The cost of paving slabs calculation. Profitability, product sales and staff recruitment. Technologies for the manufacture of paving slabs

When ennobling any territory, one cannot do without a comfortable and beautiful road surface. Production paving slabs as a business: profitability, a plan with income and cost calculations in a review for start-up entrepreneurs.

Pros and cons

Paving slabs - popular construction material for arranging paths and playgrounds in a wide variety of places:

city parks, squares, roads, squares;
area in front of shops and other business enterprises;
yards in private and apartment buildings.

The competition in this sector of the economy is very high, but the huge volumes of consumption allow all manufacturers of high-quality paving stones to make a profit.

Entrepreneurs are attracted by the following points:

Lack of permission to open your own business.
Simplicity of legal registration.
The need for a small number of employees.
Simple technological process.
Possibility to receive additional income from providing tiling services.
High level of profitability.

The negatives include:

Seasonality - most of the production falls on the warm season, since a small volume is performed in winter construction works.
The same type and monotonous work - in connection with this, staff turnover is possible.
Expensive equipment - paving stones are produced on a large scale using machines costing up to half a million rubles.

You can download a business plan for the production of paving slabs with calculations at.

Business plan

In order not to miss anything when starting a paving slab project, you must adhere to next plan actions:

Marketing research market.
Study of tile production technology.
Company registration.
Room rental.
Purchase of equipment and materials.
Search for workers.
Organization of advertising and sales.
Calculation of profitability.

To save time, you can do several things at the same time, for example, purchase equipment and hire workers.

The owner of the production of paving slabs may need a business plan in case of involvement borrowed money- bank loan or non-commercial loan.

Marketing

There are many varieties of tiles on the market that differ in characteristics and production methods. Starting "from scratch" the release of several types at once is expensive and risky. It is better to determine the most demanded goods and only after the enterprise begins to bring a stable profit, expand production.

You can identify a sales leader as on their own, and ordering a study of a marketing company. Also at this stage, it is necessary to determine the lower and upper price limits for tiles in order to be able to compete without compromising own business.

Another option is possible: if any niche turns out to be free during the analysis of the market, then if there is demand, you can take a strong position in the production of unique products.

Technology

There are three main types of coverage:

Ordinary concrete tile, which is paved with sidewalks and paths. Color and shape can be very varied, even with 3D designs.
Tile from polymer plastic. With the help of additives, it is given the necessary properties - frost resistance, reinforcement, water resistance. At polymer tiles longer service life, it is easier to process and more pleasant to operate than concrete.
Soft paving slabs. Basis for production - crushed car tires. Such a coating is used in the arrangement of sports fields, outdoor pools and other traumatic places. The tile withstands a wide range of temperatures, is highly resistant to adverse environments, and has a non-slip rubber surface.

In production, two approaches are used:

Vibrocasting is a simple and cheap method of manufacturing tiles that are not very durable and of high quality. First, a concrete mixture is prepared in a concrete mixer from cement, crushed stone, sand and additives. Then the mixture is poured into molds on a vibrating table, which works until the tile surface is moistened. The molds are dried on pallets in the room for two days, then they are heated for several minutes to 60ºС-70ºС to remove the tiles on a vibrating table. In the process of heating and knocking out the matrix, cracks and chips can form on the paving stones, especially if unskilled labor and cheap equipment are used.
Vibropressing and hyperpressing - this method uses expensive equipment, but the tiles are of high quality. As with vibrocasting, a molding sand is prepared, which is compacted with a vibropress or hydraulic press. Such a tile is dried for 8-9 hours in a natural way or 5-6 hours with hot steam. Because manual labor reduced to a minimum, there are practically no defective products.

To produce high-quality tiles, you need to consider the following nuances:

Polymer forms are treated with a special agent that removes static charge during the first use. In the future, it is desirable to apply lubrication with emulsol and, after finishing the manufacture of tiles, rinse with a 7% solution of hydrochloric acid.
To preserve moisture in the tile during drying, it is covered with a film. But then the drying time increases.

The finished paving stones are carefully laid on wooden pallets, fixed with film and tape. Store tiles in a dry, warm and well-ventilated warehouse.

Legal registration

The owner of the enterprise can register as an individual entrepreneur or open a company with limited liability. Next, you need to get registered with the Federal Tax Service and social funds. The simplified taxation system makes it possible to submit reports once a year with the payment of tax as a percentage of revenue and fixed social contributions.

No special permissions are required to operate. If it is necessary to issue a quality certificate to the customer for a tile, you must provide a product sample to the certification service.

room

The manufacture of paving slabs as a business cannot be carried out at home - for the location of equipment and storage of finished products on an industrial scale, a room with an area of at least 70 square meters is required. m. In the industrial zone of any city there is a free workshop or a suitable warehouse at an affordable price.

Basic requirements for a mini-factory:

Availability of communications - water supply, sewerage, electricity.
Insulated premises and availability of heating, if it is planned not to stop production during the cold season.
Change house for workers or the possibility of self-arrangement of a residential area.
Separate areas for production and warehouse.
High ceilings.
Access road adapted for freight transport.

It is advisable to find a room near the wholesale bases selling raw materials for production in order to save on delivery.

Equipment and raw materials

To the list necessary equipment for any production technology includes:

concrete mixer (for the manufacture of two-layer tiles you need 2 pieces);
matrices of various types in the amount of 150-200 pieces (there are metal, plastic, wood, silicone);
container for washing forms;
a heated container for removing tiles from the matrix;
racks for drying tiles;
pallets for storage of finished products;
packaging tools and accessories;
scales;
hydraulic trolley for moving pallets with tiles.

Depending on the method of making pavers, you will need:

Vibrating table.
Hydropress.

New equipment is quite expensive (from 100,000 to 500,000 rubles), used equipment is 30-40 percent cheaper. A vibrating table and iron molds can be made on your own if you have experience in mechanical engineering and the ability to work with metal. But at the same time, the production technology and the quality of the finished product are called into question.

If there is a free start-up capital you can purchase a ready-made tile production line for 800,000 rubles. - 1,000,000 rubles

Raw materials for concrete pavers are cheap and readily available. Recipe for the manufacture of 1 square. m. paving slabs 6 cm high:

This is the most common composition among manufacturers. It can also be used in production crumb rubber, glue, wire mesh, polymers, clay.

An important point: in order to obtain consistently high-quality products, the components for the preparation of the mixture must be of the same brand and manufacturer.

Employees

The number of required workers at the plant for the production of paving stones depends on the planned production volumes. For example, for production by vibrocompression 50 sq. m. paving per shift will require 3 people:

machine worker;
handyman;
loader.

Administrative work, marketing and accounting activities at the enterprise at first can be performed by the owner. After the plant becomes profitable, it makes sense to hire specialists.

Special attention it is necessary to pay attention to safety, give workers overalls and protective equipment.

Sales of products

For a novice entrepreneur, the main buyers of paving slabs are the owners of private houses and outlets. To receive an order from a construction company, it will be necessary to certify products.

The first customers may be acquaintances or relatives who need to ennoble the territory. You need to look for orders through advertisements in local newspapers, the construction press, information portals in the Internet. A good result is participation in specialized fairs and exhibitions and contacts with supply agents for construction companies.

Sometimes customers receive orders for tiles with laying. To provide turnkey services, you can conclude an agreement with the installation company or hire workers for each case.

To attract large customers, you need to make discounts, for example, when buying a certain amount of products, offer free shipping and provide a performance guarantee.

Video: how to open a paving slab business?

Economic calculations

To determine the amount of investment in a tile project, you need to make a cost-income calculation and calculate whether it is profitable to engage in this business.

Starting production by vibrocompression includes the following costs:

Half of the investment is the cost of purchasing equipment. Vibratory casting technology does not use expensive equipment and you can start a business with 700,000 rubles available. - 750,000 rubles.

fixed costs in the manufacture of sidewalk paving stones per month consist of:

The cost of 1 square. m. paving slabs will cost the entrepreneur 280 rubles. In the course of work, additional costs may arise for equipment repairs, product certification, incentive payments to employees, etc.

The income of the plant will depend on the volume of production and sale of tiles. Presumably, with a production rate per day of 50 sq. m. of paving stones and sales of 80% for 600 rubles, the monthly turnover will be:

With such calculations, the investment will pay off in 4 months - this is very high rate for production. If you also provide tile laying services, then the profitability will be even higher.

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Step-by-step business plan for the production of paving slabs: where to start
How much money do you need to start a business
Production of paving slabs: what documents are needed
- - - Similar business ideas:

Starting investments in opening a business for the production of paving slabs amount to no more than 200 thousand rubles. The profitability of the business reaches 50%, and the equipment payback is only 3 months.

Characteristics of paving slabs

The attractiveness of the production of tiles lies in the fact that the state and private individuals are increasingly using it for laying sidewalks and household plots. And this is logical, because the pavement is more reliable, easier to repair and looks much more attractive than concrete or asphalt. And the laying process itself is understandable to many homeowners, in contrast to the same asphalt, the laying technology of which is known to the best of 5% of the country's population.

For the production of paving slabs with a volume of 1000 m2 per month, it will be necessary to rent a room with an area of at least 100 m2 with warehouse and places for installing a drying chamber. The cost of renting such a room is in the range of 20 to 30 thousand rubles per month, depending on the region.

To organize a mini-production of paving slabs, it is enough to attract no more than 3 people. On the initial stage you will need one Moulder, Dismantler and Accountant.

What equipment to choose for the manufacture of paving slabs

The total cost of purchasing such a set of equipment will be about 130 thousand rubles, taking into account the purchase of plastic molds.

When choosing equipment for the production of paving slabs, it is recommended to pay attention to domestic production equipment. It may partially lose in terms of manufacturability and level of automation to imported counterparts, but our equipment is cheaper, easier to repair, easier to find spare parts and, due to its simplicity, does not require hiring highly qualified workers.

The raw materials for the production of paving slabs are crushed stone screenings, sand, Portland cement, chemical additives (plasticizers, concrete modifiers, etc.), dry pigments and water.

Paving slab production technology

The technological process for the production of paving slabs is not complicated, and includes such stages as concrete mix preparation, mold preparation, forming on a vibrating table, curing products in molds, stripping products and packing finished tiles.

Shapes are the key element in tile production. Forms can be plastic, rubber and polyurethane. The most practical are rubber molds, as they can withstand up to 500 cycles of use. Plastic molds are slightly inferior to them in strength, they last for 200-250 cycles, and polyurethane molds for only 100 cycles.

Forms before pouring concrete are lubricated with chemical additives based on C-3 plasticizer, which improves the mobility of concrete during spreading, increases the strength and frost resistance of products.

For the preparation of concrete, it is recommended to use cement grades M500 and M400. Crushed stone with fractions of 0.5-0.10 cm is used as a coarse aggregate, and building sands with a particle size of at least 2 are used as fine aggregates. Crushed stone and sand are mixed in proportions of 1: 1.

After preparing the concrete mixture, it is placed in molds and compacted on a vibrating table. Then the vibrated products are stacked on a pallet and sent to a drying cabinet, where they are kept in molds for a day.

The disassembly of the tiles is carried out on the disassembly table with the help of nozzles. The demoulding of one tile lasts about 5 seconds.

Upon completion of the formwork, the finished tiles are placed on pallets. The packaging of products is carried out using packaging scissors, tape and metal staples. The final strength of the tile is gaining within 21 days.

The cost of production of 1 m2 of paving slabs averages 250 rubles. At the same time, the main costs are made up of material costs and wages of hired personnel. The wholesale selling price of tiles reaches 450 rubles / m2.

How much can you earn by opening the production of paving slabs

Net profit after payment of all taxes is 120 rubles/m2. In the production of paving slabs with a volume of 1000 m2 per month, the entrepreneur's profit is about 120 thousand rubles.

The payback of equipment, subject to 100% sales of the produced tiles, can be only 3 months.

Even such a seemingly hard work how to make paving slabs with your own hands. You just need to know how to do it, and what materials will be needed. In this article, you will learn the entire process of producing paving slabs at home and its cost.

To begin with, we need plastic molds measuring 400x400 mm. In this case, 15 pieces were purchased, the quantity depends on the area to be covered and the speed of the work.

Before starting work, the molds must be lubricated with machine oil, you can take a test at any service station. This will prevent the concrete from sticking to the mold.

Be sure to reinforce the tiles. To do this, we will use a mesh with a wire with a diameter of 3-4 mm. For example, you can take a grid with a diameter of 3 mm with a cell of 50x50 mm or a diameter of 4 mm with a cell of 100x100 mm, or you can just use pieces of wire with a diameter of 4 mm. We cut the mesh with squares of 380x380 mm, and the wire, respectively, with pieces of 380 mm.

Now we prepare the concrete mixture. We need cement M500, sand and crushed stone of the smallest fraction (5-10 mm) in a ratio of 1:1:2. When preparing a concrete mix, it must be taken into account that the volume of the finished mixture will be slightly less than the volume of the dry components. For example, if we take 10 liters of sand, 10 liters of cement and 20 liters of crushed stone, then in the end we will get only 27 liters of concrete. This must be taken into account when calculating the amount of materials.

A plasticizer and a dye, such as a green coloring pigment, must also be added to the concrete. The dye is added at the rate of 2% of the volume of the concrete mixture. And in order to save on the dye, you can do this: first, prepare a concrete mixer with tinted concrete, which we pour into the molds in a layer of 1 cm, then we prepare ordinary concrete and completely fill the molds to the brim, not forgetting to lay the reinforcement.

After laying each layer, you need to vigorously shake the form, so we imitate a vibrating table. It will take about 6 hours to pour 15 tiles.

After a day, the forms should be covered with rags and poured with water, and then covered with a film. Only after 6 days can the tile be pulled out of the mold. At the same time, it must be folded and again covered with rags and film. For 28 days, we make sure that the rags are wet. Otherwise, the tile will crack.

How much does it cost to make paving slabs with your own hands? The cost of a tile is $1.1 and, of course, your time. Tile molds cost about $2.

You can talk a lot about the imperfection of the world, in which at least once every ten years there are economic crises, or you can independently determine the direction of activity that will bring stable income regardless of the global financial situation. These activities include those in which people will always be interested. Including all activities related to decorating the interior space of an apartment or a country house, finishing the territory of a personal plot. For example, the production of paving slabs. The main component of future success in such a situation is the high-quality and original preparation of a business plan, on the basis of which successful and fruitful activities will be carried out in the future.

The competition in this market is quite high, but the demand for this finishing material is quite large. It is formed due to the ever-increasing rates of private suburban construction, the implementation of works on the improvement of the territories of urban and rural settlements, plain asphalt on the sidewalks of which often fit during the Moscow Olympics-80.

This type of business is recognized as one of the least expensive. To get started own production, will require from 100,000 US dollars.

Registration, taxes, certification

In any situation, you have to start with registration. For small production at the first stages of activity, it is enough to register in the role. The production of paving slabs is convenient as a start-up with a minimum number of permits required for such work and a simple taxation scheme. Registration of the manufacturer as an individual entrepreneur makes it possible to choose 6%.

There is no mandatory certification for paving slabs. True, given the significant role that potential buyers give to his presence, the certificate can be ordered additionally. In such situation ready samples the certification service will carefully check the level of moisture resistance, frost resistance, readiness to withstand mechanical stress and negative influence environment, including retaining color under constant exposure to direct sunlight. Due to the ease of manufacturing industrial batches of beautiful and original paving slabs, such confirmation of high quality will be an additional argument for a potential buyer to choose our offer.

What is included in the business plan for the production of paving slabs?

An important basis for future success is a detailed assessment of the production options for this practical finishing material with selection options for buyers of lots.

Experienced producers recommend paying attention to the private sector in the early stages. It requires a small number of units of paving slabs in ordered batches. At the same time, the demand of the private sector for this material is high. Repair of garden paths can be done literally every year.

In addition, paving slabs are often in demand by representatives of local city organizations. When choosing a material that is reliable in operation, it is paving slabs that are ready to become at the same time an adornment of the territory of any locality and the basis for improving the comfort of all who live in it.

You will also need to accurately assess what equipment will be required from the first stages of activity. This will help you immediately determine the parameters of the costs that will be spent on its acquisition. Also, the business plan includes information on the amount of materials that will be required for the fast and high-quality execution of batches of any scale.

Production room

The ideal situation would be for a novice entrepreneur to have their own premises for organizing production. It can be quite compact.

All equipment can be easily accommodated in an area of 50 square meters. Of these, it is enough to allocate no more than 35 square meters for production. The remaining 15 square meters will be used for the storage of manufactured products.

You can rent the space you need. It is important that it meets the requirements fire safety and had a permanent connection to the power supply. Also in the room you will need to install a drying chamber.

Technologies for the manufacture of paving slabs

Today, there are two basic manufacturing technologies for this convenient and practical material.

In the case when it is planned to immediately start with the production of sufficiently large batches, it is recommended to use vibropressing technologies. This technology includes several basic stages of activity.

Preparation of concrete using a concrete mixer, from which, after preparing the mixture, the mass is placed in a vibropress, in its matrix.
The second stage is the work of vibrators and a punch, which make the material dense and send the material prepared for drying to a mold pallet, which is sent for drying.
At the third stage, future reliable and durable tiles are dried in a thermo-moist way, in the role of which ordinary hot water vapor can be used. To minimize the cost of performing a full range of works, pallets with products can be dried without the use of specialized steam installations - just indoors.

What is the reason for the growing popularity of pizzerias? Is it profitable to open an institution of this type? Look for answers to these and other questions in ours.

Using vibrocasting technology work is carried out differently.

The concrete mixture is being prepared.
The finished mixture is placed in molds located on the vibrating table.
Forms are laid out on pallets.
Forms are left in natural conditions for two days.
Heating molds to 50-60 degrees Celsius and knocking out finished paving slabs from them.

This technology makes it possible to create models of an almost unique shape, which are especially convenient for decorating house territories.

Equipment for the production of paving slabs

At the first stages of the work, you will need to purchase or rent:

a vibropress, the cost of which upon purchase is about 20,000 US dollars;
from 5 to 6 thousand US dollars upon purchase will be spent on the purchase of a concrete mixer;
the purchase of a punch will cost the owner of the new production 3 thousand.

The use of such technology options will allow the production of tiles by vibrocompression.

An alternative set of equipment will be the equipment used for the production of paving slabs with their own hands using vibrocasting technology. This kit includes:

vibrating table, minimum cost which is 4 thousand US dollars;
molds for the manufacture of paving slabs - from 1-8 US dollars per 1 mold;
$600 will cost a new entrepreneur a concrete mixer.

A convenient type of additional equipment will be a bath used for washing molds. Its average cost is 1-1.5 thousand US dollars.

To minimize costs at the initial stages of activity, it is recommended to purchase used equipment.

What staff will be required to do the job?

For a small production, all the works of which are located on a space of 50 square meters, it is enough to include 3 employees in the staff of the enterprise. One of them can additionally combine the functionality of a storekeeper and a driver. A convenient option that allows you to save money is the invitation of representatives of outsourcing companies to prepare tax, pension and accounting reports.

The cost of production of paving slabs

In the production of paving slabs, flat-cement concrete and a plasticizer are used. The cost of manufactured 1 cubic meter of starting material is 3,000 rubles. From it you can make up to 16 square meters of finished tiles. The average cost of manufacturing one square meter of tiles is 150-170 rubles. It is necessary to add 50-70 rubles to it, which will be spent on electricity, wages for workers, rent of premises and other production needs. The selling price of a tile is much higher - at least from 230-300 rubles.

Profitability of production of paving slabs

If a new manufacturer quickly finds potential buyers, the profitability of paving slab production due to the use of inexpensive materials reaches 150%. This suggests that even with the purchase of a complete set of equipment, the purchase will be justified.

The manufacture of paving slabs today is recognized as one of the most successful options activities to start your own successful business. Making paving slabs as a business will require financial costs at the initial stage, but will bring a high payback later.

Video: production of paving slabs

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Paving slabs continue to retain leadership positions in the construction market. For exterior decoration, the owners of private houses and organizations traditionally choose this material. This means that the production of paving slabs as entrepreneurial activity can be a profitable and promising undertaking.

Nevertheless, any entrepreneur who decides to open his own business in this direction needs to prepare for the fact that he is in for a lot of competition. However, since this business is currently one of the most profitable, in demand and promising, to achieve success, you only need to develop a competent business plan for the production of paving slabs.

Basic project properties

Target this project- definition economic efficiency creation of an enterprise for the production of paving slabs. Ready business plan can be used as offer during negotiations with potential investors or creditors.

The relevance of the business for the manufacture of paving slabs lies in the high performance of this material and its popularity in the market. Paving slabs are environmentally friendly, durable, convenient to use, and also economical. And thanks to new technologies, the term and quality of its service is significantly increasing.

Creation project manufacturing enterprise for the manufacture of paving slabs is designed for 2 years - during this period, according to the plan, all starting investments. The business plan takes into account all the risks and possible force majeure situations that can reduce the company's profits and even contribute to its unprofitability.

There are three main goals for creating a workshop for the production of paving slabs:

– creation of an enterprise with a high level of profitability;

— meeting the demand in the relevant market segment;

- receiving high profit during the period specified in the plan.

To achieve these goals, it is planned to open an enterprise that will produce paving slabs intended for arranging sidewalks in settlements of any nature and purpose.

The general funding figures are as follows:

- the cost of the project as a whole, including all types of costs - within 5.5 million rubles. It is envisaged that a commercial loan in the amount of 5.5 million rubles will be received for opening and developing a business. The interest rate in this case will be 16%;

- the investor's income, or the total amount of interest paid on the loan will be 270.9 thousand rubles;

- general economical effect from the implementation of the project for the production of paving slabs for the established period - 34 million 413 thousand rubles or more under favorable economic circumstances.

The preliminary payback period will be 1 year. But in case of force majeure or additional expenses, this period can be extended up to 2 years.

Technical features of the manufacture of paving slabs - in the video:

Stages of opening a business

The main list of stages for opening a workshop for the production of paving slabs from scratch includes:

— plan development and preliminary financial calculations;

– registration of the enterprise with the Federal Tax Service;

– lease of a site and production premises (if you have your own material and technical base – its preparation for the start production process);

— purchase of equipment and raw materials;

- recruitment;

- the beginning of the production process.

Based on a two-year period for the development of the enterprise, it is possible to draw up such a detailed step-by-step plan:

Stages	Execution conditions	Deadlines
Project start		1 - 2 year
	1 month project	First 30 banking days
Getting a loan	The presence of a mandatory package of documents	1 month
Entering into the state register, registration with administrative and tax authorities	Concluded investment agreement	From 1 to 30 calendar days
Location selection, paperwork	Preliminary work	1 month
Conclusion of a lease or purchase agreement for a land plot	Investment agreement	1 month
Purchase of equipment	Conclusion of an investment agreement	Up to 30 calendar days
Equipment installation	Receipt of investment funds	Up to 30 calendar days
Hiring	Production activity	Up to 30 calendar days
Training	End of the stage of organization of the production process	Up to 30 days
Carrying out a marketing campaign	30 calendar days	Up to 360 calendar days
End of the project		12 – 24 months

Business registration

To get started, it will be enough to register as individual entrepreneur. The law does not require registration legal entity for such activities, and at first the IP format will indeed be more successful.

The process of registering an IP requires the submission of a minimum of documents of the founder: copies of the passport, identification number, as well as a receipt for payment of state duty in the amount of 800 rubles. These documents are submitted by filling in advance on standard form application for registration of an individual entrepreneur. In it, in addition to the personal data of the entrepreneur, the code for OKVED classifier. It must be selected using the current classifier (). In the absence of additional activities, code 23.31 (Manufacture of ceramic plates and tiles) is suitable. The prepared package of documents must be submitted to the territorial office of the Federal Tax Service, and after 3-5 days the applicant is issued a ready-made certificate.

If there are several founders, the IP will not be suitable for registering a company - you will have to choose one of the existing legal entity formats. The best option is a limited liability company. In this case, the list of documents to be submitted will be more extensive, and a special entry fee is additionally paid - authorized capital not less than 10 thousand rubles. The procedure for registration and functioning of an LLC is regulated by a special the federal law 14-FZ (http://www.consultant.ru/document/cons_doc_LAW_17819/).

Paving slabs do not require careful certification. This feature greatly facilitates the process of legalizing a business. But if you wish, you can get a certificate of product quality. This document will be of great help in competition and help a newcomer to the market acquire regular customers and partners. You can get such a document in a special certification service. Previously, products must be tested for strength, resistance to frost, moisture and other qualities. If the verification is successful, the manufacturer will receive the required certificate without any problems.

Useful regulatory documents for doing business:

Equipment

Paving slabs are made by two different methods:

vibrocompression,
vibrocasting.

Depending on which method is chosen, the purchase of various production equipment will be required.

For the manufacture of tiles using vibropressing technology, you will need:

Vibropress (its cost is about 20 thousand dollars)
Concrete mixer (approximately $6,000)
Punch (about 3 thousand dollars)

Equipment for manufacturing by vibrocasting is much less expensive. The list will include the following items:

Vibrating table (about 4 thousand dollars)
Molds (about $1-18 each)
Concrete mixer (about $600)

Other types of equipment that will be needed for the production process:

– hyperpress (makes it possible to obtain large volumes of products under high pressure;
– conveyors for moving materials;
- dispensers;
– cement silos for cement storage;
– control panel for automation of dosing, weighing and solution supply;
— cleavers for splitting concrete products;
- shelving. It is better to choose steel racks that have high strength.

You can buy ready production line. It will cost more than buying individual pieces of equipment, but will greatly simplify the manufacturing process.

Technology business plan for the production of paving slabs

When developing a business plan for the production of tiles, you need to consider technological features this process. First of all, you need to familiarize yourself with the scheme of the vibrocompression method. This technology is also used in the manufacture of borders, wall and partition stones.

Production steps include:

Concrete preparation. First of all, you need a concrete mixer. In this case, the number of layers should be taken into account (if there are two of them, two concrete mixers are needed). The finished molding sand is placed in the vibropress matrix (mould).
molding. Then the punch and vibrators are started, as a result, the reaction of vibration impulses occurs, and the material is gradually compacted. Next, the product is sent to dry in a pallet.
Drying. To bring the tile to its finished form, heat-moist drying is used, for which water vapor is used. If you want to reduce production costs, you can dry the product directly in the room, without using the heat-moist method of drying.

The production of paving slabs using the vibrocasting method is as follows:

Prepare the mixture.
Concrete is placed in molds on a vibrating table.
The finished forms are laid out on a pallet.
The resulting mixture is left for 48 hours.
The hardened form is subjected to heating, then the product is knocked out.

Making tiles requires a sufficient number of molds. They can be rubber, plastic or polyurethane. Because the production technology may differ significantly depending on the choice of material, it is worth familiarizing yourself with the essential features and differences of each of them in advance.

Pproduction and organizational features tile manufacturing - below:

Selection and preparation of production premises

There are no special requirements and restrictions on the location of the workshop. The main thing is the size of the area, which should allow you to place all the equipment, as well as compliance with all specifications. Geographically, the workshop can be located on the outskirts of the city, in the industrial zone or outside the settlement. It is desirable that a highway or a major road adjoin it, which will facilitate the delivery process.

For the equipment of the workshop, it is best to rent a former production facility - there is usually everything initially the necessary conditions, including electricity of sufficient capacity, provision of water and other necessary communications.

Most suitable size- from 70 sq. meters or more. To operate the equipment, you will need an uninterrupted electrical voltage of 360 V or more. special conditions requires a drying chamber - it needs to maintain the desired temperature within 45 degrees.

When renting a workshop, you should pay attention to the presence of a large and dry warehouse, a heated office for communication with customers and partners, as well as the work of management and administrative staff. For these purposes, it is necessary to have a telephone connection and the Internet. In a timely manner, you should take care of the equipment of utility rooms and a bathroom for official use.

Staff

If the production volume does not exceed 50 sq. meters of finished tiles per day, there is no need for a large number of personnel. In such cases, a team of three people will be sufficient, who will deal with the process of direct concrete preparation, pressing and sending the batch to dry. To service large-scale production, a larger staff will be needed.

At first, while the workshop will produce a small amount of products, the manager himself can perform the role of sales manager and accountant. With the expansion of production, there will be an increase in the customer base, which will require a separate employee with experience in sales to work with. Accounting will become more complex as the enterprise develops. Therefore, within the first year, you will need a full-time specialist in the field of accounting and tax reporting. In the first months of the company's operation, these services can be provided by outsourcing specialists.

The staff will also need support staff - loaders, a security guard, a cleaning lady.

Sales of finished products

An important step will be the sale of products. To acquire a wide and stable customer base, you should provide them with the entire range of tiles produced. Right Action will be the establishment of production in such a way that the assortment includes a variety of products that satisfy the needs of all groups of potential buyers. At first, you should not take on large orders, it is better to firmly consolidate your position among small firms or individuals.

With the development of production, it makes sense to conclude long-term contracts with large enterprises who purchase large volumes of paving slabs for construction, repair work or further sale. The specifics of the marketing campaign and the choice of advertising methods depend on what the potential buyer will be like.

Marketing plan and advertising

The overall structure of the global and national markets suffered negative changes during the crisis years of 2013-2014. At this time, there was a decrease in sales, and hence the production of all types of construction and finishing materials. At the same time, the crisis also had a certain stimulating effect on the industry: the struggle for a client between market representatives intensified, as a result, the quality of products of surviving enterprises improved.

In order to freely enter the market, in which there is no shortage of tile manufacturing enterprises, it is necessary not only to offer the buyer a quality product at an attractive price, but also to attract attention. To do this, you need to immediately prioritize and decide on your target audience. So, you can focus on the sale of finished products retail customers Or stop at wholesale. In the first case, the cost of implementation will be higher, but you will have to spend more time and money on advertising and attracting customers. Choosing as a priority wholesale, at the first stage it is enough to conclude long-term contracts with several large buyers.

One of the features of the sale of paving slabs is the presence of concentrated consumer market. This means that it is usually easier and more profitable to sell products within your region. Therefore, and advertising campaign will be aimed at a limited circle of target audience.

Taking into account the already known features of the market, it is possible to determine the most accurate circle of the target audience. Main categories of buyers:

— construction organizations fulfilling the order municipal authorities;
— construction companies working privately;
- individuals or organizations purchasing tiles for personal use.

One of the trends in this industry is a slight but steady increase in demand from private buyers by 10-15% annually. But in order to keep and increase this indicator, you need to resort to the main working methods of advertising:

– dissemination of information via the Internet: your own website is required detailed information and feedback. In addition, you need to advertise your products on thematic sites and forums, online bulletin boards;

Timely placement of advertising will play a very important role. Since the peak of construction and repair work occurs in spring and autumn, the main emphasis on promotional activities should be done just before the onset of this time.

The participation of the enterprise in thematic events - specialized exhibitions and fairs will be effective. There you can present samples of your products, exchange contacts with potential buyers and partners, and study the structure and dynamics of the market.

Financial plan

There are several main cost items necessary for opening and further development of the company:

Initial investment:

Start-up and adjustment works - 110,000.00 rubles.
APN - 540,000.00 rubles.
Press D2430 - 470,000.00 rubles.
Concrete mixer SBR-500 - RUB 69,000.00
Mold PP TR - RUB 210,000.00
Scales MK-15.2 - 4,200.00 rubles.

Total: RUB 1,403,200.00

2) Wages. Calculation for a minimum staff of 3 people:

manager (salary from 25 thousand rubles),
APN operator (salary from 25 thousand rubles)
auxiliary worker (salary 20 thousand rubles)

Thus, the wage fund should be at least 70 thousand rubles (for one shift per month; 140 thousand rubles for two shifts). With the development of enterprise size wages should be increased in order to retain skilled workers.

When paying the unified social tax (UST) - 26% of the total income.

Production area

It is desirable to allocate about 100 sq.m. space to accommodate the right equipment and create a storage area for materials and products. The warehouse can be located outdoors, but also requires at least 100 sq.m. Heating in industrial premises- not a mandatory requirement for working conditions. If the rent for 1 sq. m. is 100 rubles, then the total cost of renting the entire premises should not exceed 10,000 rubles. The cost of rent per 1 sq. m. products. It will amount to 2.38 rubles.

4) The cost of materials and energy carriers. The total cost of raw materials, which includes polymer, sand and pigment, for 1 ton will be 3794 rubles. This means that the cost of raw materials per 1 sq.m. finished tiles is equal to 136.58 rubles.

The cost of 1 square. m. paving slabs:

The profitability of this type of business proper organization exceeds 100 percent. This is facilitated by the fact that even defective products can be used (for example, in construction), so the unprofitability will be minimal.

A detailed cost plan for opening an enterprise for the production of paving slabs will include the following items:

Item of expenses	Monthly expenses	Yearly expenses	One-time costs	Total expenses for the year
Buying a concrete mixer			127400	127400
Vibrating tables (pouring, stripping)			90000	90000
Forms			33600	33600
Transformer			61600	61600
Pallet truck			20160	20160
Loader / overhead crane			3800000	3800000
Baths (for washing forms, for stripping forms)			22400	22400
Wheelbarrows, trowels, shovels and other equipment			28000	28000
Production technology, technology training			61600	61600
The cost of raw materials (per 2 thousand km. Tiles)	100000	1200000		1200000
Salary	250250	3003000		3003000
Website development, promotion	55000	660000	110000	110000
Wiring			214200	214200
Unexpected expenses			456800	456800
Total	405250	4863000	5025086	5073626

Regardless of the chosen business format, the financial year for any enterprise begins in January. From this month, the necessary tax payments. The list and tax rates of the main contributions to the Federal Tax Service are standard and include the following:

In order to calculate the amount of income of the enterprise, in addition to the cost price, it is necessary to analyze the current market prices for finished products. The price list will be based on the average prices of the relevant market segment and the amount of production costs.

The average cost of paving slabs, in rubles per sq. meter:

Traditionally, the cheapest will be gray tiles, the most valuable and expensive - white, produced without the use of dye. The better the materials used in production, the more expensive will be the cost, and hence the price of the finished product.

The company's sales forecast will be determined based on the following criteria:

— the results of the analysis of consumer demand for paving slabs;

— market analysis data for tile manufacturing enterprises;

— general conclusions regarding the state of the market for the sale of paving slabs.

The calculations take into account the lowest threshold of profitability. The plan necessarily considers all existing risks in the industry. These primarily include a high level of competition and a significant barrier to entry into the market. So, in order to open production, significant initial investments are needed for the purchase of equipment and raw materials. At the same time, without a quality marketing policy, it is impossible to fully enter the market and take a strong and advantageous position in it.

Taking into account the main stages of the creation and development of the enterprise, a plan for the provision of services is drawn up:

Period	Type of service	The volume of the provided service per month	price, rub.	Sales proceeds, thousand rubles
1 – 6 months of investment		2000 sq.m	500 - 540 per sq.m	1000 - 1100 thousand rubles
1 – 6 months of investment		2000 sq.m	From 560 per sq.m	From 1120 thousand rubles.
	Production of paving slabs	2000 sq.m	540 sq.m	1000 - 1100 thousand rubles
7 – 12 month of operation	Tiling and related work	2000 sq.m	From 580 per sq.m	From 1150 thousand rubles.

At the moment, the market growth rate is at the level of 10-15 percent. If this level continues, over the next 1-2 years, the growth in sales volumes will reach 26.7 million per year and more. The main condition that will help overcome the entry barrier is to provide the enterprise with modern and high-quality equipment. The second important advantage of the tile production workshop will be the selection of qualified personnel. Accelerate the process of business promotion active marketing campaign and well-designed advertising plan.

The paving slab manufacturing business plan includes average cost calculations and a rough profit forecast for the production shop. Specific financial indicators may differ under the influence of objective and subjective factors, the effects of risks and changes in the market. Taking into account the high level of demand for paving slabs among individuals and enterprises, the following conclusion can be drawn: with a good preparation of the material base and a thorough study of the sales market, a tile manufacturing workshop will be a profitable and promising undertaking.

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