What documents are needed to open a brick factory. Each method has its own characteristics. Useful Tips for Those Who Want to Start a Brick Making Business

In our country, brick factories are not uncommon - almost every city has such an enterprise. But that doesn't mean that similar enterprises idle without work and that it is impossible to open a new brick factory. Now the construction industry is actively developing, so the products of brick factories are always in demand.

Many in this business are attracted by the quick payback and relevance of products. But there are different types of enterprises:

Powerful factories for the production of 30-60 million bricks per year and a payback period of 1.5-2 years.
Plants of medium capacity with a capacity of 5-15 million bricks per year and a payback period of 2-3 years
Small enterprises producing 2-3 million bricks per year with a payback period of 3-4 years.

These figures are valid for already operating enterprises, and new plants will require investments of much larger amounts. In this regard, an enterprise should be developed from the very beginning when the entrepreneur is confident in the sale of his products.

Brick making process

Those who wish to open a new brick factory need to understand the principles of how the production works. This process consists of several stages, and the complexity of production is proportional to the capacity of the plant. Typically, medium and large-scale enterprises are automated and therefore can produce a large number of bricks per hour.
Any production begins with clay. It is convenient if the quarry where clay is mined in an open way is located not far from the plant - no more than one or two kilometers. In this case, the cost of transportation will be minimal.

Further, from a quarry or a clay store, the raw material is sent to the feeder hoppers on an inclined conveyor, where various impurities are also added: clays that increase plasticity, burnout, plastic, etc. Various industrial wastes can also be added as impurities.

After that, the clay enters the coarse grinding rollers for crushing and removing solids. The prepared mixture enters the mixer, and from there to the press. There it is pressed into bars of given sizes, which in turn are cut into bricks. One such bar weighs about 4.5 kg, and the finished brick - 3 kg. Therefore, the bars are moved to drying sheds for natural drying, which takes place over two weeks. Then the adobes are fired in a kiln and ready-made bricks are obtained.

The process of obtaining finished bricks can take 3 weeks to small production and 6 days in a large factory. In this case, the speed of obtaining finished products depends on the following factors:

Applied technologies
Type and performance of equipment
Weather

The choice of kiln for firing bricks is important. They are tunnel and ring. The first type of furnaces is more expensive, but at the same time the process in them is fully automated, but the ring furnace at a lower cost will require manual labor. The quality of bricks made with an annular kiln will be lower than with an automated tunnel kiln.

Weather conditions are important for businesses using natural drying of prepared bricks. If the weather is damp, then the raw materials will dry for a very long time. Even if the plant has forced drying, weather conditions still affect, although to a lesser extent.

Brick production has its own seasonality: in winter, the demand for this building material is reduced, since neither private traders nor construction companies, as a rule, are not engaged in construction. In addition, during the cold season, it is difficult to extract clay from a quarry. In this regard, it makes no sense to continue production, so brick factories usually work from April to early December, and then the staff goes on vacation and the production process stops for a while.

When opening a brick production, one must be prepared for quality control by government agencies. Every year it will be necessary to obtain a certificate of conformity, and technical supervision will take place once every six months.

Types of brick

Exist different types bricks, the production of which depends on the equipment and capacity of the equipment in production and the raw materials used.

Full-bodied ceramic bricks (grades M-75, M-100 and M-125) are low-strength bricks that require high production energy costs. But the cost of such a brick is quite low. Usually it is made by low-power enterprises.
A hollow brick with good thermal insulation properties requires less raw materials than a full brick. So, the production of 1000 such bricks will take 2.5 tons of clay, and the same amount of full-fledged - 4 tons. Such bricks are produced by large factories.

Business organization

First you need to take care of the raw materials, that is, you need a quarry with clay. In order to obtain the rights to use it, you must obtain an appropriate license from the State Committee natural resources. As a rule, a permit for the operation of an object is issued if there are proven reserves for 20 years - in terms of quantity, this is approximately 500 thousand cubic meters of clay.

Such a license can cost from 6,000 to 12,000 USD. In general, the registration procedure will require an investment of 30-35 thousand USD. If we are talking about buying a small brick factory, then it will take 250-300 thousand USD. By the way, if the selected facility runs on coal, it will require gasification in the future, and this will require another 100 thousand USD.

Results

To plan necessary costs and profit, you can be guided by the following approximate figures.
Initial investment:

Acquisition of a plant - 300,000 USD
Rent for the use of agricultural land - 18,000 USD.
License of the State Committee for Natural Resources - 12000 USD
Total: $330,000

Annual expenses:

Payment for industrial application clay - 22500 c.u.
Payment utilities(for 12 months) - 9500 c.u.
Staff salary - 160,000 c.u.
The cost of buying coal (about 90 tons per month, for 10 months) - 56,000 USD.
Total: $248,000

Income per year:

Sale of manufactured bricks (three million bricks at a price of 0.15 USD/piece) - 450,000 USD.
Profit before tax
$450,000 - 248000 c.u. = 202000 c.u.
Business payback
450000: 330000 = 2.2 years

The calculations provided are indicative and for each specific case and project conditions, the figures may vary depending on the situation.

Attention! The free business plan provided for download below is an example. The business plan that best suits the conditions of your business must be created with the help of specialists.

Business plan on the example of a brick factory

A brick factory is an enterprise that will be designed for the production of bricks. Brick is the product that everyone will always need for various types of work.

This product will be in constant demand, and will be a very profitable and cost-effective enterprise for businessmen to invest their funds. The brick is used both for internal and for external works.

It has a variety of properties and has different production technologies. In the manufacture of bricks, it will be important to comply with the technology of its production.

It will also be important to learn how to reduce costs in its manufacture, only so that this does not affect its quality.

If your factory has one line, it will be able to produce up to 25 million bricks per year.

To build a factory, you will need a minimum area for the factory.

With such a territory and with the installation of additional furnaces and dryers, the plant will produce about 4-5 million bricks.

The success of your project will grow depending on which room you choose.

Your factory building should have only two rooms. In the first one you will manufacture your products, and in the second your products will be stored.

Therefore, if you build or rent a room, it is better to make it covered. Such a hangar will cost 1.5-2 million rubles, it will be difficult for novice businessmen to find such a sum.

Therefore, it would be better for novice businessmen to rent such a hangar. Renting such a hangar will cost you 150-200 thousand rubles.

Also, for such an enterprise, you will not need many employees. You will need about 20 people in total, who will work in several shifts.

At your enterprise there will be vacancies for loaders, workers behind machines, a security guard, as well as a driver who will take out finished products.

Of the production equipment that will need to be purchased and installed, you will need:

machine for crushing crushed stone (it will grind crushed stone into fine gravel);
mixing machine;
sand sifter;
the oven in which the brick will be fired;
as well as a shaper.

Brick factory (China), production of clay bricks

Water will be very important when making bricks, so it will be important to run plumbing into your hangar. Therefore, when choosing a hangar, be sure to ask how far the water supply is from the hangar.

The price of your equipment will be about 2-2.5 million rubles. This price will include everything from the purchase to the installation of the equipment.

There are many different companies that will install the equipment for you.

The price can be reduced if you want to install only the basic equipment. But in this case, performance will be reduced.

Also, you will still need to decide what raw materials you will use in the manufacture of bricks. If you will produce ordinary brick, then you will need: crushed stone, sand, clay, and also water.

* Calculations use average data for Russia

Starting investments:

from 300 000 ₽

The cost of a simple machine

from 245 000 ₽

The cost of bricks from the wholesale price

Payback period:

from 12-18 months

Brick is one of the most popular building materials in Russia. Brick production as a business is interesting because, along with large enterprises, it is possible to produce bricks with minimal investment.

The production of bricks and brick products is a business accessible to everyone, even a novice entrepreneur. Modern automated lines for the production of bricks make it possible to minimize the use of manual labor and obtain a diverse range of manufactured products. Business provides enough high profitability and acceptable payback periods for the initial investment.

Brick production: prospects and market volumes

Brick is one of the most versatile building materials in Russia. Growing volumes of construction imply more and more of its consumption by the economy. In terms of starting a business, brick production is interesting because, along with large enterprises, it is possible to produce bricks with minimal investment.

The main consumers of bricks are construction organizations. About 70% of bricks are used for housing construction.

Types and classification of brick products

First of all, a brick differs in the material from which it is made.

Ceramic bricks are made from clay with various additives. The main production of silicate brick is quartz rock, that is, sand. Hyper-pressed brick is produced by pressing in special forms screenings of marble, shell rock or dolomite, or from cement, quartz sand and crushed granite.

The second classification of a brick is based on its purpose. There are building or ordinary bricks, facing bricks, which are divided into textured and shaped options, furnace or refractory bricks. Clinker bricks are also distinguished, which is made from refractory grades of clay.

Depending on the nature of the filling, the brick is divided into solid and hollow.

Three standard sizes of bricks are standardized in Russia, and bricks are also produced according to European standard sizes.

As you can see, bricks are completely different types, each of which has its own characteristics of production and scope. Carefully analyze the market of brick products in your region and find those types of bricks in the segment of which the competition is lower, or its consumption is higher. Pay attention to the quality of products on the market. If you can provide the best quality, then it will be significant competitive advantage, as many consumers are willing to pay a higher price for the exclusive quality of the product.

Brick production technology

Let's say a few words about the main technologies for the production of brick products, since the type of equipment purchased depends on this. Immediately make a reservation that the production technology is a complex process, which has its own nuances and subtleties. We will not dwell on the technological moments of production in detail, but will describe only the essence of the technologies used, on which the type of equipment used will depend.

The basis of technology for the production of silicate bricks is pressing. At the first stage, a mixture is prepared for the production of bricks, which consists of lime, water and sand. Next comes the pressing and autoclave processing of bricks.

The production of clay-based ceramic bricks begins with the preparation of a homogeneous mixture free from impurities. Next, the brick is molded, dried and fired.

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The scheme for the production of clinker bricks is similar to the technology for the production of ceramic bricks. The differences are in the feedstock - refractory shale clay and high firing temperature.

The composition of hyperpressed bricks includes cement and screenings of limestone or other similar materials. The method of hyperpressing or, in other words, double-sided pressing in the production of bricks, is to obtain a product by compressing finely dispersed particles under the influence of excess pressure.

As you can see, brick production technologies can be conditionally divided into two groups - technology using firing and non-firing technology.

The choice of production technology should be made based on what type of bricks is most in demand in your local market.

Brick Making Equipment

A large brick factory requires investments in the amount of several hundred million rubles. For example, LLC "Kazan plant of silicate materials" produces up to 230 million pieces of silicate bricks per year, has more than 200 employees.

In this article, we will talk about a mini-factory, the investment in which is an order of magnitude lower. The variety of technologies gives rise to many types of equipment. We will not dwell on the composition of the equipment for the production line for the production of bricks, since its composition depends on both the productivity and the chosen technology.

For the production of ceramic bricks necessary equipment consists of the following main blocks:

line for grinding raw materials;

brick forming line;

line for drying and firing.

For the production of silicate bricks, the following main equipment is used:

equipment for the preparation of sand-lime mixture:

raw brick forming equipment;

equipment for processing a raw product in an autoclave.

For the manufacture of hyperpressed bricks, equipment will be needed:

hyperpresses;

crushers;

receiving and service bins;

dispensers;

screw and belt conveyors;

mobile compressor units;

concrete mixers and other equipment.

The cost of equipment depends on the technology used, the degree of automation of the production process and the productivity of the line.

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The simplest machine for the production of bricks (vibrocompression method) costs from 245 thousand rubles. This machine can also produce wall stone, wood concrete, Lego-brick, paving slabs and curb stone. The productivity of this type of machine is about 100 bricks per hour. Of course, most of the operations on this machine will have to be done manually. More productive equipment, with a capacity of 500 bricks per hour, and in which part of the processes will be automated, will cost about 1.8 million rubles.

A small line for the production of bricks by hyperpressing can cost about 1-4.5 million rubles. The availability of raw materials is an important factor, since the production is based on the low consumption of Portland cement and the use of production waste from mining, cement, metallurgical industries and different kinds dumps.

A more productive line for the production of sand-lime bricks, designed to produce 22 million pieces per year, will cost about 60 million rubles. Naturally, such equipment is delivered to order within 4-5 months. As a rule, the price includes personnel training, equipment adjustment depending on the characteristics of the initial mixture, installation supervision services and other services that allow you to start production as quickly as possible.

Equipment for large-scale production, that is, more than 50 million bricks per year, will cost more than one hundred million rubles.

When choosing equipment, attention should be paid to the possibility of production on this equipment of other products, except for bricks. This will significantly diversify the range of products sold and reduce the risks of opening such a production. Some lines of equipment allow the production of up to a dozen different types of products widely used in construction.

Brick business payback and financial results

Profit in this business depends on the performance of the equipment used and, accordingly, the capital cost of acquiring the equipment. As a rule, equipment with a small investment pays off faster than a full-scale plant.

The payback period of the mini-plant is about 1-1.5 years. A large enterprise for the production of brick products pays off in about three years. This is provided that you manage to ensure the production load of at least 70-80%.

The main investment costs when opening a brick production are the costs of equipment. The total amount of investments, taking into account the equipment and equipment of the premises, will be from 300 thousand rubles.

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The total cost of manufactured brick products is approximately 30-50% of the wholesale price. The spread in the value of the cost of production depends on the degree of automation. In fully automated factories, the participation of personnel in production is minimal, thereby reducing weight. wages in the cost structure. But automated lines are much more expensive and require skilled personnel to set up and maintain production.

Profit, depending on the scale of production, can range from 300 thousand rubles a year for a mini-plant and up to 50 million rubles and more for a large enterprise.

The cost of production and, accordingly, the profit of brick production is significantly affected by logistics. Key customers should be located as close as possible to the production, as long-term transportation of bricks is not always cost-effective, and bricks can be damaged during transportation and handling operations. Even more important is the proximity to sources of raw materials.

Legal Aspects of Starting a Brick Making Business

To open a brick production business, any organizational form Both LLC and Sole Proprietorship.

The simplified taxation system is preferable for this type of business, however, keep in mind that the maximum turnover for the simplified tax system in 2018 amounted to 150 million rubles.

The main OKVED code for ceramic bricks will be 23.32 "Production of bricks, tiles and other building products from baked clay."

For sand-lime bricks, the OKVED code will be group 23.61 "Manufacture of concrete products for use in construction."

When opening a business, it will be necessary to obtain permits from Rospotrebnadzor, the fire inspectorate and, depending on the region, Rosprirodnadzor. In addition, it is necessary to notify the municipal authorities at the place of registration or location of production.

It is desirable to obtain a certificate of conformity for the manufactured products. The legislation does not necessarily require this, however, consumers of products pay attention to the availability of the necessary certificates. This is the so-called voluntary certification. This stage must be completed after the start of production, when samples for certification are selected and a conclusion is issued for a period of one to three years. The cost of obtaining such a certificate is about 10 thousand rubles.

The main risks in the brick products business

The main risk for entrepreneurs who want to start a brick production business is the further stagnation of the Russian economy and, accordingly, a decrease in household income. The decline in household income may lead to a slowdown in housing construction, which will reduce the demand for Construction Materials. Under this scenario, more than large enterprises with a large number of large customers. Such enterprises have the ability to reduce the selling price due to large volumes of production, as well as a margin of financial strength, in particular, they are much more willing to lend to banks than small businesses.

Another significant risk is the outstripping growth of energy tariffs, which is especially critical in the production of bricks, the technology of which involves firing.

The main risk and the main issue in this business is the issue of sales. The competition in this market is very high. To enter the market, you need to make a discount to the selling price, and this reduces profits. It is necessary to open a business for the production of brick products only if there are confirmed distribution channels for products. The “we will produce and sell” method in this area may well not work. We believe that you can open such a business only if you have at least two or three customers who are guaranteed to take in total at least 75% of your products.

Thus, the brick and brick products business is cost-effective and efficient. It is significantly differentiated in terms of initial investments; you can enter the market with a very small amount of investment. A small amount of investment will involve a large amount of manual labor, which somewhat reduces the profitability of the business. The payback of the business is from one to three years, subject to a sufficiently high production load. Main risk this business is the high competition in this segment and the complexity of marketing products.

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One of the main advantages of the brick business is that this business is not subject to licensing and obtaining any special permits for this species activities. The only thing you need to get is permission from the fire department.

Before you open a business, you should conduct a deep analysis of the existing building materials market. This analysis should include the following items:

Identification of the main brick manufacturers
Analysis of the quality of competitive products
Price analysis of competitive products

After that, you should inquire about possible channels for marketing your products. As a rule, these are construction companies or large construction stores. However, it is quite difficult to get such large customers, since they have been on the market for some time and they most likely already have suppliers.

The next step is to start looking for a suitable location. Area production premises should be from 160 to 220 square meters. It should definitely allocate space for a raw material warehouse and a warehouse for finished products. The location of the plant does not play a big role, the main thing is the accessibility of the entrance.

From the equipment you will need to purchase a stone crusher, a sand sifter, a brick molding machine, a kiln and a mixer. For unloading and loading operations, a truck crane should be purchased.

To maximize the capacity of your plant, you should hire several workers (3-5 people) who will produce finished products. You will also need a storekeeper, a forklift operator, an accountant, a driver truck and a cleaner.

For a better organization production process, increasing chances of success and decreasing possible risks you should draw up a business plan for a brick factory. Below you can download and view examples of ready-made business plans.

– as the name implies, the example contains several sections. The production section provides information on production volumes in the current and planned years, as well as information on the work of the enterprise's departments. In the investment section, the size and direction of the use of investments are given. The financial section contains calculations of the main economic indicators.

- This example is one of the most complete. It contains all the necessary sections. These include: justification of the project; project summary; general description of the project; action plan for project implementation; alternative projects; expected assortment and production volumes; market analysis of consumers and competitors; marketing plans including sales strategy.

- this example shows how to fill in production section. To begin with, the nature of the products produced and the scale of production are described. Then the production technology, the raw materials used and the methods of their processing are described. The prices for production capacities are also calculated. Plus, this section provides a table of capital investments.

- this example contains a large amount of information that is necessary for drawing up a plan. The example contains information about a project to build a new brick factory with a payback period of 6 years. The example contains the most significant sections, which contain tables with the justification of the cost of equipment, the calculation of basic economic indicators, and others.

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