can organize the collection of secondary raw materials from the population.

Minuses:

• Large initial investments;
• High level of competition.

Business plan

The first thing you need to do is to draw up a business plan for the production of plastic bottles. Until you calculate future costs and benefits, it is impossible to determine the profitability of the project.

1. Calculation of the initial investment. Starting investments should cover all costs for the purchase of equipment for the production of plastic bottles, raw materials, payment of utility bills, taxes and salaries of employees. In addition, it is necessary to provide for the cost of repairing the production premises, as well as equipping the warehouse and staff room;
2. Market analysis. This important point should not be overlooked when opening any production. If someone in your city is already manufacturing plastic bottles, ask if it fully satisfies the demand for such products, check the quality and find out for what purposes their containers are intended. It is most profitable to open the production of plastic PET bottles on the basis of an enterprise that produces bottled water, juices or sweet carbonated drinks. Thanks to this, the cost of finished products will decrease by 20%. surplus plastic containers you can sell and receive additional income from this;
3. The profitability of such a business is quite high, since the raw materials for the production of plastic bottles are inexpensive. For the transportation of such products do not need special boxes. If there is a need to change the shape and size of the product, you can simply take another mold;
4. Promotion of production. The business plan should include items for business development. First of all, it is necessary to notify customers that a new player has entered the market. You need to do everything to ensure that the consumer learns about your product, otherwise the business will fail.

Before you start drawing up a business plan, you need to study the technology for the production of a plastic bottle. We will talk about this in the next section.

Technological process

There are several ways to produce plastic containers:

• extrusion method. This technology is used to produce different types hollow containers made of granulated thermoplastic material;
• Vacuum molding method. It is used for the manufacture of correxes, blisters, cups and more;
• blowing method. Used for the manufacture of polyethylene and polypropylene bottles.

In general, the technology for manufacturing plastic bottles looks like this:

• First, they buy molds for products. Each type of container has its own design and size;
• The raw material is melted in the hopper and injected into the molds under pressure. Further, the process depends on what kind of container you want to receive. You can immediately cool the product and remove it from the mold, or the workpiece is placed in a matrix, where further molding is performed. A vacuum is created in the matrix, as a result of which the product takes desired shape. After that, the matrix must be cooled and the finished bottle removed from it. For the production of such products, you can use secondary raw materials, crushed using special equipment.

The largest percentage of scrap occurs at the blowing stage, so you need to carefully monitor the air temperature and check the integrity of the thread after blowing. Only the most expensive automatic lines can fully ensure product quality. To solve the problem with marriage, it is necessary to test each batch.

Necessary equipment

Before you buy equipment for the production of plastic bottles, you need to decide what you need for work:

• preforms;
• Bake;
• Blow machines;
• Double press mold.

The preform is the basis for making bottles. They are produced under the influence of high temperatures and pressure from polyethylene terephthalate. The bases are divided into the following types:

• Thick-walled;
• Short;
• Universal.

Thanks to this variety, you can make different bottles that differ both in shape and design.

The oven is designed to heat the preforms to the desired temperature. This equipment has additional options- movement and rotation of the workpiece. Due to this, it softens more effectively and, accordingly, easily acquires the desired shape.

The final shape of the bottle is formed in the blow molding machine. This machine is equipped with a compressor and special protection, which prevents overheating of the neck, and retains the thread intended for screwing on the lid.

Using a double mold, you can create any plastic product. Often, high-pressure injection molding is used for the production of polymer containers. Products made using this technology are completely transparent and very light. They are great for filling various liquids. Such a container may have a different color and shape. Video production of plastic bottles will help you to get acquainted in more detail with the operation of the equipment.

As a raw material for the manufacture of plastic bottles, a preform made of granulated polyethylene terephthalate is used. This thermoplastic is obtained by heating polyethylene terephthalate granules to a certain temperature. When reheated, this material does not collapse or deform.

A preform is a blank of a bottle in which a neck has already been formed. The finished product is blown out of it. For the manufacture of preforms, special equipment is used. Most bottle manufacturers purchase preforms as raw materials. In this case, there are two enterprises in the production chain. Usually manufacturers of various drinks work according to this scheme, which make their own plastic containers. They believe that it is much more profitable to buy preforms than to start their production at their own enterprise.

When choosing a preform supplier, do not forget to find out what material the products are made of. If this is a recycled raw material, that is, waste, containers cannot be made from such material for food products. It is suitable only for the production of bottles for technical liquids.

Staff and production facility

The area of ​​​​the room and the number of staff depends on what equipment you will use for work. For example, if you supply the simplest equipment, you will need three workers in one shift and about 60 sq. meters of area.

The production facility should consist of the following departments:

• Manufacturing facility;
• Administrative part;
• Staff room;
• Warehouse for raw materials;
• Premises for finished products;
• Bathroom.

The total area of ​​the workshop must be at least 100 sq. meters. With a three-shift operation, it is necessary to keep an accountant, 9 workers, a driver and a manager on staff.

Financial investments and profit

Acquisition automatic line for the production of plastic bottles will require you to make a serious financial investment. With competent marketing policy all investments will pay off in the most short time. Let's try to roughly calculate how much money it will take to open a mini-production of plastic bottles:

• Registration permits- 200 thousand rubles;
• Purchase and installation of equipment for the production of plastic bottles - 3 million rubles;
• Repair and preparation of the production premises - 300 thousand rubles.

Also, do not forget about the monthly expenses:

• Salary - 250 thousand rubles;
• Taxes and utility bills - 120 thousand rubles;
• Purchase of raw materials - 100 thousand rubles.

Average Wholesale price one unit of production (when buying a batch of more than 10 thousand pieces) is in the range of 3.5-4.5 rubles, the cost of production of a plastic bottle is 1.7-2 rubles. If the enterprise works in two shifts, it will be able to produce 200 thousand pieces per month. If there are sales markets, you will be able to receive monthly 340 thousand rubles of net income. Full payback of the project comes after 1 year of work.

Profitability

Entrepreneurs who are engaged in the production of glass containers know that if the minimum volume of output must be at least 1 million units, otherwise the enterprise will be unprofitable. Modern technologies allow you to turn on the machine for the production of plastic bottles and for 1 thousand pieces.

If you compare the weight of PET bottles and glass containers, you can understand how much money can be saved on transportation costs. Such products do not break and do not require the purchase of special boxes for transportation. Plastic bottles are available in a wide range of colors, and to change the design or size, you just need to take a different mold.

No hardware required to install large room, so the plastic bottle production business can be easily organized near the soda or beer bottling line. According to experts, the level of profitability of such an enterprise reaches 100%.

Glass recycling is an important industry in the recycling of waste, necessary to protect environment and conservation of natural resources. However, in Russia this area is poorly developed and most of the glass is not recycled.

About why it is necessary to carry out the processing of glass waste and how this processing is done, this article.

Broken glass, in accordance with, refers to (catalogue code - 3 41 901 01 20 5), therefore it is considered safe, however, it is necessary to hand over glass bottles, cullet to collection points for further processing for a number of reasons:

1. Glass is not biodegradable, such as organic waste. A simple glass soda bottle has a decomposition time of 1000 years or more. It is clear that without the disposal and recycling of glass, our entire planet would be completely filled with glass waste in a short period.
2. Glass products are fragile, broken glass that gets into the environment poses a threat to both animals and people.
3. Soil contaminated with glass is unfavorable for vegetation growth.
4. glass containers and cullet allows you to save natural (exhaustible and non-renewable) resources. So, for example, the use of 10% cullet helps save gas by 3%. If the person involved in the production glass products, will use only broken glass at his enterprise, he will thereby reduce gas consumption by 30%.
5. In Russia, a relatively small share of glass waste is recycled. But even this amount of recycled waste saves about 10,000 hectares of land that could turn into huge landfills.
6. Glass containers and cullet are fully recyclable materials, that is, glass recycling is waste-free, which is extremely important for protecting the environment from the negative impact of industrial and other enterprises.
7. In addition to natural gas, the reuse of this kind of waste saves more than 1 ton of such materials used in production as limestone, soda, sand.
8. People handing over glass containers to collection points they get paid for it.

Important! Glass recycling is necessary, first of all, to protect our ecology, to save natural resources and to produce glass products and materials cheaper.

What kind of glass is recyclable

The main types of recyclable glass waste include:

1. Glass containers: glass jars and bottles. Usually people collect bottles and hand them over to specialized points that receive glass. The glass containers are then recycled to be reused. At the same time, it is washed, treated with disinfectant solutions, after which the glass container can again be used as a container for drinks.
2. cullet- Broken glass containers.

Glass cullet is classified according to color. For example, green cullet (GS), colorless cullet (BS), brown (KS), etc.

Please note that all glass materials of different products are produced on the basis of the same substances.(as mentioned earlier, sand, soda, lime are used).

However, various impurities are added to a number of glass products (for example, windows, light bulbs), the surface of many products is also treated with various special coatings. For this reason, only the glass of bottles and cans can be recycled.

Glass recycling at home

Recycling glass at home is feasible, but it requires some time and effort.

Such recycling implies, first of all, the processing of whole glass containers for reuse.

To do this, it is necessary to thoroughly rinse the glass containers, treat them with disinfectants available at home or specially purchased in the store, after which rinse the treated containers with clean running water with special care. After these steps, cans and bottles can be reused without any harm to health.

An interesting question is how to dispose of glass at home.

Broken glass can be processed independently. However, this will take much more time. Let's take an example.

At home, glass can be processed into tiles(with enough glass material). For the manufacture of tiles, only three components are needed: glass, dyes and binders.

Glass (cullet) must be crushed, then dyes should be added to the glass mass to obtain the desired color of the tile and a binder, then pour the mixture into the desired shape and leave to solidify for a while, after which the tile will be ready for use. This tile is best suited for bathroom and kitchen walls.

By the way, any mirror is also made of glass and you can’t just throw it in the trash, what to do if it breaks and how to properly dispose of it read.

How glass is recycled

Utilization and processing of cullet is a step-by-step process consisting of the following main stages:

• glass waste collection;
• transportation of collected waste to a glass processing plant;
• separation, purification from various impurities, waste washing;
• grinding glass on special equipment, grinding small pieces into powder;
• packaging of produced glass powder for subsequent use.

Recycling glass bottles (or rather, defective and broken bottles) directly at the glass container production plant itself is a competent and rational waste disposal.

Let's see how this process is carried out.

1. Stage one. Separation from cullet of all non-glass components. Grinding the battle and separating the remaining metal parts with the help of magnets. Separation of plastic and paper components from the crushed mixture in vacuum processes.
2. Stage two. Sending the resulting mixture for the secondary production of containers. The cullet is added to the feedstock (lime, soda, etc.), then the mixture is stirred and converted (at 1500 o C) into a glass fraction.
3. Stage three. Pouring glass mass into molding containers, blowing new bottles.

The quality of this recycled bottle corresponds to the quality of a bottle made from 100% fresh raw materials. The use of cullet in the production of glass containers significantly saves energy.

Large glass processing plants in Russia: RSK company (in St. Petersburg, Yaroslavl and other cities), Utility, etc.

Glass processing equipment

Modern fairly wealthy enterprises use such basic glass processing equipment as:

• automatic systems that sort cullet by color and shade;
• containers for sorted fighting;
• sinks for dirty fighting with paper remnants;
• different types of filter sieves;
• electromagnetic and vacuum equipment;
• crushers;
• belt conveyor;
• packaging systems.

Who accepts glass for recycling

Glass containers and cullet are usually accepted by collection points located in most Russian cities. Such points are organized individual entrepreneurs, since glass is, which is profitable to sell to factories for the manufacture of glass products. Also, containers and cullet are accepted by the companies involved in glass processing and/or production of glass products.

The cost of glass as a recyclable

Perhaps, everyone once thought about how much crushed glass costs as a recyclable.

Glass containers and cullet are bought by many companies for further use as secondary raw materials.

Glass prices in our country are low. So, for 1 bottle you can get from 10 kopecks to 2 rubles. The fight can be sold on average for 3000 - 4000 rubles per 1 ton, depending on the type.

Glass recycling as a business

On glass waste you can build great business. Such waste can be used by entrepreneurs in the production of sanitary ware from ceramics, bricks, glass powders, fine-grained concrete, heat insulators, etc.

At the same time, it is not necessary to create a large enterprise, you can open a mini-factory for the manufacture of products from cullet. Actual business— the idea is to produce tiles from glass waste. We also recommend reading an informative article on how to build and what you need for this.

Useful video

How to properly organize a glass waste recycling business, how this processing should be carried out, is described in the next video.

The relevance of glass processing in Russia

Glass processing in Russia is a very urgent problem today. The number is constantly increasing, and the development of glass processing industries is poorly carried out. Therefore, a glass waste recycling business can be a solution to this difficult environmental and economic challenge.

Thus, the processing of glass containers and cullet is not only an activity aimed at protecting our environment, but also a promising business, the development of which requires, among other things, governmental support. As a business, glass waste recycling is profitable and sustainable if managed properly.

Production of PET bottles: what you need to organize an enterprise. Payment necessary costs, business profitability, marketing risks.

Capital investment in business: 565,000 rubles.
Payback period for the production of PET bottles: 12 months.

Every day more and more new drinks are released, and each of them in its own exclusive bottle.

Almost all soft drink containers are made from plastic.

This material is advantageous and convenient in that it has a low cost, but at the same time it is quite light and durable.

It follows that production of PET bottles- This is a fairly popular and profitable business.

Of course, it is worth considering such a moment that it is much more profitable for large firms to produce them themselves.

But there is a small trade in branded drinks in some establishments.

It is these customers who most need PET bottle production services.

By owning such enterprises, you can consistently make big profits.

Possible risks of opening a business

Among the risks are:

• lack of markets;
• rising prices for raw materials;
• long payback period;
• low level of profit in the early stages of work.

All these factors can negatively affect the profitability of the enterprise, increase the payback period, and in the worst case, drive it into a minus.

How to prevent possible risks?

In order not to go bankrupt in the first year, it is worth taking care of the sale of products at the stage of purchasing equipment.

The sooner the product starts to sell, the sooner the profit will come.

You should never rest on your laurels: always look for new customers and collaborate with other businesses.

In order not to lose much on a sudden increase in the price of raw materials, you need to establish relationships with different suppliers, and buy different types of raw materials from different firms.

Different materials can be beneficial to buy from multiple sources.

In order not to lose heart if the profit received is lower than expected, you need to have endurance and additional capital for safety net.

It would be nice to attract investors to expand the business when your PET bottle production starts to flourish.

Theoretical video tutorial on how plastic bottles are made:

Conclusions about the production of PET bottles

From all of the above, it follows that in order to organize production of PET bottles, you need not so much start-up capital.

The main costs will go to equipment.

According to experts, the profitability of such a business is quite high, but only if the enterprise is properly organized.

In addition to the main risks, you need to monitor the quality of products.

Since even with well-established sales markets, no one wants to buy a low-quality product.

The most important thing is that the entire container is of the correct shape, and does not have a pungent odor.

You can expand your business by producing eco-bottles.

They are beneficial in that there will be more demand for them.

They harm the environment less, and this approach to life is now “in trend”.

The essence of the environmental friendliness of such PET bottles is that the wall thickness is slightly less than usual, due to which they are easier to recycle.

And the smaller the thickness, the less material is needed for manufacturing.

This is already beneficial to the entrepreneur himself, as it will reduce the cost of raw materials.

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Glass has long and firmly entered our lives. A huge mass of various products are made from it, without which we cannot imagine our lives: dishes, containers, windows, doors, furniture and other items. For enterprising people, the production of glass at home can become quite possible. This is how you can build a profitable business.

Advantages of glass business

Naturally, the manufacture of such material is not cheap, but with proper promotion and organization, it can still bring some profit. Moreover, the production of glass containers is a sought-after business.

Among the advantages of this case are the following:

• high payback;
• demand;
• the possibility of producing different products, that is, expanding the range.

Naturally, glass manufacturing technology is not simple and requires sufficient high costs(raw materials, energy carriers, equipment).

What documents are needed for work?

So, before starting this business, you should prepare a package of all the necessary papers, thanks to which you can legalize the process. You will need:

1. Room lease agreement.
2. Certificates of quality of the equipment that you will use.
3. Permission public services(SES, fire department) for work associated with an increased danger to human health.
4. License.
5. Contracts with suppliers of raw materials.
6. Plan of the building in case of evacuation of personnel.

Naturally, you will hire a certain number of employees who will maintain the equipment. All of them must have work and medical books, and are also required to undergo a medical examination. It is also desirable to arrange a consumer corner, which will contain copies of documents confirming your right to engage in this type of activity.

As for the staff, you will need at least 15 people. That is 5 workers per shift.

Criteria for choosing premises for doing business

In order to organize the production of glass containers, it is necessary to choose a suitable building. First of all, pay attention to the possibility of free access and access to it, since you will have to regularly receive raw materials and take away finished products. Also, the premises should be divided into several parts: rooms for staff, a warehouse for raw materials and finished packaging, and, in fact, a production workshop.

Please note that the building must meet all technical standards and be as safe as possible. Pay attention to the quality of electrical wiring. It depends not only on the possibility of using a large number complex equipment, but also the protection of personnel from a sudden fire due to line overload or short circuit.

It is also desirable to pay attention to the size of the room. The area of ​​the building depends on the amount of equipment, as well as the degree of development of your business.

What is the presented material made of?

Before you start working, remember that this case involves the use of a large amount of raw materials. Without it, you simply cannot make a single bottle. So, raw materials for glass production should be of the highest quality and environmentally friendly.

The container is made from a multicomponent composition. It includes quartz sand, lead oxide (potassium, calcium, aluminum), as well as salts (carbonates or sulfates). In this case, each component performs its role. For example, thanks to oxides, glass acquires certain physical and chemical characteristics. In order for the container to be transparent, sodium or calcium carbonate should be used during the production process.

The main element, without which the manufacture of glass is impossible, is sand. Other components are added as needed. For example, to lower the melting point of a substance, sodium or potassium silicate is used. Barium oxide makes glass chemically inert. Lead compounds give glass products a beautiful sheen. Oxides of other elements provide a different color of the container.

Raw materials for glass production should be purchased from trusted suppliers with a good reputation. The quality and safety of your products directly depends on this.

What mechanisms are needed to work?

Before you start your business, you should purchase necessary equipment for glass production. It must be said that it has enough high cost. So, for work you will need:

• controlled channel for supplying raw materials;
• device for cutting liquid mass;
• press for several forms with a control panel;
• cooling system of the forming machine;
• press hydraulic drive station;
• a mechanism by which the finished product will be removed from the forming apparatus;
• a conveyor line that can be controlled without human intervention;
• furnaces for melting raw materials and annealing products;
• paint sprayer and dryer.

In addition, you may need such equipment for the production of glass, which will wash the finished product. If the machines and units are to be ordered from the manufacturer (taking into account the number of molds used), then the kilns will need to be built from refractory bricks.

Equipment for the production of glass bottles is also ordered from manufacturers. Moreover, the shape of the future container should be taken into account. It will be enough for a beginner to purchase one glass processing machine worth 10-15 thousand dollars. Further production can be expanded.

Stages of production of glass products

The manufacturing process of the presented products is quite complex and multi-stage. Basically, the following stages of glass production are distinguished:

1. Preparation and supply of raw materials to receiving bins. Immediately, a dosed addition of all the necessary components is made.
2. Sending the prepared mixture to the melting furnace.
3. Mass cooking. It is produced at a very high temperature (from 1200 degrees), so the workers who control the process must be very careful (not to be near the furnace and wear protective clothing). At the same stage, various additives and dyes are added to the mixture. Thanks to these substances, the glass mass becomes light, homogeneous, freed from gas inclusions. The first three stages are very important, as the mistakes made will definitely affect the quality of the product.
4. Preparation of the mixture for the formation of products. To begin with, a certain amount of glass melt is fed into a draft mold, where the bullet and neck are made. Next, the workpiece undergoes final processing. It is already produced in pure form.
5. Annealing finished products. This process ensures the strength of the glass and its safety during further use.
6. Quality control and durability testing of products. That is, bottles or cans need to be carefully examined and some experiments should be carried out with them for resistance to pressure, high temperature.
7. Product packaging and storage.

Who will buy the manufactured products?

The market for glass is very large. Therefore, you have room to develop and expand. For example, you can start with the manufacture of bottles or jars, and then develop new activities: the production of glass sheets, decorative items, stained glass windows and other products.

The most "trading" goods are bottles and cans. The main consumer of this is alcohol and food industry as well as ordinary people. Bottles are essential for bottling alcoholic and non-alcoholic beverages, while cans are often used to preserve food.

Demand for glass has always been and will be high. The fact is that this material is environmentally friendly, as it is made from natural materials.

Business value

The presented case can bring a solid income: from several tens to hundreds of thousands of dollars a month. Naturally, the production of glass containers requires certain investments. To start a business, you need the following funds:

• rent or purchase of premises - more than 10-15 thousand dollars;
• equipment - from 100,000 USD;
• payment of energy carriers and salaries - from 40,000 dollars;
• raw material costs - at least $10,000 per month;
• additional expenses - from 10 thousand c.u.

These prices are indicative. It all depends on how big you want your glass container production to be.

If you want your products to be in demand and your business to be successful, all your products must be of very high quality and meet all international standards. Making defective batches will bring you not only financial losses, but also a loss of reputation in a market where there are many competitors.

Use only quality raw materials. Do not try to reduce the cost of production with the help of any substitutes or substances that are unsafe for health. Periodically inspect and repair your equipment.

Making glass at home can become really profitable business. You just need to try a little, be patient and stubbornly go towards the goal.

Currently, more and more products (especially food) are packaged in glass containers. Glass is considered more convenient (glass is not subject to corrosion, special “lapped” plugs do not allow moisture or air to penetrate, etc.), in some cases (for example, vinegar, oils, etc.) - technologically determined, and sometimes even a sign of an elite or branded (compare, for example, coffee in specially shaped glass jars and cans or cardboard packaging) containers.

Glass is also used in non-food industries: glass containers often serve as containers for dyes, solvents, caustic liquids; there is a huge spectrum glassware- plates, glasses, dishes, etc.; decor items (vases, figurines, ashtrays) plus various specific items such as buttons, laboratory equipment, portholes, mosaic and stained glass fragments, light filters and much more. And the cost of each of these items is several times higher than the cost of sheet glass, if you count them by weight ratio.

Therefore, the manufacture of non-sheet glass products can be considered a fairly profitable business in the segment: with much lower equipment costs compared to a factory for the production of sheet glass, the cost of manufactured products is much higher.

Although there is one point here: in absolute terms, for example, the production of glass containers is inferior to the production of sheet glass - the latter is much more in demand because window glass can only be replaced with a new package, while, for example, bottles and cans are often reused .

However, payback, profitability and the ratio of unit cost to its selling price in the production of glass containers and related products are much higher than in the production of flat glass.

The best indicators are only in the manufacture of artistic glass products, however, long and firmly taken over by small handicraft and semi-handicraft glass-blowing and engraving firms and private traders.

However, a huge advantage of the production of glass containers is independence from the geographical and economic region of the country: if factories for the production of flat glass are usually tied to a source of raw materials to minimize the cost of it, then the production of glass containers due to a larger backlash in the difference between the cost and the selling price can neglect this.

In addition, due to the relatively small raw material capacity, in most cases such an enterprise will cost, or at least cover at least half of the consumption of raw materials at the expense of the market for secondary glass raw materials.

In addition, if we consider the option of working on specific orders, then it is possible to provide for the manufacture of products from the customer's glass, either on a full prepayment basis and a slightly extended one - at the time of delivery. necessary materials- production cycle.

However, if released hot commodity- for example, bottles with a capacity of 0.5-0.75 liters or cans with a disposable or reusable cap up to 3 liters, then the sales market will be found by itself: the demand for such things is very high and depends only on the population of the region, if we talk exclusively about local market.

So opening own business for the production of glass containers can be considered one of the least expensive and most risk-free, at least when it comes to non-food production.

Glass container production technology

The raw material for the production of glass containers can be ordinary quartz sand according to GOST 22551-77 (with technological additives: dolomite flour according to TU 5716-005-21079129-00; technical soda ash according to GOST 5100-85; technical sodium sulfate according to GOST 6318-77; chalk technological according to TU 95-2317-91; alumina according to GOST 30558-98; sodium nitrate or sodium nitrate technical according to GOST 828-77; and decolorizers: cerium oxide, selenium, cobalt oxide or color-imparting substances: ferrous compounds, manganese oxide, chromium oxide, uranium oxide, cobalt oxide, nickel oxide, antimony oxide or sodium sulfide, colloidal silver, copper oxide, colloidal gold, burnt bone, a mixture of feldspar and fluorspar) or plain cullet of any color.

As you might guess, the second option for the production of glass containers is much simpler, but also somewhat more risky: cullet may not be enough for full-scale production, so in the ideal case, you should purchase equipment for processing quartz sand into glass - it also works with secondary raw materials. Actually, further, in the section “Equipment for the production of glass containers”, just such a case will be described.

The production of glass containers and glass products can be conditionally divided into several stages, described below.

At the second stage, the raw material (it does not matter whether it is cullet or a charge - a mixture of glass components: sand, dolomite, soda, etc., or a mixture of both) from the receiving bins enters the supply hoppers, where the batch components are dosed by weight batchers in certain proportions and mixing of batch components in mixers, in the case of cullet, its preparation, and in the case of using mixed raw materials, mixing cullet with batch.

At the third stage, the charge (cullet, mixture of charge and cullet) is fed into the furnace compartment.

At the fourth stage, loading of the charge (cullet, mixture of charge and cullet) into the glass melting furnace using special automatic loaders. At the fifth stage, the glass mass is melted in the glass melting furnace and the subsequent preparation of the glass mass for molding in feeders takes place.

At the next, sixth stage, the products are molded in glass-forming machines, that is, in fact, they are given the final shape.

Stage seven - heat treatment products in annealing furnaces, which are often used in a special section of the glass melting furnace.

On final stages held visual control glass quality and technical control in the laboratory with subsequent testing for heat resistance, annealing quality, pressure; packaging of finished products (eg in boxes or pallets); transportation to the warehouse or to the customer.

Premises, personnel and equipment for the production of glass containers

To compile a complete technological line for the production of glass containers, the following equipment and units will be required:

• raw material supply channel; electrical control of the raw material supply channel;
• feeder and "scissors" for cutting molten (liquid) glass;
• automatic press for several forms; adjustable press system;
• press hydraulic drive station;
• air cooling system of the forming machine;
• a system for extracting a pressed product from a forming machine;
• the line of transfer (transportation) of the product halves of the product (and the majority of glass products belong to the two-halves);
• press electronic control system and electric transport system;
• raw material supply system to the forming machine;
• equipment for automatic molding of glass blocks for the number of molds corresponding to the number of molds used in an automatic press;
• automatic unit that accepts products after glass blocks are connected;
• glass block transportation line after connection;
• ejector to the annealing furnace;
• actual annealing furnace;
• gripping mechanism - product pusher (after applying paint, if coloring is used);
• automatic electrical connection control system;
• drying unit for drying paint (if coloring is used);
• automatic paint application unit;
• equipment for grinding and washing glass, and some other small units.

Regarding the annealing furnace, a few words should be said separately. As you can see, the glass products production line does not include molds and an oven. Molds are ordered separately in accordance with the sketches and samples of the customer, for each type of product - separately.

The furnace must first be built from refractory bricks - although the considered type of delivery implies this, but then the production time of the line, taking into account the construction of the furnace, will be 3 months.

Type of furnace - regenerative, flow-through with a horseshoe-shaped flame direction. Structurally, the furnace consists of a cooking pool, a duct, a working pool, burners, regenerators and systems for removing smoke (exhaust), heating, ventilation, cooling the pool and supplying (forcing) air for fuel combustion.

The final cost of equipment for the production of glass containers is 22,160,000 yuan, which, in terms of rubles at the current exchange rate, is about 106 million rubles. When taking into account energy costs of 1200 kW and a design capacity of 28.8 tons per day (actual output may be slightly lower - by about 5%), the price of the issue is relatively low.

Service staff consists of 5 people per shift (for maximum productivity, three-shift work would be the best option), of which one will be a foreman-technologist in one person.

The only downside to glassware manufacturing is the space requirements. It is difficult to find a production area of ​​the right size for rent, especially in large cities - sometimes it is easier to build a factory.

For equipment alone, a workshop 100 m long and 36 m wide is required; thus, its area will be 3600 square meters. m.

The annealing furnace and drying chamber shall be located in a separate but adjacent industrial premises; the area required for their accommodation is 2700 sq. m.

Thus, the total area of ​​the plant will be 6300 square meters. m - and this does not include the area for warehouses - finished products and raw materials and the packaging workshop.

Videos about the production of glass containers