Organization of work on the production of plastic fittings. PVC pipe production technology. Download a ready-made business plan for the production of polymer pipes with financial calculations and an Excel financial model

To consider the topic of the manufacture of polypropylene pipes and fittings for water supply and heating pipelines, it is necessary with a preliminary detailed description of the materials used for production.

Polypropylene pipes and fittings have a lot of advantages that distinguish them from their steel counterparts:

they are much lighter;
not susceptible to corrosion;
do not grow inside during use;
do not create vibration and rumbling, as well as other noises;
do not burst when the water in the system freezes;
do not conduct electricity;
do not need painting;
very easy to work with.

Pipes and fittings made of polypropylene can work for decades. It's ecological net production, which is successfully used for pipelines of any complexity. Therefore, their production and manufacture is widely established throughout the world.

The use of fittings with chrome and brass inserts allows combine these blanks with steel pipes.

The construction of these materials is very tight, and this application brings tangible economic benefits.

A little about polypropylene

Polypropylene is the initial product of the polymerization of propylene and ethylene in specific quantities. The resulting material is named random copolymer PPRC.

In the domestic market today there is no worthy analogue to foreign polymers. We use Finnish RA 130E BOREALIS and Hungarian TIPPLEN CS4-8000 TVK for the manufacture of polypropylene pipes.

The essence of the pipe manufacturing process is simple, and it is not very laborious. Speaking about it, the following features should be highlighted:

low energy costs in manufacturing;
ecological safety;
for the production, installation and use of one set of a line for the production of polypropylene pipes and fittings, a lot of space is not needed (this is approximately 100 m 2);

The set of polypropylene pipe extrusion line is a complete cycle of extrusion, calibration, cooling, drawing, etc.

Raw material for work

Lines for the production of plastic pipes, in addition to the extruder, also have the following equipment:

raw material supply system.
A machine that cuts blanks.
Tank for calibrations and cooling.
Pulling mechanism.
Mixer.
Conveyor tape.
Vacuum forming.
Accumulating mechanism that performs the stacking of blanks.

Raw material selection

When choosing raw materials, they opt for a granular polymer, but you need to carefully look at its shelf life.

And polypropylene and polyethylene are practically not limited by these indicators, which makes it more convenient to use.

From an economic point of view, an advantageous copolymer and HDPE.

IMPORTANT! When opening own production for the manufacture of polypropylene pipes and fittings, it is advised to cooperate with one supplier. Because the change of raw materials requires the change of equipment for the production of polypropylene products.

Manufacturing process

The main equipment that processes raw materials and turns them into a polypropylene pipe or fitting is called an extruder. And the production itself takes place in the following sequence:

Raw materials for the manufacture of pipes and fittings are fed into a special chamber. It is in small granules or comes in the form of chips. Also, secondary raw material that has undergone preliminary processing (grinding) is often taken into work. Secondary raw materials are mixed with the main.
Using electric or gas heating, the poured mass is melted. Temperature indicators in this case range from 230 to 250 degrees. But at the same time, it does not turn into a liquid, but only becomes viscous. So that this viscous heated mass does not stick to the walls of the apparatus, they are coated with Teflon.
Next, the extruder extrudes the blanks from the thick mixture according to the set size. Usually the length of the workpiece is two and a half meters. The equipment performs all these actions very quickly and completely offline. Human intervention is only required to set the right parameters for the job. Most good equipment for the production of polypropylene pipes and fittings is capable of producing up to 200 kg of products per hour of work.
The next step is the cooling of the blanks. To do this, they are placed in a container for cooling. The cooling process takes a couple of minutes. Then he perfectly holds the given dimensions. In the cooling tank, the plastic undergoes a shaping process, during which the material is thoroughly rounded and takes on the desired shape.
At the end technological process production, a marking is applied to the products, which displays the parameters of the operation of the products, the lot number and the date of production of the product are put down here. Then the blanks are packaged, packaged and sent to storage facilities or to consumers.

Often they are produced at the same enterprises as pipes.

Only for the production of polypropylene fittings it is necessary to install additional equipment (machine).

It does not occupy a large amount of space, but it makes it possible to increase the range of products. For companies, this becomes an important factor especially in a highly competitive environment.

The main problems and difficulties of production

Almost all countries of the world produce building materials. This also applies to polypropylene pipes and other plastic products, the manufacture of which is excellently established in Russia.

The main problem of the industry lies in the fact that domestic investors are not very active in financing the purchase of new modern equipment.

Many enterprises have to use old technologies that are losing their relevance at the moment.

One-time capital expenditures could be the key to obtaining high profit in future. But, they don't. Therefore, they cannot create worthy competition to foreign analogues.

There are no external differences, if we compare our and foreign polypropylene products. But, practical use shows different results.

Domestic blanks do not tolerate wear as much, are not as durable, and often have surprises in the form of marriage, which cause a breakthrough.

For the above reasons, consumers often prefer more expensive, but high-quality products from German and Turkish manufacturers.

And in the end, it should be added that the production of polypropylene pipes has been turned into an automated production that does not require huge energy and labor costs. Also, this production has almost no waste and does not harm the environment.

Pipe products made of polyvinyl chloride have found wide application in many areas. modern life. The reason for its demand is the excellent quality of products. How are PVC pipes produced, and what raw materials and equipment are used for this?

They are used when laying pipelines designed to move almost any medium - gases, liquids and chemicals. Polyvinyl chloride pipes and PVC connecting elements are used in the construction of residential facilities and at manufacturing enterprises.

When building houses, plastic products are used in the laying of engineering communications, including the outer sections of highways - these are sewer and water networks, as well as drainage structures.

Such pipes are resistant to aggressive environments, they can be operated in various temperature conditions, they are easy to install. The pipelines laid from them have a long service life.

Materials for the production of PVC pipes

The raw material for the manufacture of PVC pipes is a granular polymer. They are produced by extrusion.

In order to give pipe products some properties, the following are added to the composition of the components:

catalysts- chemicals that accelerate the polymerization process;
inhibitors- cause a delay or slowdown in reactions;
stabilizers– special substances that provide stability to polymers and slow down their aging;
plasticizers- refer to special additives that give plasticity and elasticity to polymeric materials;
antistatic agents- they are introduced in order to prevent the occurrence of a charge of static electricity;
pigments- give the already made product the desired color.

In addition to the above additives, polymer raw materials sometimes include other components that affect the properties of the final product.

Equipment for the manufacture of PVC pipes

To organize the workflow, you will need equipment for the production of PVC pipes, including:

Bunker where prepared raw materials are poured.
extruder– thanks to this apparatus, the extrusion process is carried out.
Baths. Relate to installations in which products are cooled and calibrated.
Scissors guillotine or disk cutters - they are used to cut pipes.

In addition to this equipment, depending on the type of manufactured products, PVC pipe manufacturers can use additional mechanisms and devices, for example, a hydraulic stacker.

Pipe production technology

The production process of PVC pipes is simple, it is not labor-intensive, it is not energy-consuming and it is safe for environment. All the equipment necessary for organizing the production of products will easily fit on an area of no more than 100 "squares".

extrusion Production Line functions in a continuous and complete cycle, consisting of the following stages:

Extrusion.
Pipe calibration.
Cooling products in bathrooms.
Pipe extraction.
Cutting products to the desired length.
Laying finished products in stacks.

The manufacturing technology of products at the PVC pipe factory is as follows:

Granulated plastic raw materials are poured into a hopper with a screw-shaped screw and heating elements.
In the process of rotation in the bunker, the raw material is heated to the required temperature.
The polymer, which is in the molten state, is fed into the extrusion head.
To form a product, molds are used that have a certain value of the outer and inner diameters.
After extrusion is completed, a plasticized product blank is obtained.
Then the pipe is fed into a vacuum calibrator (bath) for calibration. The equipment for this process is a three-meter closed container, inside which a vacuum is created using a vacuum pump.
The workpiece, passing through the diaphragm of the calibrator, moves to the next chamber. It is a cooling bath, where there is rarefied air.
For uniform stretching of the product, a pulling device is used, which can be caterpillar or tape type.
Cutting products is carried out using a guillotine or circular saw.
At the final stage of the technological process finished goods fall into an apparatus called a stacker, which stacks manufactured products on special racks.

Scope of PVC pipes

Pipe products manufactured by extrusion can be used for arranging:

pipelines supplying household gas;
water supply systems;
structures for the disposal of wastewater and precipitation;
technological lines intended for the transportation of chemicals;
highways used for industrial purposes.

Polyvinyl chloride pipes can perform a protective function when installing electrical wiring and communication cables.

Depending on the purpose, PVC pipe products can be non-pressure and pressure. In the first case, the pipes serve to move the liquid through them by gravity, and in the second case, the content is supplied under pressure. At present, the production of non-pressure PVC sewer pipes has become widespread.

Features of the installation process

Work on laying pipes made of PVC is simple and does not require the purchase of special equipment.

Installation is carried out in two ways:

By connecting to a socket using rubber seals and silicone grease.
Bonding products using special adhesives. The resulting connection is reliable, since the polymer molecules penetrate from one to another connected product.

When organizing the production of PVC pipes, the costs of purchasing equipment and other activities are usually paid off within one year.

PVC pipes are pioneers among polymer pipes, which began their journey more than half a century ago in the countries of America and Europe. In the domestic market, PVC pipes gained their popularity extremely slowly. This is due to both the conservatism of the consumer and the lack of a full-fledged regulatory framework that allows the widespread use of PVC pipes in housing and communal services.

Slowly but surely, pipes made of polymers of this group are constantly expanding their sector in the market of pipe products due to the improvement of the quality characteristics of pipelines. This is achieved through the emergence of not only innovative technologies production of PVC pipes, but also new ways of installing pipeline networks.

The raw material for the production of PVC pipes is granular PVC polymer.

To create a full range of required properties, a number of additives are used in the manufacture of these products:

catalysts that accelerate the course of the polymerization reaction;
inhibitors used to slow down unwanted processes;
stabilizers that impart stability to the resulting polymer;
plasticizers that provide the polymer with the necessary plasticity parameters;
antistatic additives help eliminate static charges;
pigments make it possible to obtain the desired color of the manufactured pipe.

Other components can be added to the standard composition to give the product certain properties. Additives, as a rule, have foreign production.

Equipment for the production of PVC pipes

The extrusion line for the production of PVC pipes provides a continuous cycle, consisting of the stages of extrusion (forcing the material through the forming hole), calibration and cooling in baths, drawing, cutting the pipe to a given length and laying the finished product.

The extrusion line includes:

an extruder consisting of an extrusion head and a granular feed system;
bathtubs designed for calibrating and cooling pipes;
pulling device;
a mechanism for cutting the resulting pipe into measured lengths - disk cutters or guillotine shears;
stacker or automatic winder for small diameter pipes.

The extrusion head can have a constructive solution in the form of a single block with a flange for fixing to the material cylinder. It consists of the following elements: body, matrix, divider, mandrel holder.

The matrix is centered relative to the position of the mandrel with the help of adjusting bolts. The uniformity of the pipe wall thickness along the diameter depends on the centering accuracy.

The German company "Krauss Maffei" specializes in the production of high-performance extrusion lines for the production of pressure and non-pressure PVC pipes. The largest PVC pipe plant in RussiaZAO Chemkor uses several such lines. The quality of the products manufactured by the plant has increased due to the introduction of a gravimetric dosing system for raw polymer.

Extrusion technology for the production of PVC pipes

The process of production of pipes from polymers is relatively simple, environmentally friendly, requires little labor and electrical energy. The area required for the installation and operation of a complete plastic pipe production line is only about 100m 2 .

The manufacture of PVC pipes begins with the filling of granular polymer into the bunker
extruder. In the extruder, a screw made of high-quality nitrided steel rotating inside the material cylinder mixes the incoming granulate. During rotation, the material is heated to a predetermined temperature.

The molten polymer is fed into the extrusion head, where the following elements act as shaping elements of cylindrical surfaces:

mandrel - it is responsible for the formation of the inner diameter,
matrix involved in the formation of the outer diameter.

At the outlet of the extrusion head, a plasticized billet is obtained in the form of a pipe. To give the pipe billet the required values of the outer and inner diameters, while ensuring a wall thickness uniform in diameter, it is calibrated in a vacuum calibrator (bath).

The calibrator is a container of of stainless steel three meters long, at the ends of which rubber cuffs are installed to ensure tightness.

The outside diameter calibration device is located at the front of the bath and is a stainless steel cylinder with a central hole the same diameter as the pipe. Through the diaphragm of the calibrating device, the pipe enters the cooling bath, which is also maintained under vacuum.

For uniform stretching of the pipe, caterpillar or belt-type pulling devices are used. Pipe cutting is carried out with circular saws or guillotine shears. At the end of the line, devices are placed for stacking products on a special rack or for winding a small diameter pipe. These devices can operate in both manual and automatic modes.

The production of sewer PVC pipes, which belong to the category of non-pressure pipes, can be focused on the manufacture of pipes with a single-layer wall (monolithic pipes) or with a three-layer one. The outer layers of the three-layer pipe are made from virgin PVC-U. The interlayer has a porous structure and is made from either our own recycled UPVC or a third party recycled polymer.

The production of corrugated PVC pipes is most often carried out by the method of twin screw extrusion of double-layer pipes. The inner surface is smooth cylindrical, the outer surface is corrugated wavy. Both walls are produced simultaneously by the hot method and form a single monolithic structure. The cavities formed between the outer and inner walls facilitate the construction of the pipe. The outer corrugated wall contributes to the achievement of the required ring stiffness.

Process Innovation

One of the innovations in the production of PVC pipes is the production of biaxially oriented pipes. This product has high performance impact strength and others mechanical characteristics with a simultaneous reduction in wall thickness, pipe weight, and, consequently, its cost.

Currently, two methods of biaxial orientation of PVC pipes are used:

The two-stage batch method consists in the extrusion of the product and its subsequent biaxial orientation in two different installations. This production is quite energy-intensive and labor-intensive, but it makes it possible to obtain products of very high quality.
In the second method, extrusion with orientation in both directions is carried out on the same line. This production requires high qualification, it is unprofitable in small-scale production.

Because the PVC manufacturing pipes is not too complicated and labor-intensive process, and the demand for such products is constantly increasing, this direction is promising for those wishing to organize own business. The payback time of invested funds depends on the degree of workload of the equipment. With a 50% loading of the extrusion line, the costs pay off in about a year.

1.GENERAL DESCRIPTION

Purpose and scope of polypropylene pipes:

Universal sewer polypropylene pipes with a nominal outer diameter of 110 to 160 mm are designed for laying:

in the systems of internal domestic sewerage of buildings at a maximum temperature of constant effluents of 80 ° C and short-term (within 1 minute) effluents with a temperature of up to 95 ° C, at their maximum flow rate of 30 l / min .;

in external sewage systems with a laying depth corresponding to the stiffness class;

in drainage systems and storm sewers.

When using sewer polypropylene pipes in outdoor sewage systems, their advantages are fully realized in comparison with pipes made of both traditional materials (steel, cast iron, etc.) and modern plastics.

By the combination of properties, it is polypropylene pipes and fittings that are the most optimal solution for outdoor and storm sewer systems of small diameters.

Benefits and Features:

resistance to high waste water temperature, up to 95°С;

high chemical resistance to most aggressive media, under the influence of which traditional materials corrode and age;

there is no cracking under the influence of surfactants (detergents), which is especially important when used in domestic sewage systems;

pipes made of polymeric materials do not conduct current, which distinguishes them favorably from steel and cast iron pipes, which, in the conditions of the proximity of cable routes (in cities and industrial areas), are subject to accelerated aging under the influence of electrochemical corrosion;

high resistance to hydroabrasive wear, which makes it expedient to use PP pipes for transporting liquids containing solid particles;

low roughness coefficient makes it possible to use minimal slopes, there is practically no overgrowth of pipes;

impact resistance at low temperatures is an important advantage in installation and repair work.

Polypropylene pipes, in contrast to PVC pipes, have a significantly higher impact resistance at low temperatures. The ring stiffness of polypropylene pipes must be at least 4 kN/m2, i.e. pipes have a stiffness class of SN 4.
The stiffness class of the pipe is the main parameter that determines the maximum depth of the pipeline. The maximum depths of laying a non-pressure pipeline made of polypropylene are determined by the method given in SP 40-102-2000 Design and installation of pipelines for water supply and sewerage systems made of polymer materials .
The approximate maximum depth of laying pipelines made of polypropylene with an average transport load is 5 - 6 m, depending on the density of the backfill.
Service life - not less than 50 years.

2. SERVICES

As part of this project Proposed production of polypropylene pipes.

Replacement of sewer and storm metal pipes on polypropylene allows you to permanently get rid of the shortcomings that cast iron or steel are prone to. Plastic is not subject to corrosion, does not collapse under the influence of low temperature, is light and relatively cheap.

Solving the problem of replenishment in the South Federal District market of sewer polypropylene pipes of various lengths and wall thicknesses for outdoor and indoor use.

3.1 Market analysis

Products made in Germany:

Gebr Ostendorf Kunststoffe GmbH&Co.KG (Ostendorf) is Germany's largest manufacturer of high-quality polypropylene pipes for sewerage systems. The company's products are recognizable all over the world, the products are also appreciated by Russian consumers. The company is certified according to DIN EN ISO 9001.

This is traditionally high-quality products without any complaints. The price is high. Those who do not save choose a German manufacturer of polypropylene pipes.

In second place are Czech pipes:

Ekoplastik provides polypropylene pipes and fittings throughout the Czech Republic. The company is known all over the world, products are widely used in Europe and Russia. Of course, there are developers and individuals who, in principle, use only Ekoplastik polypropylene pipes as a guarantor of quality, proven by time.

In third place is Turkey:

Turkish pipes are known from manufacturers TEBO, Pilsa, Valtek, Vesbo, FIRAT, etc.

The Turkish manufacturer Pilsa produces products that are wear-resistant, durable and elastic, so they are used in water supply systems. If the manufacturer's recommendations are followed during installation, then the lines on these pipes will serve flawlessly. These pipes cannot be used in closed systems and at temperatures above 95 degrees Celsius.

Turkish pipes Valtek and Vesbo at a low price of products are of high quality, but a modest selection of shaped elements is considered a disadvantage - that small thing, without which wiring cannot be done.

The Chinese manufacturer of polypropylene products Blue Ocean is a subsidiary of a British company and produces a variety of products. good quality. There is only one drawback of pipes from this manufacturer - they have a variable outer diameter of the pipe, but this does not affect the results.

Another well-known plastic pipe manufacturer in China is Dizayn. Polypropylene pipes DIZAYN confidently occupy their niche in the market, and the quality indicators of their products are comparable to leading European manufacturers, but at a lower price.

Lots of small businesses with unpredictable product quality but low prices.

Russian manufacturers:

the Russian market is dominated mainly by Russian-European joint ventures: Sinicon; Santrade; Politek

Russia was not the first to join the race for pipe prestige and the period of dominance of competitors, but by maneuvering its pricing policy and improving technologies, it manages to gradually win over its buyer. According to some indicators, Russian pipes show significantly best performance, than the closest competitor - a Chinese manufacturer, and in some cases they pressed both Turkish and Czech counterparts, but at lower prices.

The products of Russian PP pipe manufacturers have all the advantages characteristic of this type of product at the lowest price and the most affordable delivery.

Problems in the PP pipe production market:

Normative documentation does not clearly and clearly clarifies some issues. If we talk about the introduction of new technologies - plastic pipes, then in some regions materials are used in the old fashioned way, the use of which is not economically feasible in these weather conditions. There, plastic would be more cost-effective, much cheaper, and could pay for itself in a short time.

Interruptions with polymeric materials in the summer, as many refineries stop for a month for maintenance, and the remaining ones simply cannot cope with the volumes. The shortage of polymers in the summer months, which are raw materials for production, leads to a shortage of them on the market and, as a result, to a decrease in production volumes.

There are few professional installers on the market who distinguish high-quality and low-quality products. Manufacturers are forced to deliberately and unintentionally save on everything in a row, and primarily on raw materials and equipment, so they slide into a low-quality sector.

The system of passing tenders, and if we talk about housing prices - budget construction. This tendering policy results in the winner of the manufacturer who gave the cheapest price. It is impossible to make a cheap pipe from high-quality raw materials.

3.2 Market segmentation

Price policy

Since today there are many buyers and many sellers on the Russian PP pipe market, and the latter charge different prices within a certain price range, there is quite serious competition in such a market, marketing strategies its participants influence each other to a lesser extent. The emergence of a price range is due to the presence of differentiation of offers. Differentiation of the offer is carried out both at the expense of the product itself (its quantity, quality, properties), and the service accompanying its sale (delivery, merchandising, technical training of specialists). Buyers perceive the differences in the products offered by competitors and, based on this, make a purchase decision. When setting prices, other factors were also taken into account. external factors. The pricing policy should take into account the state of the economy, the level of inflation, the size of the interest rate, since these factors affect both the amount of production costs and the consumer's perception of the price and consumer value of the product. In addition, the possible impact of its prices on other market participants was also assessed. It is necessary to establish an attractive price for resellers, providing them with an acceptable profit and, thus, stimulating them to promote the goods.

Thus, a range of competitive prices has been formed, taking into account the services for laying out the goods and the initial training of personnel for resellers and delivery to the consumer:

No. p / p Name Unit. var.Maximum Price, rub.Minimum Price, rub. 5msht81705Pipe PP 110x2.7 (inner) 3m piece2472156Pipe PP 110x2.7 (inner) 2msht1611407Pipe PP 110x2.7 (inner) 1.5msht1441258Pipe PP 110x2.7 (inner)1msht86759 75msht817010Pipe PP 110x2.7 (internal) 0.5msht585011Pipe PP 110x2.7 (internal) 0.315msht403512Pipe PP 110x2.7 (internal) 0.25msht353013Pipe PP 110x2.2 (internal) 3msht219190 2 pieces 13211515 Pipe PP 110x2.2 (inner) 1.5 pieces 12711016 Pipe PP 110x2.2 (inner) 1 piece 756517 Pipe PP 110x2.2 (inner) 0.75 pieces 696018 Pipe PP 110x2. ) 0.315msht353020Pipe PP 110x2.2 (inner) 0.25msht322821Pipe PP 110x1.8 (inner) 3msht18416022Pipe PP 110x1.8 (inner) 2msht12110523 Pipe PP 110x1.8 (inner)104 (pipe. PP) 104 (pipe 63 52) ,5msht292525Pipe PP 110x1.8 (internal)0.25msht2320

The target audience

Our target audience are legal entities: various construction organizations, wholesale and Retail Stores building materials and plumbers, as well as individuals.

Promotion tools

The main distribution channel at the first stage is direct sales. end users legal entities, so the main promotional tool is commercial offers potential clients directly.

In addition, our products can be purchased through the online store, and as additional tools promotion will be used flyers, online advertising, participation in specialized exhibitions.

In the future, it is planned to promote the product through sales agents.

4. ORGANIZATIONAL MANAGEMENT STRUCTURE

Organization Chart management

Project staffing enterprises:

Structural subdivisionPositionNumber of staff unitsTariff (salary)SurchargeTotalAdministrationDirector130000.0030000.0060000.00AccountingChief. Accountant130000.0010000.0040000.00 BUHGARIABUHGALTER Calculator120000.005000.0025000.00 Supply and sales sales120000,00,00,0040000.00.00.00.00 Modeling and sales supply for supply120000,00,00,0040000.00 Logistics department. складом125000,0010000,0035000,00Отдел логистикиКладовщик220000,0010000,0060000,00Отдел логистикиВодитель220000,0010000,0060000,00Производственный цехНачальник цеха130000,0010000,0040000,00Производственный цехТехнолог125000,0010000,0035000,00Производственный цехОператор линии220000,005000,0050000,00Производственный цехПомощник оператора линии215000,005000, 0040000.00Auxiliary departmentCleaning lady210000.0020000.00Auxiliary departmentElectrician115000.005000.0020000.00Total19625000.00

The total wage fund will be 812,500.00 rubles, including wages - 625,000.00, insurance premiums to funds - 187500.00 per month.

5. PRODUCTION PLAN

The study "Construction industry in the south of Russia 2014", conducted by "Expert Yug" together with the Krasnodar consulting company MACON Realty Group, showed that in general in the South last year there was a reduction in the volume of commissioning in all segments of real estate. Two factors acted as the main sources of decline in indicators last year. On the one hand, the Olympic facilities have mostly already been commissioned, and on the other hand, a particularly noticeable drop was observed in housing construction. The active growth that was characteristic of the market in the past decade has finally been exhausted, and today in the southern construction, at best, there is a moderate development, and often a downward trend.

The main difference between the new period and the previous one is that high dynamics will be observed only in certain segments construction market, and with reference to individual regions. The most important growth points are as follows. Firstly, this is mass housing in those regions that were not fully affected by the recent construction boom or showed insufficient dynamics (this is primarily the Volgograd and Rostov regions). Secondly, everything related to sports, tourism, hotels and resorts - here the main incentives will be the upcoming World Cup (Rostov and Volgograd) and the government's plans to build new resorts in the North Caucasus. Thirdly, social infrastructure - in this segment, the North Caucasus Federal District will also be under special attention a state planning multi-billion investments in social and cultural facilities in the Caucasian republics. Fourth, transport infrastructure - in the South, new ports, airports, roads are currently being built, and this process will stretch out at least until the end of the decade. Finally, the building materials market has good growth prospects.

Based this study The following monthly sales volumes are predicted:

No. p / p Name Unit. Izm.Sen, rub. Shttsumma, rub1 pipe PP 110x3.2 (b.) 3MST29010002900002 POP PP 110x3.2 (NAR) 2MST19510001950003 PP PP 110x3.2 (Nar.) 1mht1101000110004 PP 110x3.2 (NAR) 0.5MSHT7007000 (NAR) 0.5MSHT7007000 (NARS ПП 110х2,7 (внутр.) 3м шт21515003225006Труба ПП 110х2,7 (внутр.) 2мшт14015002100007Труба ПП 110х2,7 (внутр.) 1,5мшт12515001875008Труба ПП 110х2,7 (внутр.)1мшт7515001125009Труба ПП 110х2,7 (внутр.) 0,75мшт70150010500010Труба PP 110x2.7 (internal) 0.5MST501500750001111111111111111.7 (internal) 0.315MST3515250012 PP 110x2.7 (internal) 0.25MST30150045000 13 pipe PP 110x2.2 (internal) 3MHT1901500285000142,2,2,2,2,2,2,2,2,2,2,2,2,2,2,2,2,2,2,2,2,2,2,2, 2мшт115150017250015Труба ПП 110х2,2 (внутр.)1,5мшт110150016500016Труба ПП 110х2,2 (внутр.)1мшт6515009750017Труба ПП 110х2,2 (внутр.)0,75мшт6015009000018Труба ПП 110х2,2 (внутр.)0,5мшт4515006750019Труба ПП 110х2,2 (внутр. ) 0.315msht3015004500020Pipe PP 110x2.2 (inner) 0.25msht28150042000 21Pipe PP 110x1.8 (inner) 3msht160100016000022Pipe PP 110x1.8 (inner)2 msht105100010500023Pipe PP 110x1.8 (inner)1msht5510005500024Pipe PP 110x1.8 (inner)0.5msht2510002500025Pipe PP 110x1.8 (inner)0.25msht20100020000Total300450 The total production plan will be 41,195 m of pipe per month.

6. FINANCIAL PLAN

Product costing:

Raw material Quantity, kg Price, rub Amount, rub

Thus, the cost of 1 kg of pipe is 52.27 rubles

1 m pipe - 41.82 rubles

Other production costs

Name Amount of expenses per month Utility expenses 10,000.00 Electricity 60,000.00 Premises rent 65,000.00 Other 10,000.00 Total 145,000.00

Fixed assets:

The complete plastic pipe production line includes an extruder, a pipe cutting machine, a raw material supply system, a calibration and cooling bath, a mixer, a hauling device, a conveyor belt, vacuum former and an accumulator laying pipes.

Productivity depends on the pipe size: 110 - 130 kg/h. The line can produce about 1000 meters of pipes per day. The lines have different parameters, so you can order machines for your business, or you can save money and buy used equipment. The lowest cost of such a set is about 400 thousand rubles.

Calculation of profit and profitability

1Income, thousand rubles360541.1Sale of polypropylene pipes, thousand rubles360542Expenses, thousand rubles332662.1Cost of products, thousand rubles206762.2Rent, thousand rubles7802.3Utility expenses, electricity, thousand rubles8402.4Wages and insurance premiums, thousand rubles97502. 5Taxes, thousand rubles7002.6Purchase of fixed assets, thousand rubles4002.7Other expenses, thousand rubles1203Profit, thousand rubles27884Return on sales, %7.7 polypropylene business plan

CONCLUSIONS

Russian market The production of pipes made of various plastics has expanded significantly in recent years. This is due to the simple production technology, as well as the high demand for this product. Plastic pipes are widely used. They are used in sewer and heating systems, in water and gas supply systems, as well as for arranging a "warm floor". Such a wide range of applications is explained by the qualitative characteristics of plastic pipes:

they are durable, do not rust, do not rot;

withstand temperatures up to 160 -170 ° C;

they do not have lime deposits;

shelf life of about 50 years;

five to seven times lighter than metal pipes.

Pipe manufacturers are improving technology and expanding the range, because the competition in this type of production is quite high. For successful business for the sale of pipes you need to produce a quality product at an affordable price.

To open production, you will need to obtain permits from the gas service, the fire inspectorate, the sanitary and epidemiological station, the local division of the Gosnadzorohrantruda, local authorities executive branch, etc.

The initial investment required to open the production of plastic pipes, with the purchase of used equipment and 100 tons of raw materials, will amount to about 3,139 thousand rubles. The business pays off in about 1 year. Profitability will be 7.7%

First you need to rent a small plant or part production premises in the country. Mandatory conditions: good transport accessibility, convenient access roads, area not less than 200 sq.m. Electricity at 380 volts, sewerage, water supply must be carried out.

It is important to provide for several zones separated from each other:

manufacturing facility;
warehouse complex;
bathroom;
premises for employees.

Taking into account the fact that the pipe production line includes high and heavy equipment, the ceiling height should be at least 10 m. Powerful air conditioners and fire protection systems should be installed in the workshop. AT warehouse should be at normal humidity and room temperature.

Hiring and organizational issues

When organizing a line standard size and picking in the state it is necessary to hire about six people workers. This is necessary to ensure uninterrupted production (three employees per shift).

In addition, it is necessary to hire an accountant, auxiliary workers, a process engineer, two machine operators. Thus, in the list monthly expenses will need to include $6,000 as wages employees.

Since the HDPE pipe manufacturing business belongs to the category of technically complex industries, at the stages of its organization it will be necessary to obtain permission from the local administration, the Sanitary and Epidemiological Station, the State Energy Supervision Authority, and the fire inspectorate. As for registration, the optimal form is LLC.

Equipment for the production of polyethylene pipes

You can buy both new and used equipment of domestic or foreign production. When buying a line Russian production you can save some money.

List of required line components:

dryers;
automatic loader;
screw extruder;
containers for cooling blanks;
conveyor;
coronator;
device for marking products;
control system;
auto stacker;
vacuum calibrator.

Raw materials for the production of polyethylene pipes

Products for the manufacture of HDPE pipes are selected individually. High-quality raw materials are polymers of different pressures, polypropylene, polyvinyl chloride,.

Raw materials should be ordered from trusted suppliers. The highest quality and most reliable brands are Hastalen 5416 (Bazell), Vestalen 9412 (SABIC) imported.

Technology for the production of polyethylene pipes

The pipe manufacturing process is based on the extrusion method. The essence lies in the homogenization of raw materials in order to soften them in a special device - an extruder. With the help of spinnerets of the equipment, the pipe is formed to the set diameter with their subsequent cooling.

In the first step, the material is placed into the extruder receiving device. Next, the raw material moves into a preheated cylinder. Gradually, the material is transferred to the hottest parts of the cylinder, slowly warming up.

Thus, the cylinder consists of three components: a feeder, a raw material compression zone, and an output zone. The high quality of the extruder die is important, since it is on it that the dimensions of the finished pipes depend. It must be maintained at a fixed temperature.

After passing the raw material through the cylinder and obtaining blanks, they are placed in a container for vacuum forming under pressure. Then the pipes are removed from the cooling chamber and, to prevent its deformation, they are immediately transferred to the conveyor.

On the final stage pipes are cut and laid in prepared coils. For cutting, special saws or cutters are used (depending on the selected diameter).

Investments and income

In order to launch the production of HDPE pipes, at least $140,000 will be required. This includes the cost of monthly rent, wages, renovation of the rented premises, purchase of equipment and raw materials.

The price of a finished unit of production depends on its type. In this case, the rule applies: the larger the diameter, the more expensive the product.

With the full sale of products, the monthly income can be up to $ 6,000. The investment pays off in about 2 years.

Polyethylene is serious business. It requires not only large financial investments, but also professional knowledge in the field of production, experience in managing a large organization.

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