Equipment for the production of foam rubber. Foam rubber production technology as a business: organization of production, legal aspects, equipment and personnel. Sales of manufactured products

20.11.2019

The business idea is to organize the production of foam rubber to meet the needs of the furniture market, manufacturers of soft toys, sports and other goods.

Foam rubber (polyurethane foam) - is an elastic elastic material made of polyurethane foam, the volume of which consists of 9/10 air cells.

Where is foam used?

furniture (and even in),
Stuffed Toys,
car seats,
(sponges, rags).

Soft tissue production in Russia is growing annually, the growth rate is at least 7-10%, according to preliminary forecasts, the market growth in 2012 will be at least 7% in value terms. According to analysts' forecasts, sales of upholstered furniture by 2015 will increase by 4 times compared to 2010.

The growth of the upholstered furniture market leads to an increase in demand for expendable materials used in production.

For it is sold in the form of foam rubber crumbs:

One of the main materials used in the manufacture of upholstered furniture is foam rubber ( PPU).

There are two main technologies for the production of polyurethane foam:

continuous method
periodic method.

Small enterprises use the periodic foam rubber production method, as it is simple, the costs are negligible, the production process does not require special education, it is enough to go through the training offered when purchasing the equipment.o

Required equipment

The minimum composition is as follows:

foaming machine
thermal camera
Material cutting machine
Dosing equipment
Pumps, hoses, couplings, etc.
Form block

To organize a full-fledged year-round production with maximum productivity, you need to purchase the following optional equipment:

Waste crusher
Rolling and wrapping machine.

All of the above equipment can be purchased both individually and as part of a turnkey production line.

The cost of a minimum set of equipment with a capacity of 10-12 cubic meters finished products per shift will be about 300,000 rubles, a semi-automatic line, which includes all the necessary equipment for the production of various grades of foam rubber, with a capacity of 20-30 cubic meters per shift, will cost 1.3 million rubles.

If we consider the purchase of a line in China, then for 1.6-1.8 million rubles, you can purchase a mini-plant with a capacity of at least 50 cubic meters per shift.

Feasibility study of activities

Organizational form ownership: Sole proprietor (learn)
Taxation system: Simplified tax regime, taxable base "income minus expenses", 15%.
Production shop: rent, 200 sq.m.
Main buyers: Organizations and individual entrepreneurs engaged in the manufacture of upholstered furniture.
Form of payment: When drawing up a contract for the supply of products over 100,000 rubles, payment is only by bank transfer, in case of shipment of products for a smaller amount, payment is possible in cash. Postponement of payment for shipped products no more than 30 days-60 days. Postponement is possible only when working with verified buyers and when buying more than 100,000 rubles.
Banking services: To work with suppliers and buyers, the company has a . To cover cash gaps resulting from shipments of products with deferred payment, a loan product in the form of 300,000 rubles was issued in the servicing bank.
Features of doing business: The activities of the foam rubber production shop are directly related to the volume of sales of upholstered furniture. The peak of revenue falls on the period from September to December and February - April, as during this period the maximum sales of upholstered furniture are observed. During the period from May to August, there is a seasonal decline in revenue. January is the best time to practice. maintenance equipment, so there are practically no orders this month.
Number of staff 7 people
Working hours: 8 hours per shift, 23 shifts per month.
Number of teams: 1

Capital expenditures

total amount capital costs for organizing the production of foam rubber will be approximately 2,530,000 rubles. Cost structure:

Calculation of the profitability of the enterprise

* Revenue

The average monthly revenue is calculated based on the equipment load by 50%. Subject to the production of foam rubber with a width of 20 mm and a density of 25 kg / m3, the wholesale price for 1 sheet is 200 rubles (retail price for a sheet is 250-270 rubles).

** Cost price

The cost of manufacturing 1 sheet includes the cost of raw materials and electricity:

The return on investment in the organization of the production of foam rubber is 12 months.

planning to start own business in the field of production, it is better to give preference to the production of products that are in high demand, independent of the season and the economic situation in the country. One of such solutions is the production of foam rubber (elastic polyurethane foam, PPU) in Russia. Of course, this area (as well as) requires large investments, but with a competent approach, all costs will pay for themselves very quickly.

Production of foam rubber in Russia

Today, the manufacture of foam rubber in Russia is going through hard times. Almost all raw materials, apart from oil and gas, are purchased abroad. The same applies to foam rubber, because domestic volumes of its production cannot fully satisfy the existing demand.

In this regard, the question arises: why not increase the production of polyurethane foam in Russia? After all, with the existing demand for foam rubber, its production will bring very tangible benefits to the manufacturer, especially since the quality of Russian products is in no way inferior to imported ones, and transportation costs are commensurately lower, which allows domestic manufacturers to offer their goods at more attractive prices.

Strengths and weaknesses of the business

Foam rubber has been used both for domestic and industrial purposes for many decades. Despite the fact that today the market is replete with modern materials with similar characteristics, flexible polyurethane foam is still very popular among wholesale customers. This is precisely the main advantage for the entrepreneur.

The production and sale of polyurethane foam in Russia is still very poorly developed, which gives novice businessmen a high chance of an early payback. If you enter the market with a quality product, you can bypass any competitors.

The main difficulty in business is the equipment of the premises. The production of flexible polyurethane foam is a hazardous process, and therefore all workshops must be equipped with powerful ventilation, which, in turn, implies significant costs. You will need permission from the supervisory authorities to conduct business. An entrepreneur must strictly observe working conditions, control the amount of harmful emissions into the atmosphere, and also be prepared for constant inspections by fire authorities, environmental inspectorates and sanitary services.

Advice: the best time to start production - early spring (from March to April). It was at this time that furniture factories began to actively purchase raw materials, which means that it would be much easier to find buyers for their products.

What industries does foam rubber cover?

PPU is a reliable softening and supporting material used for thermal insulation and giving elasticity to things. The main niche for the sale of polyurethane foam is occupied by the following industries:

enterprises producing fragile and mechanically affected products that need a soft lining to prevent their deformation and breaking;
furniture firms using foam rubber for stuffing armchairs, sofas, etc.;
construction companies that use polyurethane foam for heat, vibration and sound insulation.

To potential buyers, purchasing relatively small amounts of foam rubber, include:

shoe manufacturers using this material in the manufacture of insoles;
enterprises producing audio equipment - for the manufacture of headphones and audio speakers;
building materials stores.

opening own production foam rubber in Russia, it is necessary to correlate the planned volume of manufactured products with the actual expected volume of its sales. At the same time, close proximity should be taken into account. potential clients. If the plans are to supply material outside the region, then first you need to assess the competitiveness of the final cost of the transported foam rubber, taking into account the costs of its delivery.

Production technology

The manufacture of foam rubber is considered an environmentally hazardous, and sometimes harmful to health, production. After all, this process uses polyol, aromatic isocyanates, some types of catalysts and foam stabilizers.

Some of these "ingredients" are toxic when evaporated, but when in contact with water and air, they decompose into non-hazardous substances. It is for this reason that the production workshop must have running water and good ventilation, and the working staff must have respirators.

The technology for the production of polyurethane foam depends on the method - batch and continuous. The first option is most often applicable to small (up to 500 tons/year) and medium-sized (500-2000 tons/year) enterprises. The continuous method is suitable for large enterprises engaged in the production of large volumes (over 2000 tons / year).

The "averaged" production scheme is as follows:

acceptance and accurate dosing of raw materials;
mixing "ingredients" and their subsequent foaming;
pouring the solution into special block molds with folding walls;
exposure of foam rubber (up to ¼ hour), in which, as a result of a chemical reaction, the mixture rises to the upper edges of the mold;
block cooling;
cutting foam rubber into sheets of the desired geometry (after three days);
warehousing.

During the production of polyurethane foam, waste is generated. They can be put on sale, or you can organize the production of recycled foam rubber. This technology consists in foaming foam rubber crumbs and scraps with special glue and in their further crimping. The finished material is characterized by increased strength, service life and sound insulation. Acoustic foam rubber and mats for gyms are made in a similar way.

Technical equipment

The manufacture of foam rubber, as well as, requires sophisticated technical equipment. The purchase of equipment is considered the most expensive item in the budget. To start the workshop, you need to purchase the following machines:

dosing equipment;
foaming machine;
thermal camera;
forms for solidification of the mass;
cutting machine;
plant for grinding waste;
packing machine.

It is very difficult to independently assemble a line consisting of individual machines. Therefore, it is easier for novice businessmen to buy a ready-to-work line. The cost will depend on the power of the machines. can be equipped with a low capacity line capable of producing up to 12 cm³ of material per shift. This equipment will cost the entrepreneur 400,000 rubles. If you buy machines of greater power (up to 50 m³), you will have to spend at least 2,000,000 rubles. To the above costs, it is also worth adding the services of a commissioning wizard for the purchased equipment. Of course, you can set up the production line on your own, but for this you need to be well versed in the specifics of its work.

If the starting capital is limited, then you can save money by buying a used line. The cost of used devices is much lower. And if you can find a reliable seller, then such equipment will last a very long time.

Workshop room

Foam rubber factories are best located in vacant premises on the outskirts of the city. Firstly, the rent here is much lower, and secondly, the requirements for environmental safety are more loyal. All these factors only play into the hands of a businessman.

The main requirements regarding industrial premises are reduced to only two criteria:

ceiling height - it should be at least three meters;
maintaining the air temperature at 18°C (not less!). If in the shop for pouring the foamed mass into molds it falls below this limit, then the production of foam rubber will be impossible due to the lack of the necessary chemical reaction.

The working area of the premises itself should be at least 200-250 m², taking into account the household room for workers and a small office for a technologist. The operation of the ventilation system must always be in good working order and be in the active phase. You will also need a 380 volt electrical wiring with grounding. To install band saws, you will need to build a small foundation.

For ease of transportation, it is necessary to provide for the presence of an adjacent territory. The larger it is, the higher the loading speed and better job transport in general. Access roads must be equipped with special symbols - both drivers and staff will be easier to navigate in their work.

Staff

No more than ten employees will be required to start the production workshop. First of all, a chief technologist is needed, preferably a person with the education of a chemical technologist. At worst, one who has undergone specialized training and practice.

Five workers are enough to service the production line: three people for the casting machine and two for the cutting machine. Also, you can not do without the help of several handymen. Their duties will include loading and unloading of raw materials and finished products. The presence of special education and qualifications for this category of workers is not required.

Development prospects

The production of flexible polyurethane foam has its own prospects, which are primarily associated with the manufacture of molded products. Similar products are used in the manufacture of car seats and expensive furniture. It is also possible to establish additional production of household sponges, washcloths, rugs, fillers for children's toys, etc. without significant costs.

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With successfully established sales channels, in a year (and if you're lucky, a little earlier), the company will begin to make a profit. It is best to look for clients among furniture manufacturers, it is they who provide high demand and special profitability of this business idea. If things go uphill, then after a while it will be possible to think about.

In contact with

The exact name of foam rubber is "elastic polyurethane foam". It received its name at the time Soviet Union when it was produced by the foreign company Porolon. Foam rubber is a soft substance consisting of air cells. It serves as a softening and shaping material.

Application area

Foam rubber is used as:

insulating material for heat and noise insulation;
shock-absorbing filler;
packaging material for fragile goods;
stuffings in the manufacture of upholstered furniture;
material for the production of household goods (various sponges, mops); sports equipment and equipment (simulators, pears, helmets, gloves, bandages, etc.);
filler for soft toys.

Currently, foam rubber manufacturers in Russia are quite in demand. Taking into account the wide use of this material and the growth trends in its consumption, it is necessary to consider the direction of the business for the manufacture of these products. Today, the domestic production of foam rubber cannot fully cover the needs of the market, so it is imported from other countries.

The volume of this material, even with a small mass, is large, which can adversely affect the final cost of the product after transportation. In this state of affairs, it is necessary to open our own factories for the production of these products in our country and expect high profitability from them.

The main feature of foam rubber production technology

Let's consider this issue in more detail. The production of foam rubber is associated with harm to human health, because this process occurs using a polyol and aromatic diisocyanates such as toluene diisocyanate or diphenylmethane diisocyanate, as well as foam stabilizers and catalysts.

Many of the components that are used in the manufacture of this material are toxic when evaporated, but when decomposed by air and moisture, they become safe. All this requires equipping production workshops with good ventilation and plumbing, and providing working personnel with respirators and goggles.

The most popular is the use of technology for the manufacture of this material on polyesters, based on a six-component system. The base mixture for making foam rubber includes:

main components (isocyanate and polyester components);
modifying additives (catalysts, surfactants);
water.

Material manufacturing sequence

Foam rubber is produced in this way:

A certain dose of the required mixture of liquid chemicals is placed in the mixer.
A special machine foams and quickly mixes it. This mixing mode largely depends on quality characteristics production of foam rubber: its density, compressive and rupture stress, deformation under loads.
The resulting mixture is poured into special mobile molds. They must be with folding walls. Here, a characteristic foam is formed, rising to the edges of the mold.
The workpiece is kept for the allotted time (about 15–20 minutes).
Then the form is disassembled, and the block itself is transported to the final formation room. Here the process of cooling the obtained products is carried out.
After 1-3 days, the blocks are cut into sheets with a thickness of 5 to 150 mm on special horizontal band saws.

Foam rubber production methods differ in their characteristics. For example, in a continuous process, mixed reagents are poured not into special molds, but into a moving conveyor, where the foaming process is already taking place. There, solid layers of foam rubber are cut into blocks of a certain length, and after exposure they are already divided into sheets of the required thickness.

In the production of this material, waste is inevitably obtained in the form of small pieces that cannot be sold. These elements go through a recycling process, and recycled foam is obtained, which is successfully used in the manufacture of furniture, for example, to fill the armrests of chairs.

Methods for the manufacture of this material

The production of foam rubber can be carried out in two ways: this is a batch method, which is used for small and medium volume production of the specified material, and a continuous method, used for the production of large volumes of products. Let's consider them in more detail.

continuous method. At this method a certain amount of components is fed into the flow mixing head by a filling machine, from there the resulting mixture is poured onto a moving conveyor, where already liquid foam rubber foams. Next, the layers of material are cut into blocks of the required length. Then they are kept for 3 days, as a result of which they are cooled. At this stage, all chemical reactions are completed. After that, the blocks are cut into finished sheets of the specified material of the desired thickness. This technology gives foam rubber High Quality, but its use will require large production areas and the investment of large sums of money. However, with the right approach, it can produce up to two thousand tons of this material per year. A small amount of foam rubber is more profitable to produce using the technology of another method described below.

Periodic method. In this case, the production of foam rubber includes such processes. First, a mixture of liquid chemicals to obtain a block of the specified material is dosed in a mixer of the required volume. Then it is quickly mixed in a special machine for foaming. After that, it is poured into a mold, in which the walls open. Inside this container, a chemical reaction of foam formation takes place. The resulting block of foam rubber is aged for some time in the form. Then it is taken out and moved to special place, in which it is aged until fully cooked. A day later, the foam rubber block is cut into pieces of the desired thickness on special machines. After that, the resulting material is ready for implementation.

Using this technology, elastic foam rubber is obtained, which is mainly used for the production of upholstered furniture. Said process is economical in terms of equipment costs and does not require large areas for said operation.

Today, the manufacture of this material allows you to get different grades that differ in their physical and mechanical properties, color and other features, such as super-softness, fire resistance, high rigidity and others.

Necessary equipment for the production of foam rubber

The required line for the manufacture of these products must be equipped with:

foaming machine;
form for solidification;
band saw machine;
pumping equipment;
conveyor;
various equipment for measuring the volume of products and weighing it.

After some time, to increase the volume of products produced, it may be necessary to have a thermal chamber, as well as a set of dosing devices and belt-type machines.

Production of packaging foam

As already mentioned, the production of this material entails the appearance of scraps, deformed small pieces. There is a technology for the secondary foaming of these residues. As a result, high quality foam rubber is obtained, which is necessary for packaging goods during transportation.

He is also important material. Packaging foam is needed to protect fragile and mechanically broken goods, such as a variety of electronics, GPS navigators and others that need a soft pad to protect them from breaking.

Requirements for the premises when organizing this production

Most experts agree that the optimal area for the start of production can be 200-250 m 2 (this should include offices and utility rooms). The optimal ceiling height is about 3 meters, there must be good ventilation and water supply, because during the production of foam rubber substances toxic to humans are released into the air.

One more important requirement- constant observance of the temperature regime in the room. The temperature of the zone in which the blocks are poured must be constant - 18 degrees Celsius. At a lower temperature, the manufacturing process is technically impossible. Next, you need to select equipment for the production of foam rubber.

Required personnel

For the production cycle it is necessary to hire:

a chemist-technologist with skills in this field of activity. He must know the foam rubber production technology;
2-3 workers in the pouring shop;
2-3 people for loading / unloading finished products.

Prospects for this business

The cost of equipment for the production of foam rubber is calculated as follows: a low-power finished line will cost about 500-600 thousand rubles. Its installation and training of workers will require another 150-200 thousand rubles. Plus, it is supposed to pay the rent of the premises and the payment of salaries to the existing staff. This amount will vary depending on the region in which this business is organized, within 500-700 thousand rubles.

If you successfully establish sales of products, then in a year or a few less enterprise can start making a profit. In this case, it will be profitable to sell and supply foam rubber for furniture.

This is important when starting a business. In other words, potential customers and buyers must be sought in workshops and enterprises that manufacture furniture. They are more in need of this material. Here foam rubber for furniture is in high demand.

Among the promising areas entrepreneurial activity The production of foam rubber, recently, has been of stable interest to novice businessmen, as well as their more experienced colleagues. This trend is explained very simply: domestic enterprises operating in this industry are not able to satisfy the steadily growing demand for foam rubber, and buying these products abroad, firstly, is very expensive (especially after the growth of the dollar), and secondly, normal trade is hampered by political instability in relations with supplier countries.

Therefore, domestic businessmen need to take advantage of the current situation and actively organize enterprises that will produce foam rubber, and this article will be a great help in this difficult task. The reader will be able to study not only the technical nuances production process, but also learns what is needed to draw up a business plan, what legal form is suitable for this activity, how to start a business, and what start-up capital is needed to open a foam rubber manufacturing company.

Production of foam rubber - advantages and disadvantages

Despite the development modern technologies and a huge number of discoveries in the field of inorganic chemistry, foam rubber continues to be in demand, as in the 40-50s of the last century. Elastic, soft, but strong enough material is indispensable for clothing and furniture production. In addition, excellent children's toys are made from it, and it is also used as a packaging material for fragile products and in enterprises for the production of modern computer technology. In everyday life, foam rubber, like 50 years ago, is an indispensable thing. In short, the demand for this material in our country will be stable and high for at least the next ten years.

Let's move on to the disadvantages of this material. Its production harms the health of the company's employees and the environment. You will have to buy powerful fans, obtain the appropriate permits from regulatory authorities, and also allocate money for measures to reduce the negative impact on the environment. Get ready for constant "courtesy calls" from fire inspectors, as well as representatives of sanitary and environmental services. In addition, equipment for the production of foam rubber is not cheap, which means that a large start-up capital is needed to open an enterprise.

Legal aspects

Today, even schoolchildren know that in order to open their own business, it is necessary to register a company in tax office and special funds. For the production of synthetic materials, LLC is best suited. Registration legal entity will cost more than paperwork for an individual entrepreneur, but this will help you get all the necessary permits faster, suppliers of specific raw materials often refuse to work with individual entrepreneurs, and many large buyers of foam rubber sign cooperation agreements only with legal entities.

There are exceptions when you can limit yourself to registering an IP. For example, you create your business specifically for the work of several large companies(2-3 furniture factories). In this case, even before the start of your activity, you have preliminary agreements, you know exactly how many materials you need to produce, and the buyers agree to cooperate with the individual entrepreneur.

Full package required documents(permissions fire inspection, ecologists, SES, certificates for finished products, etc.) You will receive only after preparing the premises and concluding contracts with suppliers of raw materials. That is, when you have everything ready to start production, you will be able to close all issues related to the execution of permits.

Preparatory stages of production organization

Almost every foam rubber manufacturer in Russia focuses on its own circle of buyers of finished products and does not violate the boundaries of its territory. Before starting production, you must carry out thorough marketing research and determine how much foam rubber you can sell in a certain period of time.

Representatives target audience in this area of activity are:

furniture factories;
construction shops and supermarkets;
companies producing soft toys;
firms that need foam rubber as a packaging material;
manufacturers of audio equipment and footwear.

You need to conduct preliminary negotiations with all enterprises in your region on the specified list and, ideally, agree on cooperation, as well as clarify how much finished products they will buy. This parameter will allow you to draw up the most accurate business plan. Knowing it, you will be able to choose the right equipment, figure out what kind of staff is needed for the production of foam rubber, calculate the cost of production of finished products and the amount of profit.

Premises, equipment and staff

When choosing a room in which the production of foam rubber will be carried out, it is necessary to adhere to the following criteria:

the air temperature in the workshop should be at least 18 degrees;
The optimal area for a small factory is 200-250 sq. m;
ceiling height not less than 3 meters;
it is obligatory to have electrical wiring with a voltage of 380 V and grounding;
there must be a large area for the entrance of trucks.

Entrepreneurs experienced in such matters recommend looking for premises on the outskirts of the city. It is easier to comply with environmental safety standards here, and renting production space costs much less than in areas close to the center.

For the operation of your enterprise, it is necessary to purchase a foaming machine, molds, a belt machine, dosing tanks, automatic machines for grinding raw materials and waste, a thermal chamber and a packaging machine. It is better to buy a ready-made production line, which will be set up and your specialists will be taught how to work on it. It makes sense to look for a company operating under a leasing agreement. This is especially important for businessmen who do not have enough own funds to open a factory. Some entrepreneurs buy used equipment to save money, but it all depends on your personal luck. If you decide to buy used equipment, do it only together with a highly qualified specialist, so as not to buy a lot of scrap metal for a lot of money.

To work at your enterprise, you definitely need a technologist, preferably with the appropriate education, 3-6 workers per workshop, 2-4 handymen and a fitter. With regard to administrative staff, this issue depends on individual factors.

Definitely needed Chief Accountant (good specialist will keep you 2-3 of his salaries), the manager, as well as the manager for working with suppliers and buyers. But if you take part in the work of the enterprise, then the list of administrative personnel may look completely different.

Production technology

Considering the production of foam rubber as a business, it is necessary to pay attention directly technological process. Without this, your knowledge of the production organizer will be incomplete. As mentioned at the beginning of the article, the manufacture of foam rubber is a process that is very harmful to human health, so all workers must have respirators, and fans must be installed in the workshop.

Technologists distinguish two methods for the production of this material: periodic and continuous. The latter is used in large factories, where more than 2 thousand tons of finished products are produced per year, and the former is used in small and medium-sized enterprises. But there are no fundamental differences between these methods, the only question is performance. The process itself is carried out as follows: the necessary reagents in a special mixer enter into a chemical reaction, and then poured into a collapsible form, where the interaction of the ingredients continues. As a result, a block of foam rubber is obtained, which is released from the mold and placed in a prepared room for a couple of days, where the reaction ends and the foam rubber familiar to us is obtained. The final stage- cutting the finished product on a band saw to get sheets of the right size.

Economic indicators

To start the presented business, you need to: register an enterprise, rent a room, make repairs in it if necessary, buy equipment, obtain all necessary permits. This requires an initial capital (we take average figures, focusing on real data) of about 90 thousand dollars.

Monthly expenses necessary for the normal functioning of the company include:

salary of employees, including deductions and taxes - 9 thousand dollars;
raw materials, consumables - 14 thousand dollars;
rent and communal payments- 9 thousand dollars;
taxes and other expenses - 6 thousand dollars.

The total monthly expenses are $38,000. This enterprise has a net profit of about 8 thousand dollars every month, while the calculations include the salary of the manager, which can be received by both the owner of the enterprise and the hired manager. Based on these indicators, we can calculate that in a year, maximum one and a half, all the money invested in the development of the enterprise will return to investors. Summarizing, we can conclude that in modern economic conditions it is quite difficult to find a business such as the production and sale of foam rubber, which allows you to earn big money without fear of competitors or other unforeseen circumstances.

Polyurethane foam, or foam rubber, is a very common material that is successfully used in construction, furniture manufacturing and other areas of life. In order to choose the right equipment for the production of polyurethane foam, it is necessary to figure out what materials are needed for work, what type of product you will be producing.

Classification of the presented product

So, the presented material can be divided into 2 types:

Elastic. This type of material is most often used in the production of sponges, washcloths, furniture upholstery or in the manufacture of shoes.
Hard. The presented type of polyurethane foam is used in construction for insulation of buildings.

It should be noted that foam rubber can also be used when packing fragile items: dishes, electronics.

Material advantages

Before purchasing equipment for the production of polyurethane foam, it is necessary to understand the advantages of the presented product. Among them are the following:

consistently high demand from buyers, especially since their own production capacity they cannot provide the consumer 100%, so your business will quickly pay off;
light weight of the product;
the possibility of manufacturing polyurethane foam of different sizes and stiffness, which will allow you to sell it for completely different purposes;
low cost of the product.

What equipment is needed for work?

Naturally, now you will have to choose equipment for the production of polyurethane foam. Try to buy it at certified points of sale. Of course, the equipment must be of very high quality. Therefore, give preference only to those manufacturers who have already established themselves in the equipment market with positive side. Naturally, try to carefully examine the technical condition of the devices at the time of purchase.

Standard equipment for the production of polyurethane foam includes the following machines:

a machine for foaming the mixture;
a device with which the grinding and mixing of raw materials with all the necessary additives is carried out;
dosing machine;
molding unit;
apparatus for the production of polyurethane foam, which provides cutting the finished product into elements;
device for packaging and storage of material;
a machine that provides shredding of waste in order to launch them into a new production.

The most important apparatus is the foam generator, in which all the necessary components (polyol and isocyanate) are mixed.

In addition, such equipment can be divided into low and high pressure. In the first case, you will not need to spend a large amount of money. In the second, the equipment is equipped with various sensors and automatic control.

What raw materials are needed for work?

Naturally, for the manufacturing process, you will need not only equipment, but also, in fact, the material from which you will make the final product. That is, you will need to purchase such raw materials for the production of polyurethane foam:

liquid polyurethane;
hardeners;
special additives for foaming raw materials;
isocyanate component;
various catalysts;
watera.

In principle, such components are not too hard to find.

Product manufacturing technology

The presented material is produced continuously or periodically. The second method is most suitable for those firms that have just opened and have not yet expanded their capacity. In addition, the periodic production of the product allows you to constantly monitor the market and sell it quickly enough so that it does not stay in stock.

During the manufacture of polyurethane foam, you must be extremely careful, since an extremely dangerous substance is used for the chemical reaction - polyol, as well as some catalysts and foam formers. However, they subsequently decompose and become non-poisonous. Therefore, the final product will not cause any harm to health.

The manufacturing technology of the product itself is very simple. The plant for the production of polyurethane foam is filled with all the necessary ingredients: there the reaction takes place. It should be noted that the initial raw material has a liquid state. Naturally, it is necessary to strictly dose the number of components. After the foam is formed and stays in the mold for some time, it is sent to another block where it is cooled.

Polyurethane foam is cut after 24-72 hours using a special band saw. Then the finished product can be sent to the customer. If necessary, foam rubber can be stored and stored for a long time. That's all the features of the manufacture of polyurethane foam. Good luck!

The domestic market for the production of foam rubber cannot fully satisfy the needs of the population. Most often, this material is purchased abroad. Therefore, the production of foam rubber is a good idea to start your own business. Due to the vast market, convenient transportation, as well as the fact that this business does not require much initial capital, at right choice equipment you will be able to make it successful.

The production of foam rubber is quite harmful, because the fumes that occur during the manufacture of this material can cause significant damage to the human body. They are found in large quantities in environment. However, after that, harmful substances completely decompose into safe chemical elements that do no harm.

Therefore, it is very important that the production is equipped with a modern ventilation system and plumbing. In addition, production shop employees must have respirators and other protective equipment.

The choice of equipment for the production of foam rubber depends on the required capacity and volume of finished products, as well as on the method of manufacturing products, which can be batch or continuous.

To get foam rubber, you need chemical substances mixed in a foaming machine. After that, the finished mixture dries out after a while, and it is cut into sheets of the required thickness.

Necessary equipment

To set up the work of the foam rubber production workshop, you will need the following equipment:

Apparatus for foaming solution.
A machine that dispenses components for the production of foam rubber.
Thermal camera.
Equipment for cutting finished material.
Additional equipment, namely couplings, pumps, hoses, waste crushers, packaging machines and more.

This equipment can be purchased separately, or as a production line, which will include all the necessary elements to organize the work of the production workshop.

However, what should be guided by when purchasing equipment so that the business can generate maximum income?

The choice of equipment depending on its cost

The choice of equipment for the production of foam rubber should primarily be based on the initial capital that you are willing to invest in it, as well as on the required productivity. In addition, you should decide whether you will buy a finished production line or equipment separately. The production line is much more convenient. The fact is that in it all the elements are perfectly matched. Thus, malfunctions occur much less frequently.

In the event that there is no possibility of large investments, it is worth considering purchasing a machine with a capacity of about 10 cubic meters per shift. The line for the production of foam rubber will cost two to three times more, but its capacity is about 25 cubic meters per shift. If the sales of products are well established, then it makes sense to purchase even more powerful equipment, otherwise it will be impractical.

Choosing equipment for a small budget

In the event that your financial capabilities are small, you should take a closer look at non-new domestic machines. You can buy them very cheaply, but you will have to spend a little more to get them back in working condition. Thus, it will be possible to purchase more expensive raw materials for the production of foam rubber so that the quality of the finished product meets all indicators.

If you have the opportunity, it is better to purchase imported equipment. It is more durable and high quality.

Basic equipment for a small production workshop

by the most necessary equipment, without which no production can do, is:

A machine that froths the foam rubber components. This device is the main one in production.
Forms into which raw materials are poured for solidification.
Machine for cutting foam rubber into sheets of required thickness.

Of course, for the normal operation of the production workshop, additional equipment will be required. However, it can be purchased gradually. To start production, the main thing is the presence of the three above-mentioned machines.

Equipment search

The choice of equipment for the production of foam rubber will be more successful if you first consult with the owners of existing industries. If you can do your own research on this subject, then you will definitely avoid the mistakes made by others.

There are several ways to find out this information.

Call your future competitors by introducing yourself as the manager of a company that sells Chinese equipment parts. You will be able to find out which manufacturer's equipment is used in the workshop, and how often it fails.
You can call the sales department and say that you go to buy products. At the same time, ask on what equipment foam rubber is produced. You can come and see for yourself advertising samples to make sure the quality of the products.
Communicate on forums where owners of the foam rubber business discuss their problems with this or that equipment. In addition, in this way, you will be able to understand which production site slows down the production of the product the most. Most often this is the packaging of finished products.

When choosing the direction of the future business, it is better to give preference to the production of those products that are in high consumer demand, regardless of the season and the state of the economy in the country. Here we include the production of foam rubber. Investments in launching an enterprise will be impressive, but with a competent approach, investments will pay off very quickly. Study the issue thoroughly to take into account all the nuances.

How to open a plant for the production of foam rubber in Russia?

Our business valuation:

Starting investments - from 1,000,000 rubles.

Market saturation is low.

The complexity of starting a business is 6/10.

Business Advantages and Disadvantages

Foam rubber (polyurethane foam) is used in everyday life and in production purposes many decades. Despite the appearance on the market of fundamentally new materials with similar properties, foam rubber does not lose its popularity among consumers. This will be the main advantage for a businessman - you can always find wholesale customers!

Foam rubber is a soft, elastic material used in furniture and clothing production. But these areas of application are not limited - the manufacture of soft toys, the transportation of fragile goods.

The production and sale of foam rubber in Russia is not very developed, which gives future entrepreneurs good chances for a quick payback of the project. If you supply quality products to the market, you can beat any competition.

As for the shortcomings, the main one is the difficulty with the equipment of the room. The production of foam rubber is considered harmful, so powerful ventilation equipment must be installed in the workshops, which will entail financial costs. You will need to obtain permission from the regulatory authorities to operate. The enterprise must strictly observe working conditions and control the amount of harmful emissions into the atmosphere - frequent inspections of sanitary, environmental and fire services cannot be avoided.

It is better to start a mini plant in early spring. It was during this period that all furniture factories “activated” - an active purchase of raw materials began. So you will quickly find buyers for your products.

Legal registration of the enterprise

It will take at least 3 months to collect all documents and permits for registration of the enterprise. Much faster, you can arrange everything with the help of a lawyer.

OKVED is suitable for the enterprise to be opened: 24.70 (Production of artificial and synthetic fibers).

It is better to formalize the industrial production of foam rubber in the form of an LLC - it is easier to find buyers of finished products and suppliers of raw materials. You will receive a permit to conduct activities only after the premises are found and prepared, contracts are concluded with suppliers of raw materials, and certificates of quality of finished products are received.

Business premises

Place the production of furniture foam rubber in a free room on the outskirts of the city. Firstly, renting real estate here is cheaper, and secondly, the requirements for environmental safety will not be so high. This will greatly facilitate the process of starting an enterprise.

To organize a production workshop, storage facilities and service rooms will require at least 200 m 2. If a large capacity plant is planned, look for a larger building.

In addition to ensuring that the workshop is well ventilated and that treatment facilities, other requirements are imposed on the found premises:

To accommodate the equipment for the production of foam rubber, the height of the ceilings must be at least 3 m.
The temperature in the shop for pouring the foamed mass into molds is not lower than 18 ˚C.
The presence of electrical wiring for 380 V.

If free space does not allow, the company's office can be located in another place - where it will be convenient for customers to get to. But this is an extra cost for the organization of activities.

foam production technology

Raw materials for foam rubber are polyol and diisocyanates. These substances, if the technology is not followed, can be harmful to the human body. But if good ventilation is provided in the workshop, and only high-quality “ingredients” are processed, there will be no chemical poisoning of personnel and harmful emissions into the atmosphere. The specific ratio of components will depend on the type of foam produced. There are several of them:

Standard (ST). For production, 1 type of polyol is used. The stiffness of the resulting material is determined by its density.
Increased rigidity (EL). In the foam manufacturing process, several types of polyol are used to give the finished product a special rigidity. Ideally, it is this material that should be used in the manufacture of furniture. But because of high price many furniture makers refuse it.
Hard (HL). The manufacturing technology differs little from the previous method. But the final price of the product, due to cheaper raw materials, is much lower.
Highly elastic (HR). The material is made on the basis of special grades of polyol. After the raw materials pass through the equipment, foam rubber blocks are obtained.
Soft (HS). It is a soft, resilient material used to make some types of upholstered furniture and pillows. In this case, components for foam rubber are used, which give the material greater porosity.

There are also special brands of foam rubber, which later go to the manufacture of sponges for washing dishes, self-adhesive insulating strips. There is foam rubber, which has soundproofing properties. Prices for products in this case will be slightly higher.

It is better to immediately agree with suppliers on the wholesale supply of raw materials - this will ensure the uninterrupted operation of production equipment.

The production technology of foam rubber depends on the method - continuous and periodic. To choose the appropriate option, it is necessary to evaluate the planned capacity of the plant, the raw materials used. It is advisable for small enterprises to introduce a periodic method in production. "Averaged" technology system making foam rubber looks like this:

Preparation of raw materials - acceptance, dosing.
Mixing liquid components
Mass foaming.
Bookmarking the mass in special forms with folding walls.
Form cooling.
After 3 days, the foam rubber is cut into sheets of the desired size.

In the process of manufacturing the finished material, waste is generated. They can either be sold to consumers (the same furniture factories, for example), or you can plan the production of recycled foam rubber. The technology involves foaming foam rubber chips and scraps with a special glue, followed by pressing the mass under pressure. Finished products have excellent quality characteristics - increased strength, sound insulation, durability. It is in this way that the production of acoustic foam rubber and mats for gyms is carried out. So you will find more buyers interested in your products.

Foam production. Business idea

Secondary foam rubber is available in several grades - BB-60, BB-80, BB-100, BB-120, BB-140, BB-160. Materials differ in properties and physico-chemical parameters.

Purchase of technological equipment

The simplest line for the production of foam rubber

The foam rubber production line is the most expensive budget item. For the manufacture will require the following machines:

raw material grinding machine,
dosing tanks,
frother,
thermal Camera,
forms,
packing machine,
waste shredder machine.

It is difficult to assemble a line from separate devices. It makes sense for novice entrepreneurs to buy a line that is already ready for work.

The price of equipment for the production of foam rubber will depend on the capacity of the machines. The mini-shop can be equipped with a low-productivity line that produces up to 12 cm 3 of finished products per shift. This will cost 400,000 rubles. But you can buy equipment for foam rubber of greater power (up to 50 m 3) by spending at least 2,000,000 rubles. To the cost of purchasing devices, add the seller's services for their commissioning. All manipulations to set up the line can be done on your own, but you need to know the specifics of its work well.

You can save money by buying used equipment. The price of used machines is much lower. And if you find a reliable seller, the purchased line will last a long time.

Profitability of the planned business

All costs for the foam rubber machine will begin to pay off when contracts are concluded with regular customers of finished products. Depending on what type of material is produced within the walls of the workshop, offer the goods:

furniture factories;
factories of toys and household products;
enterprises producing sports equipment;
mattress factories.

Offering consumers special types of products, such as foam rubber with an adhesive layer, can attract more customers. If this cannot be done at the beginning of the formation of the enterprise, be sure to think about developing the business. It is important to constantly improve production methods.

The payback period depends on the initial costs. If we consider the minimum, then the organization of the workshop will take 1,000,000 rubles. This will include funds to buy a foam rubber cutting machine and other equipment, prepare the premises for work, and formalize the enterprise. You will open a high-performance plant if you have at least 3,000,000 rubles.

We'd love to hear from you!

The domestic market for the production of foam rubber cannot fully satisfy the needs of the population. Most often, this material is purchased abroad. Therefore, the production of foam rubber is a good idea to start your own business. With a vast market, convenient transportation, and the fact that this business does not require a lot of initial capital, with the right choice of equipment, you can make it a success.

foam production technology

The production of foam rubber is quite harmful, because the fumes that occur during the manufacture of this material can cause significant damage to the human body. They are released into the environment in large quantities. However, after that, harmful substances completely decompose into safe chemical elements that do no harm.

To make foam rubber, the necessary chemicals are mixed in a foaming machine. After that, the finished mixture dries out after a while, and it is cut into sheets of the required thickness.

Necessary equipment

To set up the work of the foam rubber production workshop, you will need the following equipment:

Apparatus for foaming solution.
A machine that dispenses components for the production of foam rubber.
Thermal camera.
Equipment for cutting finished material.
Additional equipment, namely couplings, pumps, hoses, waste crushers, packaging machines and more.

This equipment can be purchased separately, or as a production line, which will include all the necessary elements to organize the work of the production workshop.

However, what should be guided by when purchasing equipment so that the business can generate maximum income?

The choice of equipment depending on its cost

Choosing equipment for a small budget

If you have the opportunity, it is better to purchase imported equipment. It is more durable and high quality.

Basic equipment for a small production workshop

The most necessary equipment, without which no production can do, is:

A machine that froths the foam rubber components. This device is the main one in production.
Forms into which raw materials are poured for solidification.
Machine for cutting foam rubber into sheets of required thickness.