Production of polymer sand tile. Detailed business plan. Business Plan of Polymer-Sand Tile Production Technology Tile Production of Plastic and Sand

The polymer tile appeared on the Russian market of building materials recently, but has already managed to establish itself as a material worthy of becoming a full-fledged substitute for traditional cement tiles. The demand for such a tile is growing, and those businessmen who are not afraid to work in the innovation sphere, there is a great opportunity to show their entrepreneurial talent, of course, appreciating all possible risks.

The emergence of this building material was initially due to the desire of technologists to find the coating that two main problems of cement tiles can solve: low frost resistance and durability. And, you need to recognize, they succeeded: the polymerpessic tile has many advantages. She is:

  • Durable: According to the manufacturers, its service life is about 30 years.
  • Stable Negative impacts of the external environment. The polymer tile is not afraid of frost, moisture, direct sunlight, exposure to acid-containing liquids and oils. It is resistant to high mechanical loads and is completely not prone to point splitness.
  • Decorative: may have any shape, any surface: matte, glossy, structured. It is manufactured in a wide range of colors, and more importantly, over time does not lose its decorativeness.
  • Does not allocate toxic evaporation under the scorching sun
  • Easy wash
  • Easy to repair and easily withstand multiple use

The polymer tile can be applied:

  • when building garden sites;
  • for the arrangement of the house territories;
  • in places of mass attendance: courtyards of summer cafes, parks, trading and exhibition pavilions);
  • in garages and indoor parkings;
  • in workshops;
  • to cover the operated flat roofs;
  • for cladding the base.

All of the above indicates about validationthis products among buyers and as a result of a large capacity of the market, and taking into account the simple manufacturing technology and relatively not high expenses to start business, all this makes the production of polymer-step tiles fairly relevant for the start.

The implementation of the finished tile can be carried out:

  • directly consumers of products: individuals, construction teams and organizations, organizations whose activities are aimed at landscaping the city;
  • through the wholesale network: Wholesale warehouses, databases.
  • through a retail chain: Building supermarkets, specialty stores, markets.

Raw materials For the production of polymer tiles serve:

  • sand without clay inclusions, whose fraction does not exceed 3 mm;
  • polymers: primary and secondary - the last option is more attractive from an economic point of view,
  • pigments like mineral and organic.

The main stages of production

  1. Crushing or agglomeration of raw materials. This stage may be absent if the manufacturer purchases a polymer crumb.
  2. Mixing the source materials in the concrete mixer.
  3. Melting mix in extruder (APN).
  4. Forming the product with the press.
  5. Shipment of finished products to the warehouse.

When calculating the economic efficiency of production of polymer tile, such parameters were taken as the basis: the work is carried out in 2 shifts, the duration of each of which is 12 hours. The performance of the mold - 5.83 m 2 finished products per hour, respectively, the entire line gives 140 m 2 finished products per day.

Characteristics of finished products

  • Tile size - 330 x 330 x 35 mm;
  • The number of pieces of the product in 1 m 2 - 9 tiles;
  • Weight tile - 4 kg;
  • Weight 1 m 2 - 36 kg.

Initial business costs

Naming of expenditures

Price without VAT, rub.

Depreciation for the year, rub.

Commissioning works

Scales MK-15.2-AB20 general purpose

Visit the list of equipment for the polymer tile in a special section.

Requirements for production premises and rental costs

The cost of renting in recalculation to 1 m 2 of the finished polymerlestone tile will be 2.38 rubles.

Labor costs

Number of employees

Salary, rub.

TOTAL, rub.

OPU operator

Opening worker

Total per month

The cost of materials for the manufacture of 1 m 2 finished products

Thus, the costs for the manufacture of 1 m 2 of the polymer piling tiles will be 136,58 rubles.

Electricity consumption for 1 working shift

Equipment

Power, kW / hour

Quantity, pcs.

General consumption

Consumption for 1 shift, h

TOTAL, kWH / shift

Press d2430 upgraded

Concrete mixer SBR-500

General purpose scales MK-15.2-AB20

Lighting

The average cost of electricity in Russia is 4,03 rubles. For 1 square / h, from which it follows that the manufacture of 1 m 2 paving slabs will entail the cost of electricity in the amount of 7.8 rubles.

Current workshop costs for 1 month work

Naming of expenditures

per month, rub.

per 1 m2, rub.

Electricity

Salary

Depreciation

The final calculation of the profitability of a business for the production of polymer tile

Cost 1 m 2, rub.

Overhead costs, rub.

Taking into account the overhead

Market price 1 m 2, rub.

Profit before tax on 1m 2, rub.

Profit tax (20%), rub.

Profit from 1 m 2, rub.

Profit on the day of all, rub.

Profitability,%

Payback period, days

* Calculations presented in the section are conditional in nature and give only a common understanding of the profitability of this type of activity on the basis of the author's expert opinion. To determine the exact amount of profitability, it is necessary to independently make a feasibility study, based on the specific numbers of your region and the business size planning.

In the construction market, the mass of materials characterized by the most different properties. And many of them can be a source of high income for an enterprising person. We will take here and the production of polymerpess tile. And the main advantage of the organized business will be not only a large demand for products on the market, but also that it can be made on relatively inexpensive mobile equipment. The polymer tile is a construction and finishing material made on the basis of sand and polymers. He possess several positive qualities, for which you won the trust of buyers - durability, frost resistance, durability.

Our business assessment:

Starting investments - from 10,000,000 rubles.

Market saturation is small.

The complexity of the opening of the business is 5/10.

Open the production of polymer-sand tiles is easy - neither huge investment, nor hiring highly qualified personnel. What will have to take into account the entrepreneur?

Production process

As raw materials for the manufacture of finished tiles are publicly available and inexpensive components. You can get them in every region of the country.

Technological scheme for the production of polymer tile

These include:

  • peeled sand
  • polymers
  • pigments.

To reduce the cost of purchasing all the necessary components, you can buy secondary raw materials - it is much cheaper.

As for the exact recipe, then everything is strictly individually - each manufacturer works with its composition. You can develop a formulation yourself, and you can invite to consult an experienced technologist.

The technology of production of polymerlestone tiles is extremely simple and will not require an entrepreneur (if he solved all the work to carry out his own) of any specific skills and knowledge.

The manufacture of polymer tile is carried out with their own hands as follows:

  • Preparation of all components and mixing them.
  • Melting raw material.
  • Pressing products.
  • Storage of finished products.

Business prospects.

Purchase of equipment for products

The next thing you need to make an entrepreneur is to buy equipment for the production of polymer tile. And even home production will require the presence of certain machines.

Polymer tile production line

To technical equipment, we will assign the following equipment names:

  • Dispenser - from 30000 rubles.
  • Concrete mixer - from 40000 rubles.
  • Melting-heating machine - from 350000 rubles.
  • Press - from 150,000 rubles.
  • Molds - from 1500 rubles / pcs.

The final price of the equipment for the polymer tile will depend on the power of the machines, their configuration and the degree of automation. The minimum cost of the production line for the mini-shop and its commissioning is ≈800,000 rubles. And this figure can be significantly more, if we talk about a more powerful enterprise.

Sales of finished products and profitability

Sale of polymer tile, with adjustable sales channels, should bring a high profit to the entrepreneur. And given the demand for products, it does not have to doubt that many customers will be interested in acquiring high-quality tiles from the direct supplier. It is used to pave roads, internal and external cladding.

Products can be sold:

  • building stores and warehouses,
  • developers
  • repair firms
  • private buyers.

Despite the fact that the bulk of profits will bring wholesalers, should not be discounted from accounts and private buyers. For this purpose, a small pavilion can be organized in the workshop where manufactured products will be displayed.


The production of polymer-sidewalk tiles, as practice shows, will begin to recoup it quickly. The launch of a small workshop will require investments in the amount of at least 10,000,000 rubles. This will include the following expenses:

  • purchase of the most main equipment
  • preparation for the work of the room (carrying out light, water and sewage),
  • ensuring the raw material base for the release of the first batch of goods,
  • registration of the enterprise.

For calculations of the profitability of the planned enterprise, take an example of a low-power line with a capacity of up to 50 m 2 of the finished tile for the 8-hour shifts. It turns out that one month can be obtained over 1000 m 2 products. The polymer tile for the base is worth today on the wholesale market 250-500 rubles / m 2. So, if you immediately sell all the released products, the entrepreneur can get a revenue of 500,000 rubles. And these are excellent profitability indicators for the workshop in the small business segment.

For calculations of net income and the total amount of revenue, it is necessary to subtract variable costs:

"Business Plan for Production -" Cable Closing Plates ". Prices and equipment are indicated on January 1, 2011.

To learn the relevant prices and get the current "Business Plan". Fill out the form at the end of this page, or call the on-site Speaker or in the section.

Consider an example of calculating the cost of manufacturing a polymer tiling, which can be brought as a basis for drawing up a business plan and a feasibility study of production.

All calculations are given as an example. Data are relevant to January 1, 2011 for the Udmurt Republic. All prices are shown without VAT. A simplified taxation system is taken to calculate.

You can also order and substitute your data.

Produced building material: Tile.

Main settings.

The work is made in two shifts, a duration of shift 12 hours. The performance of one press form is 6.66 m 2 per hour. Thus, during the day, the line gives 160 m 2 finished products (tiles). For a month 160 x 30 days \u003d 4,800 sq.m

Initial investments

The total cost of a set of equipment, including the value of commissioning works "turnkey" is: 2 708,780.00 rubles not including VAT.

Foundation for labor

For the work of the site is enough three people - the manager (25,000 rubles), the APN operator (20,000 rubles), the utility work (20,000 rubles). The labor facility is 65 000 rubles per month for one shift and 130,000 rubles. At the rate of 2 shifts.

Thus, the costs of salary on 1M 2 is 27.08 rubles.

Esn - 30%, gives 8,12 rubles. The cost of 1m 2 finished products.

Required industrial space

For the placement of equipment and storage areas of raw materials and products, it is necessary to provide about 100 m 2 production areas and 100 m 2 warehouse (may be outdoors). The production premises should not necessarily be heated, heating occurs due to the heat being allocated. Finished products are stored in the workshop, and then moved to the warehouse.

At the rental rate of 100 rubles per sq.m. The cost of renting production areas will not exceed 10,000 rubles. Thus, the cost of renting 1M 2 products is 2.08 rubles.

Cost of energy and materials

Total, the cost of raw materials (polymer + sand + pigment) for one ton is 5 000 rubles.

Tiles Weight 1 sq. M. 9 pcs * 1.8 kg \u003d 16.2 kg. Thus, the cost of raw materials on 1m 2 tiles is 81.00 rubles. On 1 piece 9 rubles.

Electricity consumption for shift

  • The crusher with a capacity of 300 kg \\ h consumes 22 kWh \\ h. For the production of the mixture in an amount of 2,592 kg, 637 kg of polymer is necessary. To prepare it, the crusher will work 2.1 and consume energy with 46.2 kW.
  • APN - 29 kW / hour when heated, when working around the clock, during the heated APN, consumption decreases in the 4rd times. Calculation: 7.25 kW x 24 hours \u003d 174 kW / day
  • Press hydraulic - 5.5 kW / hour. When the product forming the product, the program on the presses is designed to consume email. Energy in lifting mode and lowering the upper punch, with molding email. Energy is not consumed. The passage of the slider is 40 seconds. Per day 1440Wektuk x 40 sec. \u003d 57 600 seconds. \u003d 960 min. \u003d 16 hours press
  • Consumption per day 88 kW.
  • Mixer - 5.5 kW / hour 1 Zam - 3 min. Stirring 0.5 tons per move. Per shift 2,592 tons of mixture at 1440 pcs. Per day 15.6 min. Electricity consumption of 1.4 kW
  • Lighting - 12 kW / hour

The polymer tile is considered an analogue of natural, but this material can be called a qualitatively new, possessing winning characteristics compared to other market proposals. This passing material is lighter than natural 2 times, and in terms of value wins significantly. With it, it is possible to make a roof more noise and thermal insulation than using metal tile. As one of the important advantages is the lack of corrosion. The roof is more durable compared to bitumen. And in the process of laying there is no need to carefully prepare the surface.

Overview of features

Polymer's tile is resistant to ultraviolet and temperature drops, laboratory tests are evidenced. The exploitation of the material is possible at temperatures in the range from -65 to +100 ° C. Tile retains its appearance for long years of operation, because for the complete decomposition of the polymer film takes about 100 years.

Thermoplastic composite material has a slight coefficient of moisture absorption, so it is protected from the emergence and further development of moss, mold and fungus. In addition, the roof surface will be resistant to the effects of acid rain. The polymerpess tile has a low thermal conductivity, it allows to maintain temperature regime under the roof. Under such a roof, it will be cool on hot days, and in winter it is warm. That is why this undercover material is often used in the device terraces and attic. As a result, it is possible to form a reliable barrier for condensate.

Additional properties

Roofing design turns out to be reliably protected from destruction, which is especially important for elements from wood. Tile perfectly delays noises. Sound absorbing layer when installing will not need. The roof will show noiselessness in any bad weather. The role of another important advantage is shockproof, which makes the styling economical. When transporting, the material does not be afraid, as at installation. It meets all the standards and requirements of sanitary, epidemiological, fire and radiation safety.

The main advantages

The tile polymerpessic has many advantages. In the production process, it is coated with a substance that is resistant to ultraviolet radiation. This indicates that even over time, the color remains pristine, and the surface does not fade. The material perfectly copes with a sharply continental climate, it is resistant to frost and is able to withstand about 200 cycles of freezing and thawing.

If you compare with metal roofs, the latter have a drum effect. Tile does not corps, it is resistant to chemicals. It has water-repellent characteristics and eliminates the flowering of the roof. The material is a dielectric, so the roof does not require lightning protection. The canvas easily lay, for this the master will not need to have special skills. Even if you have to work with roofs of complex forms, then waste will be minimal. The roofing of the polymer tile can be operated with a point load ranging from 150 to 360 kg.

Negative feedback

In order for your idea of \u200b\u200bthe described material to be fully, it is necessary to note its disadvantages. Among them, consumers marked the fact that over time the roof erresses, this suggests that its thickness can decrease under the influence of negative factors.

But many consumers This deficiency does not consider so serious, because the process is sluggish, in addition, the source thickness of the material is quite impressive. Although the quality of the material itself, according to consumers, does not deteriorate under the influence of temperature deformations, but the lock compounds can be deposited, the consequence of the covering becomes.

What should be taken into account

Choosing the described tile, many consumers emphasize that the buyer may run into fake. Some manufacturers are used in the process of manufacturing poor quality raw materials, which affects the final product. Despite the fact that the installation is not so complicated, the negligent attitude towards it can lead to the opposite effect. The roof in this case will be corrupted. Therefore, many consumers believe that it is better to attract specialist material to laying. However, this will entail additional costs, which is also impossible to call the advantage.

FEATURES OF MONTAGE

The tile from the back side is equipped with a protrusion, which is fixed to the shap. Elements between themselves are attached by side locks, which allows you to get a solid carpet. For additional fixation on each element it is time for technological holes. Starting the installation of polymerpess tiles is required below.

It is not very hard to ensure that the elements are not very fastened to the shepherd, it is important to ensure the presence of a backlash, otherwise the material will not have the ability to move when exposed to temperature. If you do everything correctly, the roof will perceive the load from the wind, snow, temperature drops and precipitation is quite free.

After mounting on the front side, rust flutters should not appear. To do this, galvanized nails or anodized screws should be used as fasteners. The first is preferable, because they allow you to achieve acceleration of the installation process, in addition, provide a rigid fastening.

Frontal and skate tile should be fixed with anodized self-drawing. Some tiles will be attached to the Yandov's gutter, it refers to the skate elements. They are additionally fixed by mechanical way using anti-conflict or stainless steel skaters.

Tile Production Line

The line for the production of polymerpessage tiles is a correct-heating apparatus that mixes and warms the ingredients, among which:

  • polymer;
  • sand;
  • pigment.

As a result, it is possible to obtain a homogeneous consistency in the form of a tight dough. The performance of such equipment can reach 1000 kg per hour. The mixture is pre-prepared and heated, and after it is supplied to the heated chamber through the receiving bunker. Inland, the material is pushing the screw, which rotates and ensures mixing the mixture. It moves inside and undergoes three heating zones.

The polymer tile, the reviews of which were presented above and should help you make the right choice, at the first stage of heating it is dried, where the residual moisture is removed. The second zone involves plasticization of polymers. This allows you to get a homogeneous composite mass. The last zone is to maintain the temperature of the mass, which is required for molding.

The weight in the finished form is moving to the graduation window, which is located in the front flange of the case. For production, molding presses can be used, which provide an effort from 100 tons. The resulting mass is laid in a form, the mixture is exposed to pressure and simultaneous cooling, which allows you to increase productivity. The production of polymer tile at the final stage involves the extraction of products by the lower pusher. After the tiles are stored on the pallets and it cuts out, which distinguishes them from cement products.

In the process of manufacturing the described material, a radial crusher may be needed, which prepares the polymers, fractioning them to a homogeneous fraction. The raw material helps to save on the polymer, because the cost of waste is an order of magnitude lower than the cost of finished raw materials. The production of polymer tile can provide for the use of the following polymers:

  • film crushed;

In the second case, we are talking about low polyethylene, in the third - on high pressure polyethylene. The use of secondary polymers not only saves the procurement of raw materials, but also solves the problem of waste disposal.

Conclusion

If you decide to purchase the material described in the article, you should be interested in the manufacturers of polymer tiling. As one of them, the company "Bistot", which provides a complete burst room. You can buy a tiled by the manufacturer "Polyzand", which is located in the Moscow region. As an additional advantage of this company, it is possible to acquire remnants of roofing material at reduced prices.

So all of us loved in childhood the occupation is the modeling of kulchi from wet sand and even the construction of whole cities from it - it turns out to be quite popular and in adulthood. Buildings, of course, do not build from this material, but it is possible to produce a whole range of the most diverse product from a polymer mixture.

To obtain the desired composite, only it is necessary: \u200b\u200bmix sand with a polymer and add an appropriate color pigment to this solution. And then create from this mixture: roofing, building, finishing and other elements of improvement. Coim includes tile, sewer hatches, paving and facing tiles, paving slabs, borders, trays, drains and many other products of various shapes and colors.

What to work on?

For the organization of this business, it is not necessary for the presence of a complex and cumbersome technique. Main set polymer and equipment Includes 3 machines: radial crusher, melting-heating unit (extruder) and molding press. In addition, naturally, the molds will need, as well as auxiliary settings: screw and belt conveyors, feed and dosing systems of the mixture, oil suite, and finally, tables for the separation of finished products.

We will not speak about secondary techniques, since these are universal equipment and there should be no problems with its choice. But the main machines worth paying attention to.

First, intensely think about the acquisition plastic chopper. It is best to take a radial crusher. This will make it well to save on raw materials, since the cost of the finished polymer is significantly higher than the used waste. And the chopper can process absolutely everything: banks, bottles, cans, films, etc. It is only necessary to find the supplier of this garbage (you will not collect it yourself).

Further we select extruder. The problem of the smelting unit - in heating and mixing of all components into a single mass to the consistency of the tight test. The performance of these machines can reach 1000 kg / h, so you need to take the device according to your needs.

Well, the last car in the production chain - molding press. In our case, it should be with an effort of at least 100 tons and with a variable size of the desktop. The last factor is necessary to accommodate various molds (curb, tiled, etc.). By the way, at their cost it is better not to save. The fact is that only high-quality forms made from alloyed steels with a thermal concern are capable of listening for a long time and withstand up to 5 million molding.

Despite the ease of operation of polymerpess equipment, trusting his commissioning is better than professionals. Suppliers of this technique will not only put production, make technical binding to other equipment equipment and carry out a test production, but also tell your staff about all the subtleties of work on these machines.

Overview of machines

Let's start immediately with good news. Massively produced in Russia. Therefore, the choice of what is called, there are and prices are quite acceptable. It is possible to purchase a set of installations in each region of the country, which, naturally, significantly reduces the cost of transporting machines to the place of their future operation.

If we talk about the leaders, the most popular among customers uses Machines Polymerstroy 18. The production company from Izhevsk offers not only a wide range of high-quality installations of its own development, but also the technique of proven suppliers from the subway. For example, in their nomenclature line there are 2 universal crushing units of the polymer raw materials of Russian and Chinese production. 300-watt machines are designed to grind solid, soft and film plastics up to a 5-8 mm fraction.

Also, Polymerstroy 18 offers an extruder of its own design, which, due to the variety of modifications, can be combined with various types of related equipment. Productivity of the melting and heating machine - 600 kg / h. Depending on the tasks, you can choose the press from the D24 series with an effort from 100 to 400 tons. Digital blocks of control of overseas production are used as a program-managerial press organ. With their help, you can make it possible to make up to 50 sewer hatches or about 140 square meters of paving slabs per day. Well, in general, Izhevsk molds made from alloy design steels (40x and 45x) allow for about two dozen species of various products.

Another leading manufacturer of polymerpessic equipment is located in the city of Zlatoust Chelyabinsk region. The Montolithic enterprise has established itself across the country from the Baltic to the Far East. Here you can purchase a set of cars for organizing full-fledged production. First, the radial chopper of plastics up to 8 mm thick and a capacity of 100 kg / h. Secondly, economical in the consumption of electricity Extruder's own brand "Masters", producing 500-600 kg polymer mixes at one o'clock. Third, semi-automatic molding press with an effort of 100 tons. As well as additional equipment: aggregate for drying and sifting sand, forced mixer, agglomerator for processing polyethylene films into granules.

We will also tell us about one domestic manufacturer, whose installations worth paying attention to. This is a polymer technology from the city of Orsk Orenburg region. According to the specialists of this enterprise, the warranty for polymerpess products made on their equipment is at least 50 years old! And the resource of each mold with proper operation is 5 years! The minimum setup complex includes 3 aggregates: polymer crusher, thermoshosuctive machine and molding assembly with a vertical hydraulic press. The productivity of the shredder is 700 kg / h; Extruder - 250-370 kg / h. And another competitive advantage of this manufacturer is the cost of equipment. The basic set (and in fact - a whole mini-factory) will cost only 772 thousand rubles.

 

Perhaps it will be useful to read: