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, everything can be done 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 arrange the industrial production of foam rubber in the form of an LLC - it is easier to find buyers finished products and raw material suppliers. 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. The finished product has 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.

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.

Profit, based on data on expenses and income from sales, can be calculated independently. Standard foam rubber for upholstered furniture costs at least 140 rubles per sheet measuring 20/125/2500 mm. The price of a material with improved properties is much higher - up to 500 rubles per sheet. At the same time, the cost of production is at least 30% lower, which will show good profitability in the future.

The production of foam rubber (elastic polyurethane foam) is a technologically simple process. This fact should be considered as a business idea for small investments. The main thing is to adhere to all safety standards in production. In fact, foam can be made in elementary laboratory conditions in a chemistry lesson. Today we all meet with foam rubber every day in its various manifestations. Upholstered furniture is covered with foam rubber, soundproofing is done, doors are insulated, etc. Elastic polyurethane foam (PPU) is found in our kitchen, and in the bathroom, and in the children's room, and in our furniture, and in many other things that a person faces throughout the day. Based on the fact that foam rubber uses in great demand, you should think about its production. Moreover, the price of the minimum configuration of equipment is quite affordable for small businesses.

Equipment for the production of foam rubber

Foam rubber is produced using two production technologies:

1. Continuous production technology.
2. Periodic production technology.

The batch production method of foam rubber is simpler, which is why it is ideal for small business and newbies in the field. At the same time, equipment for the batch method of manufacturing is somewhat cheaper, and this method does not require special training. The equipment can be installed by a company that sells and installs working equipment. The services of such a company usually do not exceed 10% of the cost of the machines themselves. Minimum set of equipment:

1. Foaming apparatus.
2. Thermal camera.
3. Foam cutting machine.
4. Dosing device.
5. Block forms.

Additionally, you can purchase a crushing machine (it will allow production to be waste-free) as well as a packaging machine (for twisting foam sheets into rolls and wrapping them in plastic wrap). The minimum set of equipment can be purchased from $7,000.

Periodic technology in the production of flexible polyurethane foam

The batch production technology is as follows:

1. In a mixing tank of the required volume, a polyurethane foam mixture (water, isocyanate, polyol and other standard components) is poured in a certain amount.
2. Depending on what type and with what characteristics the foam rubber should be obtained, a strict recipe for mixing the components is observed. Although they can be purchased already dosed for each type of flexible polyurethane. Prepared components are slightly more expensive, but greatly simplify preparation before production. Depending on the proportions of the components, during the reaction, cells of distinctive sizes and shapes are formed in the foam rubber. The smaller the cells, but the larger the walls of the cavities, the better it resists loads. For example, furniture elastic polyurethane at break must withstand 270 Newtons. Such high-quality foam rubber will be elastic and quickly restores its shape. On the other hand, it requires more consumables and therefore has a higher cost.
3. The mixture is stirred in special equipment. The mixed mixture is poured into a special block mold. In this block mold, the foaming process takes place. After that, the resulting foam block is kept in shape for some more time. After the allotted time has elapsed, the side walls are opened in the block form and the finished foam block is removed. But, in order to make the foam rubber fully ready, it is moved to a separate room, where it will be kept for at least another day. And only after that, the foam blocks are cut into sheets of the required thickness, which are mainly used in the furniture industry.

This production technology does not require large financial costs for equipment and personnel. That is why it is suitable for small businesses.

Profitability of a business idea

We calculate the profitability using the example of one standard portion of foam rubber produced by a batch production method. To get one block (2000x1000x1100 mm) of the finished product, you need to purchase a six-component portion of raw materials 50 kg (in the kit, all the necessary components are already in exact proportions) = $ 140. After the production process, we get a block of foam rubber at the output, which should be cut into foam rubber sheets (2000x1000x10mm). The retail price of one such sheet is $2. We should get at least 100 sheets (because 2 of them will most likely be defective).

And that $2 x 100 - $140 = $60 profit. With a large production facility, the $7,000 line can produce 10 tons of flexible polyurethane per month.

Properties in quality foam rubber

By itself, the foam rubber is quite dense and light material. It, like all other types of polyurethane foam, has a porous structure and consists mainly of air bubbles (up to 90% by volume).

The main parameters for assessing the quality of foam rubber:

1. Strength of flexible polyurethane foam. At this stage, the level of ultimate strength is checked, which is determined by the level of elongation at break.
2. Elasticity. This indicator directly depends on the rigidity of the elastic foam, the greater the rigidity, the less elasticity. Such a quality item is checked by measuring the height of the "jump" of the ball that falls on the sample.
3. Rigidity. This indicator is checked by compressing the sample of the product by 40% of the total length of the sample. The stiffness depends on the pore size, the larger the size of the balloons, the higher the stiffness.
4. The density level of PPU is measured in kg / cubic meter. And this is the main indicator of quality.
5. Percentage of permanent deformation. This parameter indicates the ability of flexible polyurethane foam to maintain its original performance throughout the entire service life. It is measured by squeezing a polyurethane foam sample for a certain amount of time, and setting the percentage of the original values.
6. Comfortable elastic foam. This parameter distinguishes furniture foam rubber marking HR.

Based on these basic evaluation parameters, it is divided into three main types:

1. Standard (ST).
2. Highly elastic (HR).
3. Rigid polyurethane foam (HL).

In the furniture industry, mainly EPPU with the HR marking is used. With the ST marking, they are also used for the production of furniture, but only for those that will not be subjected to heavy loads.

Sales of manufactured products

Still, the main consumers of flexible polyurethane foam are furniture manufacturers. Therefore, before starting such a business, it is necessary to consider ways to market the products. But do not forget also about the manufacturers of soft toys, household companies (production of various types of sponges), acoustics and many other areas of activity. Elastic polyurethane foam has always been a sold type of consumables, so it will be easy to sell.

Today, we can say with some certainty that the market for the production of foam rubber is quite competitive. Therefore, you should not count on large factories and enterprises as partner-consumers. But if you have small furniture enterprises in your city, you may well compete with large competitors.

Manufacturing Precautions

The elastic polyurethane foam itself is safe for humans, therefore it is allowed to produce upholstered furniture from it. Although the finished foam rubber itself is not hazardous to health and meets all hygiene standards, the process of its production requires strict adherence to industrial precautions. Chemical components in contact with mucous membranes in humans can cause irritation. Isocyanate (mandatory component) has a negative effect on the skin and respiratory tract. Therefore, the operator must wear a respirator, goggles and a protective suit. It is also necessary to equip the production room with supply and exhaust ventilation, which is designed in accordance with safety standards. This will get rid of the bad smell. And all harmful substances decompose under the influence of air into elements that are absolutely safe for humans. It is forbidden to pour non-recycled components into the sewer, as this affects the pollution of the environment. Unrecycled raw materials should be safely disposed of.

Elastic polyurethane foam, better known as foam rubber, has practically no analogues on the market in terms of price and consumer qualities. The material is distinguished by high wear resistance, good elasticity, moisture resistance, tightness, excellent level of noise and heat insulation, safety (does not cause allergies), and long service life.

Production methods

The technology for the production of flexible polyurethane foam is based on the foaming of polymers, during which air cells are formed, which make up 90% of the finished product. There are two ways - block and continuous.

With each of them, the raw material for the production of polyurethane is poured into the mixer, where it foams until the desired volume is obtained. Depending on the mixing modes, foam rubber with different physical properties is obtained.

With a continuous method, the prepared foam at a temperature of 20-21 ° C is fed to a conveyor with high sides, where in the process (5-7 m) it foams up to a height of 1-1.3 m.

The next 25 m of the movement of the tape, the raw material is gaining the necessary physical properties as a result of the polymerization process, 32 m after the start of the conveyor movement, the resulting material can be cut off with a special guillotine. In this way, you can get a long block up to 64 m long.

Then the material is transported to a special workshop, where its final formation takes place at the completion of chemical processes and gradual cooling. The PPU obtained in this way is of higher quality.

Types and areas of use of the material

Depending on the operational purpose, foam rubber is produced according to various technological maps. This allows you to get the following types of foam (in terms of rigidity):

• ST - standard;
• S - soft;
• HR - highly elastic;
• EL - increased rigidity;
• HL - with high bearing capacity;
• HF - acoustic;
• SPG - special purpose (refractory, with memory function and others).

All of these types of foam are used in the production of upholstered furniture. From foam rubber various kinds manufacture mattresses and mats, stuffing for sports equipment, upholstered furniture, car seats.

Foam rubber has also received the widest distribution in the automotive, medical, clothing industries, and construction. Manufacturers of overalls, soft toys, household appliances, recording equipment. Foam rubber is needed by all industries where packaging of fragile products is necessary.

Where to buy foam rubber in Moscow?

The Santeks LLC company is engaged, including to order.

Many years of experience in this field, as well as modern equipment, careful control at all stages of production allows us to guarantee high quality products.

If you are interested in purchasing foam rubber, call us or place an order online. Information on how to obtain goods and prices will be provided to you as quickly as possible. Our consultants will help you choose the type and configuration of foam rubber, we work with both large and small wholesale.

The post has been changed:

How to organize own production foam rubber

Foam rubber (polyurethane foam) is a soft and elastic material that is used in furniture and clothing production, as well as in the manufacture of soft toys and for packaging fragile goods. The production of foam rubber in Russia at the moment is not able to fully satisfy the demand for products, so the niche is considered relatively free, which opens up opportunities for start-up entrepreneurs.

Brief business analysis:
Business setup costs:from 20 thousand dollars
Relevant for cities with a population: without Borders
Situation in the industry:average level of competition
The complexity of organizing a business: 3/5
Payback: 8 - 18 months

Production of foam rubber and its application

Despite the fact that every year the production of foam rubber in Russia increases by an average of 7%, in order to meet the demand of all consumer companies of this material, it has to be imported from abroad. Considering the volume of foam rubber with a relatively low weight, logistics costs often exceed the cost of the material itself. Given these factors, each new mini-factory immediately acquires regular wholesale customers who want to save on components for their products.

Polyurethane foam is widely used in the production of the following products:

• cushioned furniture;
• Kids toys;
• washcloths and sponges for washing dishes;
• clothes;
• car seats;
• Sports Equipment;
• packaging materials.

In addition, during construction and repair, a special soundproof foam rubber is used, which has slightly different properties.

foam production technology

The production of polyurethane foam is considered harmful, so it is better to select a production facility on the outskirts or outside the city - this will help to avoid problems with supervisory authorities and save on rent. In addition, employees must strictly comply with safety rules, using means personal protection such as respirators, goggles and gloves.

Components for making foam rubber

The main components used for the production of polyurethane foam are polyester, isocyanate and water. Polyester and isocyanate are complex chemical compounds, the production of which on their own will entail additional costs for equipment and qualified personnel, therefore it is most advisable for a mini-factory to order raw materials from specialized laboratories.

Methods for the production of polyurethane foam

There are two main ways to produce foam rubber:

• periodic (suitable for mini-factories);
• continuous (characterized by greater productivity).

The process for the production of polyurethane foam in a batch method is relatively simple: the components are mixed in mixers, poured into a mold and, due to the action of water on polyester and isocyanate, within a few minutes the material rises, takes shape and elasticity. The resulting block "reaches" in the form for another 15-20 minutes, then it is removed and transferred to the final formation room, where it stays for at least another day at a lower temperature. After that, the material is considered ready, it is cut into blocks of the desired shape and sent to the buyer.

With the continuous method, the mixture is poured onto the belt and rises during the movement. When the end point of the conveyor is reached, the material is already shaped, cut into blocks and transported to the final shaping room.

The main feature of the production of secondary polyurethane foam is the presence of foam rubber chips among the components. Often the crumb is formed during the production of ordinary foam rubber, and its use helps to create waste-free production and save on raw materials.

A mixture of crumbs and a polyurethane binder is pressed under a certain pressure, and the resulting material has increased rigidity and durability. Due to its technical properties, this material is used as rigid pads in the manufacture of furniture, to protect the top layer of ordinary foam rubber from rapid abrasion and wear.

Acoustic polyurethane foam has the highest density, which provides soundproofing of the premises. Often, foam rubber is used in its production.

Depending on the shape of the final product, there are embossed and non-embossed polyurethane foam. The first is made with "wave" and "pyramid" profiles. The sound absorption coefficient of the material directly depends on the shape and thickness - for example, PPU "pyramid" with a thickness of 70 mm has a coefficient of 0.62.

For industrial production PPU will require the following types of equipment:

• form (for the periodic method);
• conveyor (for continuous method);
• thermal camera;
• foaming machine;
• machine for vertical or horizontal cutting;
• dispenser;
• hoses and pumps.

Beginning entrepreneurs are advised to purchase a ready-made production line, since assembling the entire set on their own is difficult and often more expensive than ordering equipment from one supplier. A finished line for the production of polyurethane foam in a periodic way will cost about 15-17 thousand dollars, with installation - about 20 thousand.

Also of the current additional equipment, it is worth noting a machine for twisting and packing sheets (this will help reduce the volume of products during transportation and, accordingly, reduce costs) and a waste crusher (needed for the production of recycled foam rubber).

Premises and personnel for the organization of production

To organize a mini-factory, a room of 200 square meters is enough. meters. It should be divided into several production workshops, and utility rooms for staff should also be present. The ceiling height must be at least 3 m.

Considering the increased harmfulness of production, it is necessary to ensure high-quality ventilation of the room. It is also necessary to maintain a certain temperature regime - at the time of pouring the working mixture into the mold, the temperature should not fall below + 18 ° C, otherwise this will affect the technical properties of the finished material. For ease of maintaining the temperature, it is recommended to protect the pouring shop from the rest of the premises. Other operations such as curing, cutting and storage can be done at a lower temperature.

For uninterrupted operation of electrical equipment, 380 V electrical wiring with “grounding” is required. For loading finished products, as well as the supply of raw materials, there should be convenient access roads, as well as a turnaround area in front of the building.

To service the equipment and perform other work, 8 workers and a chemical technologist with the appropriate education will be needed. Of these, 5 people are needed to service the machines, pour the mixture and cut the material, and another 2-3 for loading goods and other work.

Profitability and business prospects

The main difficulty in the path of a novice entrepreneur who decides to start the production of polyurethane foam may be the lack of money for equipment. However, if you have 20 thousand dollars, you can already launch a full-fledged production, the profitability of which is 15-20%, taking into account all costs.

The advantage of the business is its versatility - both construction companies and manufacturers of furniture and car seats can become clients of the mini-factory. In addition, almost no additional costs it is possible to organize the production of small finished products: sponges, rugs, window insulation and other household goods with which you can go directly to the market.

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.

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 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:

1. Apparatus for foaming solution.
2. A machine that dispenses components for the production of foam rubber.
3. Thermal camera.
4. Equipment for cutting finished material.
5. 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:

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

Of course, for the normal operation of the production workshop, it will be necessary to optional equipment. 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 issue, then you will definitely not make the mistakes made by others.