Business plan for the production of woven polypropylene bags. Equipment for the production of polypropylene bags. Premises for the future workshop

When organizing production for the manufacture polypropylene bags you should pay attention to the features technological process... You need to know that the release of such products should take place in conditions of increased requirements for the cleanliness of the room, since the presence of even a small amount of foreign impurities can lead to a change mechanical properties products.

Bag making is a process with increased level pollution environment, therefore, additional requirements apply to the enterprise:

the production premises must be located in a non-residential area;
the room should be equipped with a system for aspiration of harmful substances and air filters for fine air purification;
it is necessary to have a water supply and sewerage system in the building;
the presence of an alarm for the excess of harmful substances in the air and a fire alarm;
the electrical input to the building must be three-phase;
it is necessary to organize a separate protective ground loop.

In addition, all the standard requirements of the regulatory authorities are applied to the production of polypropylene bags. The average production area is small - about 60 m2. This allows power to be placed even in small buildings.

Materials used in production

It is used as the main raw material in the manufacture of products. Other synthetic materials not widely used due to the worst characteristics or high cost. Polypropylene is characterized by resistance to abrasion and high temperature resistance, which, together with chemical resistance to aggressive substances, has determined its widespread use as a material for the manufacture of universal packaging for bulk food products, fertilizers, salts and various chemicals.

Depending on the purpose of the final product, a variety of raw materials are used for the manufacture of canvas:

For the production of polypropylene bags intended for storage and transportation of bulk products (flour, sugar, salt, food products), primary polypropylene is used. It is also used for the production of big-backs (flexible container for transporting bulk materials) due to the high strength of the material. These bags are white.
For the production of polypropylene bags intended for the transportation and storage of non-food bulk substances (agricultural feed, fertilizers, chemicals), mixed polypropylene is used. It is made from a mixture of primary polypropylene and recycled materials. Bags made of this material are gray.
For the collection and disposal of construction waste, polypropylene bags are made entirely from recycled materials. These bags are less durable and cost effective.

Manufacturing technology

Processing of secondary raw materials

A grinder is used to prepare raw materials from secondary materials. The main element in the installation is the drum, which grinds the material to the required size. The installation is serviced by one person, whose duties include monitoring the operation of the device, loading material for processing and monitoring the filling of the hopper with raw materials.

Drying of raw materials

In this production cycle, pre-drying is performed to eliminate the formation of vapors in the heating hopper of the extruder. The procedure is performed in an industrial oven at a temperature of about 80 C until moisture is completely removed from the original raw material. At this temperature, substances harmful to human health begin to be released, therefore it is necessary to use an exhaust ventilation system of the equipment. The operation does not require constant monitoring by a person, therefore, as a rule, this work is performed by a worker serving a shredder.

Mixing raw materials and producing material for fabric making

Raw materials are poured into the extruder and mixed in the receiving hopper, where, if necessary, a dye is added. Then the mixed raw material is fed into a heating tank, where a constant temperature is maintained, which is optimal for melting. At the end of the melting process, the heated mixture is fed through a slotted nozzle. In the process, a continuous layer of polypropylene film is obtained, which cools down under the pressure of air.

The film is wound on a drum to a certain diameter, after which it is replaced with a new one. To work on the machine, one worker is required who monitors the film production process, the level of raw materials in the receiving hopper, and also removes the finished drums with polypropylene film.

Cutting film to obtain filament

The machine cuts the film into threads of a given thickness and winds it onto finished spools, which are used in the weaving machine. In the process of cutting, keep an eye on the uniform thickness of the thread; if necessary, you need to adjust the machine knives. To work on the machine, a qualified worker is needed who can quickly adjust the machine. His responsibilities also include replacing film drums and changing wound spools with polypropylene thread.

Fabric making

For the circular loom is used, which produces the sleeve required size from a thread wound on spools. It is necessary to monitor the operating parameters of the machine:

weave density;
bag width;
lack of marriage in the canvas;
uniform thread consumption.

The finished sleeve is rolled up and transported for printing or further bag making. This machine is notable for the complexity of adjustment; for its maintenance, a specialist is needed who monitors the correctness of the technological process.

Print image

A flexographic machine is used for printing. The device uses special elastic dyes, which are fed to drums with a printing plate for each ink color using a dosing device. The roll is fed through a system of rollers that rotate printed forms with paint. In this case, the required pattern is formed. The finished product is wound onto a drum for further cutting and manufacturing of polypropylene bags.

To work on the machine requires a person who monitors the print quality and loads the material for printing. Pay attention to the synchronization of the work of the printing rollers in order to avoid printing defects.

Slicing, bag sewing and packaging

A woven sleeve is fed into the bag making machine from a drum, which, using a photocell, determines the location of the logo and cuts the sleeve to the required length. For cutting, a thermo-knife is used, which fuses individual threads in order to avoid unraveling of the web. Then the fabric is folded up at the bottom of the bag and the bottom is sewn. The upper part can be stitched depending on the settings of the machine. If necessary, the inside of the bag is fed, which is sewn to the bottom of the bag.

Packing of finished products is carried out in packages of 10, 50, 100, 500 and 1000 pieces, after which the products are transported to the finished product warehouse.

Considering such wide possibilities of use, bags of this type are in great demand on the market and are sold quite quickly. Finished products do not require special conditions storage, has no expiration date, takes up little space when transporting.

Polypropylene bags (PP) are a durable type of industrial packaging that is made from polypropylene threads woven into bags. PP bags are very strong, widely used for packaging and transportation of bulk materials industrial type and building materials, the agricultural sector and Food Industry.

Depending on the type of fabric, the bags can be used for cereals, sugar, flour, grain, mixed feed, mineral fertilizers, expanded clay, cement, etc.

Sales of finished products

Target consumers of PP bags are:

construction companies;
agricultural producers;
industrial companies and enterprises with warehouse complexes;
wholesale and retail;
households.

The sale of finished products can be carried out through the following main distribution channels:

through and agricultural shops (wholesale construction bases);
by promoting products end consumers through the media - printable advertisement on stands in garden and dacha cooperatives, print ads) and using interactive media - creeping line on electronic displays, advertising on monitors and light boxes.

Production technology

The following main stages of manufacturing can be distinguished:

mixing and drying of raw materials;
production and winding of threads;
obtaining a woven fabric;
cutting the canvas into bags;
logo laying on;
sewing a finished bag;
package.

Required equipment

Let's consider a complete set of a production site using an example.

This line is designed for the production of 1.5 million pieces of bags per year, the equipment is characterized by a high degree of automation, most of the components and assemblies responsible for controlling the line are made in Japan.

The total cost of completing this technological line is 3 696 139 rub.

Feasibility study

Capital investments

Purchase of a line: 3 696 139 rubles.
Delivery of equipment, adjustment: 300,000 rubles.
Purchase of raw materials in granules: 300,000 rubles.
Registration in the INFS, payment of rent for one month. Other expenses: 200,000 rubles.

The total amount of initial investment in the business for the production of polypropylene bags is 4 496 139 rubles.

Revenue calculation

Cost calculation

The average weight of the bag is 70g.
14 bags are made from 1 kg of granules (-2% technological losses).

Production cost of one bag:

General expenses.

Wage(6 people, with two shift work, 3 people per shift) - 108 thousand rubles.
Social deductions from the wages fund - 32 thousand rubles.
Premises rental - 100 thousand rubles.
Administrative expenses - 50 thousand rubles.
Other expenses - 100 thousand rubles.

Total fixed costs: 390 thousand rubles.

Profit calculation

Profit = RUB 998,400 - 359,424 rubles. - 390,000 rubles. = 248 976 rubles.

Return on investment(Capital Cost / Profit): 18 months.

For storage, transportation and packaging of food and non-food products, polypropylene bags are often used. They have a fairly low cost and widespread use. Polymer packaging practical and greatly simplifies the implementation of products. Such packaging is more often used for packaging bulk food products(sugar, salt, cereals), fertilizers, building materials. The maximum weight of the contents of the bag depends on the size and density of the bag and can reach several centners.

The production process of polypropylene bags consists of several stages:

1) cleaning and extrusion of the film for the web;
2) obtaining the canvas;
3) cutting of bags;
4) applying logos;
5) sewing bags and packaging.

For greater strength and reducing the slipping of bags in the hands, special additives are used that make the fabric rougher, and the threads for sewing products more durable.

For the production of polypropylene bags, the following equipment is used:

1) dispenser;
2) extruder;
3) circular loom;
4) machine for cutting the web and stitching and edging;
5) filling machine.

The Sino-Russian Golden Bridge company offers you equipment for the production of polypropylene bags and their processing.

PP filament extrusion machine and PP filament winding machine

Recently, polypropylene bags have been widely used. Most often they are used in the agricultural and food industry, as well as in.

Polypropylene bags are packed with:

Loose food products;
Stern;
Cement;
Building mixtures;
Sand.

The manufacture of such packaging products is a fairly promising direction, since it is in great demand. The production of polypropylene bags is profitable business, which provides a stable high income.

Paperwork

To open your own business, you must complete all documents and permits. Novice businessmen usually register an individual entrepreneur.

If you plan to open large enterprise, it is better to register a company with limited liability... In addition, it is necessary to obtain permits from all the necessary authorities.

Raw materials

Before purchasing equipment for the production of polypropylene bags, you should first decide on the production technology and the type of raw material.

Bags can be made from virgin or recycled polypropylene. Recycled material is called recycled material obtained from various polypropylene products.

Raw materials are supplied in the form of granules. To provide it with certain properties, various substances are added to the granules during processing. Finding a supplier of raw materials will not be difficult, since there are many similar offers on the market.

Premises

For the production of bags, you will need a room with an area of at least 800-1000 sq. meters.

It should be divided into separate zones:

Workshop for the production of polypropylene yarn;
Weaving shop;
Slicing workshop;
Warehouse for finished products;
Warehouse for raw materials;
Administrative premises.

Production areas should be located at a distance of 50 meters from residential premises. It is advisable to decorate the walls and floors in workshops with ceramic tiles.

Be sure to take into the room:

Heating;
Ventilation;
Sewerage;
Water pipes.

Project development industrial premises can be ordered by specialists.

Equipment

The standard line for the production of polypropylene bags includes:

Mixing machine;
Feeding device;
Extruder and winding device;
Loom;
Thermal knife;
Sewing machine;
Printing device for applying a logo.

You can also purchase a finished product laminating machine. There are special devices that simultaneously laminate and apply color printing.

In addition, you will need a crusher for recycling waste products, as well as a granulator, with which the crushed waste is processed into granules. They are used for recycling.

So that there are no problems with service equipment, it is advisable to buy it from local suppliers. Since the cost of equipment for the production of polypropylene bags is quite high, its purchase must be taken seriously and responsibly.

Staff

The production line can be serviced by three people. Typically, such an enterprise operates in two shifts. The salary of one worker is 18–20 thousand rubles.

In addition, you will need a sales manager, movers, accountant and driver.

Since the machine for the production of polypropylene bags is fully automated, it does not require a lot of personnel to maintain it. All workers must be trained. The training courses can be organized by the equipment supplier.

Technology

The technological process of manufacturing polypropylene bags includes the following stages:

Drying and mixing of raw materials. Polypropylene granules are mixed with all the necessary additives and colorants. Calcium carbonate gives the bags the necessary rigidity and snow-white color. The finished mixture is fed into an extruder;
Hot polypropylene is passed through a special nozzle. After cooling, a thin film is obtained, which is cut into threads of the required thickness. After quenching, they are pulled out to be wound onto a reel;
Fabric production. On a loom, the width and density of the weave of the threads are set. The polypropylene sleeve is wound on bobbins;
With the help of a thermal knife, the canvas is cut into blanks. The cutting line can be wavy or straight;
Polypropylene fabric is tucked several times using a special apparatus and stitched with synthetic thread. The neck can be sewn or raw. Polyethylene liners are sewn into bags intended for certain products;
A black-and-white or multicolor logo is applied to the finished product using a flexographic machine;
Products are packed in packs of 500 pieces and tied with twine.

Expenses

To start the production of polypropylene bags, you will need a large start-up capital:

Premises rental - 1 million rubles;
Equipment - 0.6 million rubles;
Salary - 0.6 million rubles;
Other expenses - 400 thousand rubles;
Purchase of raw materials - 500 thousand rubles.

To ensure the operation of the enterprise for one year, it is necessary to invest approximately 2 million rubles. If you manage to find regular customers and establish sales, in 10-15 months your business will start making a profit. The enterprise will fully pay off in 2.5 years.

Production profitability

One kilogram of polypropylene costs 33–45 rubles. From one kilogram of raw materials, 14 bags are obtained. The cost of one product unit is 2.9–3 rubles. They sell it in bulk for 8 rubles.

Accordingly, factories for the production of polypropylene bags receive a monthly net profit of 250 thousand rubles. Therefore, this business can be described as very profitable and profitable.

Summing up

Since the production of polypropylene bags in Russia is very popular, this business can provide you with a stable high income. The products can be sold to manufacturers of building mixtures, as well as to agricultural enterprises. In addition, the bags can be delivered to hardware stores and hardware stores.

To open our own plant for the production of polypropylene sacks, it is necessary to collect about 3 million rubles. You will spend part of it on the purchase of equipment and raw materials, and the rest of the money will be needed to develop a project and equip a production facility that must meet all the established requirements.

To save money at the start, you can purchase Chinese equipment. Despite the low cost, it is of good quality. You can also lease machines in order to redeem equipment over time. The production of polypropylene bags as a business requires an attentive and responsible attitude to the execution of all the necessary documents.

A mini-enterprise for the production of polypropylene bags is considered a fairly profitable investment. The widespread use of such products leads to high demand, so there will be no problems with the sale of bags. Finished products can be stored anywhere. In addition, it has no expiration date limits.

It might be useful to read: