Raw materials for the manufacture of foam. What is needed for the production of expanded polystyrene? Calculating the cost of acquiring the equipment necessary for the production

Polyfoam is made of Polystyrene Suspension Foaming Self-extinguishing. Abbreviated PSV-s.

We do not sell raw materials. Here is a list of domestic manufacturers of raw materials for the production of foam:

1. Alfapor alphapor.ru

2. Plastic oaoplastic.ru

3. Angarsk polymer plant azp.ru

Foreign manufacturers:

1. LG Chem (South Korea) lgchem.com

2. Xingda (China) xingda.ch

3. Loyal (China) loyalgroup.com

4. BASF (Germany, South Korea) eps.basf.us

5. Kumho (South Korea) kkpc.com

6. Taitarex (Taiwan) ttc.com.tw

7. Sinopec (China) sinopecgroup.com

Tips for choosing raw materials for the production of foam:

1. In the 90s, SNiPs were amended according to which the use of polystyrene without flame retardant (an additive that prevents burning) was prohibited. Therefore, all raw materials used on the territory of the Russian Federation have the letter "C" at the end of the abbreviation of domestic suppliers: PSV-s. The letter "C" means - self-extinguishing.

Foreign manufacturers of raw materials for the production of polystyrene do not always indicate the presence of flame retardant in the raw materials. Therefore, when buying raw materials for the production of polystyrene foam, check with the supplier if there is a flame retardant in the composition of the raw materials for the production of polystyrene foam. If there is no flame retardant, you will receive flammable polystyrene. If there is a flame retardant, you will receive a non-combustible foam.

2. Each type of raw material for the production of foam has its own purpose. When buying raw materials for the production of polystyrene, be sure to specify: for which brand of polystyrene the raw materials are intended. The raw material from which the PPS-10 foam brand is obtained is not suitable for the production of PPS-45 foam. And vice versa.

3. Raw materials for the production of foam have a guaranteed shelf life of 6 months. Therefore, when buying raw materials for the production of foam, be sure to specify the release date of the batch. If you come across raw materials with an expired shelf life, you will not be able to make high-quality foam. This is especially true for the production of low-weight foam. The more “fresh” raw materials you buy, the easier it will be to get high-quality foam with a low specific gravity.

4. There is no single standard in the world for marking the brand of raw materials for the production of foam. Different manufacturers have different labeling systems. But. All manufacturers have the same measure to indicate the brand of raw materials - this is the diameter of the PSV-s balls and the weight of the foam cube that can be achieved on this raw material.

For example, consider the characteristics of Alfapor raw materials (excellent domestic raw materials, but at the same time the most expensive of domestic ones) and foreign producer King Pearl (also excellent raw materials).

Figure 1. Raw Alfapor. Under item 1 (highlighted in red + arrows) we see the designations of the grades and the size of the granules. Designations are 101, 201, 301, 401, 501. Designations of marks are made only in numbers. The higher the number, the finer the granules. The finer the granules, the higher the density of the foam that can be obtained. Green indicates what density of the foam can be obtained from each density. The weight in kilograms per cubic meter is indicated. At the same time, the domestic manufacturer does NOT indicate how many foams must be produced in order to obtain a light foam. For the production of foam with a weight below 14 kg per cubic meter, as a rule, two foaming is required.

Figure 2. Raw materials King Pearl (Loyal). At this manufacturer of raw materials for polystyrene, the designation of the brands of raw materials is made only in letters. The red arrow and oval indicate the size of the granules. The green arrow and rectangle indicate the weight of the foam, which should be obtained from this type of raw material. Weight is indicated in grams per liter, in contrast to the domestic manufacturer. At the same time, the table shows the brands of raw materials for foam, which are designed for double foaming. They are highlighted with a blue rectangle. The red arrow in the blue rectangle marks the word two - two in English. That is, the first five grades are intended for single foaming, and the subsequent four grades of raw materials for double foaming. At the same time, as you can see, the domestic manufacturer and the foreign manufacturer have one and the same dependence: the lower the diameter of the granules, the higher the density of the resulting foam. And vice versa: the higher the diameter of the granules, the lower the weight of the foam that can be obtained from this brand of raw materials.

Summarizing all of the above, a simple rule can be deduced that you should be guided by when choosing a brand of raw materials: if you want to get foam with a low weight, you need to buy raw materials with a larger diameter of balls. And vice versa, if you want to get high density foam, you need to buy smaller PSV-s balls. Regardless of the supplier, the name (labeling) of the raw material, just ask for a quality certificate or other document that will contain a column with a diameter and weight that should be obtained from this raw material. And how the manufacturer labels the raw materials - only in numbers or only letters - does not matter.

Foam production: 10 material properties + composition + foam classification + labeling + 4 areas of application + 9 stages of production organization + production cycle features + calculation and profit.

Polyfoam first appeared in Germany in the 50s of the twentieth century under the name Styrofoam. Since then, this universal material has gained widespread use in almost all sectors of human activity.

Foam production today is engaged in many companies, because Styrofoam as a heat-insulating product only occupies more than 10% of the market. From the point of view of profitability, it is not worth talking about the feasibility of the production of polystyrene, even despite the competition.

Therefore, in this article we will consider the important stages due to which legal entities can start production of polystyrene foam, increase competitiveness and get their own “piece of cake”.

The properties and composition of the foam

Each manufacturer, before organizing the production process of a particular product, studies its technological features and scope. Let us first consider the properties of the foam.

Polyfoam is characteristic:

Thermal insulation properties, moreover, a high degree. In severe weather conditions, it will prevent freezing of structures.
Environmentally friendly, so some types of material can come into contact with food.
Ease. Due to this, the foam is convenient for laying, assembling buildings, fastening, transporting fragile items.
Soundproof. Polyfoam can act as a protective tool from the wind.
Durability. If properly exploited, the material will last several decades. In addition, the foam does not swell over time, does not lose its shape, does not shift.
Moisture resistance, resistance to weak acids, salts, alkalis.
Fire resistance. Unlike wood, polystyrene does not ignite or smolder. When interacting with fire, it melts.
Temperature "endurance". The production result is not afraid of low temperatures, and the maximum threshold is + 100 ° C.
Intolerance to bacteria, microbiological factors.

However, the foam has some negative factors:

Polystyrene foam products are not protected from the damaging effects of such aggressive technical solutions (their vapors) as acetone, oil products, benzene, ethylene chloride, turpentine.
Some types of styrofoam for construction purposes under specific operating conditions harm humans and other living organisms, as well as buildings, worsening their thermal insulation.
Polyfoam is rarely used in the decoration of facades and is limited in the cladding of residential premises, since toxic substances are nevertheless released, but with the possibility of burning.

As you can see, the advantages prevail over the disadvantages, which leads to high demand for the production of foam. What gives the material such beneficial properties? To give an answer to this question, you need to know its composition.

The plastic mass is mainly composed of gas. The feedstock is vinylbenzene polymerization products. Due to the filling of the main volume with gas, the finished product is significantly lower in density than a polymer substance.

To be precise, only 2% is polystyrene. The remaining 98% is air. The material has a rigid porous structure, odorless, white.

1. Assortment: what kind of polystyrene can be produced and produced?

Now we will deal with the assortment of goods that you will produce. Styropor can be produced in different classes, differing in durability, strength. It all depends on your chosen technology, formulation.

So distinguish press foam and the one whose production is carried out without pressure method.

The second is done at high temperatures so that the granular substances bake. Such a foam we see most often. This is a material that has a spherical structure.

But the press styrofoam lends itself to high temperature, mixes, but in its production it is still necessary to add a foaming solution. This type of foam wins with great strength indicators. It is practical and difficult to break.

Material labeling has its own characteristics. For example, the production of domestic polystyrene entails the mark PS. In the case of non-press production technology, the designation PSB should be put. The maximum density is PSB-S-15. Also on store shelves there are brands with a numerical value: 25, 35, 50.

3 more types of styrofoam are isolated according to the production method:

Polyurethane (PPU) or foam rubber.

It is characterized by: elasticity, porosity. Due to the fact that such material passes air well, it is used in construction and furniture production.

However, smoke when ignited PPU is poisonous. And the sun's rays lead to its yellowing, durability "lame."

The second type of material is polyethylene (PES).

It is also very flexible and is most often used for the protective wrapping of fragile products when moving.

Styrofoam is supplied to retail outlets in sheets of various sizes. Unlike polyurethane material, it is environmentally friendly and has a long service life.

It is also possible to establish the production of polyvinyl chloride foam (PVC).

Its characteristic is not much different from the previous type. PVC does not ignite when not in contact with fire.

But when ignited, this polystyrene is a threat because it releases hydrogen chloride into the environment, which, when combined with the liquid, forms strong hydrochloric acid.

2. Where is the foam used?

Foam production is beneficial for the following industries:

Construction.

Polyfoam has found its application as a finishing, structural material for shaping, performing decorative elements. Often it fills compartments where there is no heating (for example, on small vessels).

Styropor can save on thermal energy, reduce material and time costs for installation and construction. Due to the fact that polystyrene foam boards reduce the thickness of the walls, in parallel with this, the area of \u200b\u200bthe building itself increases.

Foamed polystyrene is the basis of ceiling tiles, baseboards. He established himself well as a heat-insulating material for the floor.

It is noteworthy that when cutting and other work with the polymer, it is not necessary to wear protective clothing, to use special devices, as it does not form dust, does not cause irritation of the skin. However, some safety precautions should be followed. So, working with the material is necessary in well-ventilated workshops.

Fishing, marine.

Polyfoam is used in the manufacture of life jackets, fishing equipment.

Medical.

Styropor serves as an auxiliary substance in the manufacture of pharmacy and medical containers.

From the production of polystyrene, people who use products as packaging get their benefit. It is also necessary as a heat insulator in household appliances.

Polyfoam is also used in the manufacture of metal products, allowing you to form a sample, the shape by which the molding takes place. Styrofoam is also in demand in the manufacture of disposable tableware and children's toys.

Due to the widespread use in various sectors of the economy, environmental safety, good technical characteristics, versatility, low cost, ease of production, the demand for foam increases ¸ and the manufacturing process becomes economically viable.

9 stages of foam production organization

To organize the production of foam, an entrepreneur must follow a certain algorithm. It is carried out in 9 stages.

Market analysis.
Registration IP.
Description of production technology, provision of raw materials.
Equipment selection.
Determination of location.
Recruitment.
Sales organization.
Calculation of cost, estimation of expenses and income, payback.

Let us dwell on each specific stage.

Stage 1. Analysis of the niche.

First you need to give a real assessment of consumer opportunities at the site of the future presence of the foam plant. To do this, market conditions, sales aspects, demand, competition are studied.

These factors will affect the success of the case. If in your region there are many competitive enterprises for the production of foam, and the supply exceeds demand, it is better to abandon the venture.

Potential consumers of styrofoam are usually builders, construction companies. They own 85% of the market. 15% falls on the production of gear, packaging materials, fillers, etc. You must focus on mass consumption. Studying these questions will help you determine the type of trade.

In the case of retail, it will be necessary to supply polystyrene to construction stores, to end consumers. Typically, one outlet orders approximately 30 cubic meters per month. m of foam. The retail type of trade will save you from renting premises for the store, employing sellers and advertising costs.

However, there are also drawbacks:

Wholesale can be carried out directly from the warehouse. For its organization, you need to purchase and install a cash register, allocate some space for the demonstration of product samples.

In this case, your customers will be wholesale customers. Suppose a person wants to insulate the facade of a house with an area of \u200b\u200b150 sq.m. To do this, he will need 25-30 cubic meters. m of material. It is more profitable for him to contact an entrepreneur engaged in the production of polystyrene, and to purchase goods without extra charges. Some legal entities try to combine both types of trade.

When analyzing competitors, consider their presence in a radius of 100-200 km, the quality and types of products they produce, wholesale / retail value. It is important to pay attention to the promotion tools used by competitors: the provision / non-provision of additional services, the effect of discounts, promotions.

Interesting fact ! In Europe, as a building material, polystyrene is very popular. So, in Italy there are 400 enterprises for the production of foam.
In the developed countries of Western Europe, up to 5-7 kg of expanded polystyrene per citizen. Recently, there have been trends towards the production of “black foam” containing graphite filler.

Stage 2. Writing a business plan.

A clear design of the project is the basis for the production of any product. Therefore, you should write a detailed business plan where to reflect the results of research and analysis from the first paragraph.

In addition, you need to highlight the following information in the document:

calculations of the cost, profitability and investment;
description of the development strategy;
estimated production volumes of foam;
argumentation of equipment selection, etc.

A business plan for the production of polystyrene foam products is especially necessary if you do not have your own, and it is planned to attract investors, obtain bank loans, subsidies from the state.

Stage 3. How to register for the legal production of foam?

Before establishing the production of polystyrene, an entrepreneur must legalize it. Even if you intend to engage in production at home, this does not relieve you of this obligation.

Many are registered as individual entrepreneurs and pay a single tax. At the stage of production, making tax contributions in full will be unprofitable. When the company expands, at any time you can re-register the production of foam in the LLC, and then work according to the simplified tax system.

The opening of the IP is accompanied by paperwork and the payment of state duty within 800 rubles. If you will not be able to personally provide the necessary list of documents to the regulatory authorities, you will have to resort to the services of a notary public, who must certify each paper. This takes up to 1.5 thousand rubles.

When submitting an application, a tax system of five currently operating is elected. It is recommended for the production of polystyrene to pay attention to UTII or USN. Thanks to them, accounting is simplified, the tax burden is reduced, because they are intended for small businesses.

After that, you need to determine the type of activity in the OKVED-2 directory, since the selected code is indicated during registration. The production of expanded polystyrene foam corresponds to 25.21.

25.21 - the production of plastic products (pipes, blocks, plates, sheets, profiles, etc.).

Then you can start collecting documents.

You will need:

The documentation is either handed over to the tax office (look for the address here - https://service.nalog.ru/addrno.do) or through the MFC (list of branches here - https: //mfts.rf/mfc/index/regions) After 3-7 days, you will have to come for documents and a sheet of record on the registration of foam production as an IP.

It also follows. Also, the production and marketing of polystyrene is not possible without obtaining permits and coordination with the fire inspectorate, concluding agreements with service organizations that will take out and dispose of waste.

In addition, internal documentation is being prepared:

Stage 4. The production cycle for the production of foam: technology, raw materials.

Polystyrene granules, which belong to the class of plastics, are taken as a raw material for the production of foam. Some order imported, because they are better than domestic. The difference is not only in cost, but also in their chemical parameters.

On average, the price per 1 kg of polystyrene granules is $ 2-3. The average quality granular polystyrene PSV-S costs 60-70 rubles. They resemble beads measuring 0.02-0.35 cm (in diameter). For each type of foam, the corresponding granules are selected.

For example, in the production of PSB-S-50 polystyrene, polystyrene is used under number 1, i.e. the smallest. Production of PSB-S-15 grade involves the use of polystyrene No. 4. The most popular brand is PSB-S-25F.

In order to achieve production of 1 cubic meter. m of foam, you need to have in stock 15-50 kg of raw materials. The consumption rate is determined by the brand of foam. Many try to establish production even at home, because the technology is simple.

Production technology can be described as follows:

Loading granular polystyrene into the pre-foamer tank and steam supply via a steam generator. This will lead to an increase in granules in a volume of 20-50 times and their transformation into balls.
This production process takes 4 minutes. Then the treated polystyrene is discharged from the tank. If the specific gravity of the foam is 12 kg, one procedure is enough.
For lighter products, it is necessary to repeat the task several times, moreover, after aging the granules.

Removing excess moisture by drying.

From below, hot air enters the PSV-S polystyrene, at the same time they lend themselves to shaking. At the end of such actions, the granules through pneumatic transport fall into a special hopper.

4 minutes later you can proceed to the next stage of foam production.

Maturation of foamed raw materials.

Depending on the size of the substances, room temperature, granules are tracked for 4-12 hours.

Molding (sintering).

To do this, the foam is placed in certain forms, then it is exposed to hot steam under high pressure.

The result should be a monolithic structure due to bonding, the acquisition of an adjacent shape, sintering. This production procedure lasts up to 12 minutes.

Sorting and warehousing.

The foam should be recovered after removal from the block form for at least a day. Finished blocks during this time should lose moisture.

Cutting blocks.

At this phase of production, polystyrene is cut using a special machine into a certain plate thickness (2-100 cm). Standard sizes: 100x50, 100x100, 200x100 cm.

Processing of residues (in non-waste production).

The remaining layers of material, allowances at the edges, "crumbs" can be processed and mixed during subsequent production, observing a proportion of 1: 8.

Stage 5. What equipment for the production of foam is necessary to purchase?

To find out what kind of polystyrene is needed, you need to determine the volume of products you are counting on. This indicator is crucial for the selection of technical equipment and affects its cost.

For example, for the production of 20 cubic meters. m of foam during the 8-hour duration of the shift is suitable set of equipment, the price of which is at least 500 thousand rubles.

To double productivity, the cost of acquiring aggregates in the amount of 800 thousand rubles will be required. and higher. For the production of 100 cubic meters. m. of products it is better to buy a complete assembly line, the cost of which exceeds 1.4 million rubles.

This line will be:

pre-foamer used in primary processing;
a special hopper where the foam goes through the aging phase;
molding compartment;
machine designed for cutting, bags, etc.

Maximum automation is provided by a complete set:

In some cases, a steam generator for the manufacture of the product is purchased separately.

Such equipment consumes at least 1 thousand liters of water per shift, the energy consumption depends on the steam generator.

To simplify the production and production of polystyrene, many buy additionally:

a device for packaging products (costs about 130 thousand rubles);
extractor hood (about 35 thousand rubles);
teflon coating for molding bin (at least 25 thousand rubles);
pipes intended for pneumatic transport (within 45 thousand rubles).

The price of a steam generator varies depending on fuel and performance. Focus on 250 thousand rubles. Electric consumption is not profitable to buy. However, it does not need to obtain the appropriate permissions and is safe to use.

Equipment for production does not require special maintenance. Installation and launch are within the power of everyone. However, in order to avoid a negative impact on the cost of foam, it is better to consult a specialist.

Stage 6. In what room can you organize the production of foam?

The foam production workshop should have high ceilings (at least 5 m). It is necessary to choose a room with an area of \u200b\u200b200 sq.m.

It must meet the following requirements:

the presence of a ventilation system,
sewers
electricity (380 W),
heating.

The temperature regime cannot be lower than + 15 ° С. The water supply must satisfy the minimum needs (about 3 cubic meters per shift).

Still requires a separate room measuring 60-70 square meters. m, operated as a warehouse. The storage room is fenced with fireproof structures. It is desirable that it be closed. Although, if necessary, it is possible to store expanded polystyrene foam under a canopy, so that no precipitation or ultraviolet rays do not have a negative effect.

Another unit is a warehouse for raw materials. For this room, 10 square meters is enough. m square.

It is advisable to rent a mini-factory for the production of polystyrene out of town (it’s cheaper).

Stage 7. Who should be hired for the production of foam?

Having finished with the material and technical base, proceed to the selection of personnel. The staff involved in the production is recruited without special requirements. It is not necessary to look for workers with higher education, but experience is appreciated.

Technological equipment is quite simple. The supplier of the equipment upon delivery explains the operating rules, so staff training will not cause difficulties. For one shift, 2-4 people are enough. If necessary, you can conclude an employment contract with a large number of employees.

The composition of the staff is affected by the performance of the equipment. Thanks to the efforts of one worker, production of 6 cubic meters can be expected. m of foam. And for other organizational issues, people with other qualifications will already be required.

In the production of any brand of polystyrene, staffing is needed:

technologist;
accountant;
sales manager;
seller;
2-3 loaders;
driver for product delivery.

The production staff has a piece-rate bonus. Under these conditions, workers will have an incentive to increase productivity.

Stage 8. Necessary measures to establish the sale of foam.

It is not enough just to take care of the production of quality products. It is important to establish its sales. To do this, they go the classical way, that is, they place ads in various sources: print media, on television and radio, on the Internet.

If at the expense of the first methods you can doubt, then the opportunities provided by the World Wide Web should not be neglected. If you want - create a corporate website, if you want - buy places on advertising platforms for your ads. An additional way to make yourself known is the distribution of booklets with your contact details, an image of the products you are manufacturing.

Please note that competitors can lure your customers. To avoid this, try to conclude profitable contracts for the wholesale supply of polystyrene foam, and, as soon as possible. Competently make a commercial offer, so that it would be beneficial to both you and the customers. If there are difficulties with finding large customers, the best option is to supply styrofoam to construction markets or sell it from a warehouse.

Foam production technology.

What are the benefits of this business idea? Tips for
organization of production.

Stage 9. Calculation of the price of polystyrene foam, possible costs and profits.

Foam production cost of running 25th brand of foam depends on the cost of raw materials and a communal apartment, the purchase of equipment.

One block of material weighing 16 kg (per 1 cubic meter) requires 1 kg of raw material. If we take into account the costs of electricity and water, the salary of 2 workers (600 rubles per person per shift or for the production of 30 cubic meters of foam plastic for each), the approximate cost will be 150 rubles. For the purchase and delivery of raw materials (1 kg) will have to pay about 70-75 rubles. Multiplying this number by 16 kg, we get 1.2 thousand rubles.

It turns out that the cost of production is 1 cubic meter. m of foam make up: 1.2 thousand rubles. + 150 rub. \u003d 1350 rub. Cheaper raw materials will cost 975-1000 rubles.

Profit from this amount of material will be formed depending on the type of trade and sales value. This is approximately 250-400 rubles. In general, it is impossible to indicate a number, because You will have your own production and sales of foam.

The payback of equipment for the production of products can reach 7-12 months. If sales rates are good, given the seasonality, investments will return in a shorter time.

The cost of the mechanism depends on its configuration. An automated line will cost 1.3-1.5 million rubles. By purchasing the equipment separately, you can keep within 500 thousand rubles.

Foam production entails monthly expenses:

communal payments;
salary;
payment of taxes;
advertising;
rent price;
maintenance of transport.

About 100-150 thousand rubles will have to be allocated for labor remuneration. Lease payments start from 60 thousand rubles. Tax deductions - 26.7 thousand rubles. A large advertising campaign should not be launched, 10 thousand rubles. enough for her.

In total, transportation costs, utilities and other expenses can give 90-100 thousand rubles. and more.

If the cost of production will be 1285-1350 rubles., 1 cubic meter. m of foam can be sold at a price of 1.5 thousand rubles.

We give one more example of the calculated data on the actual production of foam:

Necessary investments, taking into account the purchase of a technological line and other costs in the range of 2.5-2.7 million rubles.

Styrofoam Productionjudging by indicators of profitability, payback, simplicity of technology, product demand - a very promising and profitable idea. The main thing is to make all the calculations correctly, take into account the characteristics of the market and draw up a business plan.

Useful article? Do not miss the new ones!
Enter your e-mail and receive new articles in the mail

Own production of extruded polystyrene foam and polystyrene is a fairly profitable business. Investments in new equipment and the arrangement of the workshop pay off in the first couple of months. After that, the business begins to bring a stable income, which, after deducting salaries and raw materials, easily overcomes the figure of 20%. With such profitability, a business fully pays for itself within six months. Add to this the high demand for polymer insulation, which continues to grow, and get an excellent version of our own business.

What will be required for work?

In order to organize the production of polystyrene at home and choose the necessary set of equipment, you need to navigate the processes that the foamed polymer goes through. The main stages of this technology:

1. Heating of PSV polystyrene granulate and its foaming.

2. Curing in a cold bunker for a period of 12 hours to 24 hours to equalize the internal pressure and harden the shells.

3. Pressing in the mold and reheating with steam - for bonding the foam balls to each other.

4. Cooling and cutting plates.

Creating your own mini-shop for home production, you should think about the arrangement of equipment for convenient operation in advance, as well as bring a three-phase network to 380 V.

The main elements of the line

1. Devices for preliminary and secondary foaming (to obtain a lighter material with a density of up to 12 kg / m3).

For expanding the foam granules, the usual PN-01 is enough. The receiving hopper of this unit holds up to 60 liters of PSV, and the raw materials are sent to a larger chamber (700 liters) for processing. Pre-foamer productivity - 600 kg / h. As a rule, it is made of sheet steel, but it is possible to order the production of steam pipelines and the main capacity from stainless steel, although this will increase the cost of equipment by 65%. The dispenser in the kit will also affect the price of the unit - another plus 35-40%.

Instead of a standard receiving hopper, a pre-blower can be equipped with a compact rotary fan heater for primary heating of granules. The unit is supplemented by BP 80-75 with a capacity of 750 m3 / h and a power of 180-2200 watts.

2. Steam generator with storage capacity (battery).

It would be better if it was an economical solid fuel boiler with a waste disposer. But its maintenance will require another worker and compliance with a number of fire safety requirements. If it is not possible to use such a heater, an electric steam generator with a capacity of 100 kg / h is suitable for a line designed for 20 m3 of foam per shift.

3. Hopper with cooling fan and inserts.

The system is so primitive that if desired, it is easy to weld it yourself. Machine plants produce collapsible models pulled together by bolts. This is just a stable frame made of metal pipes (second-hand can) with stiffeners. The internal volume of the aging hopper depends on the performance of blowing agents, but usually does not exceed 15-30 cubic meters. Here, the main detail is a dense bag insert made of rubberized belt fabric, which is worn on a frame structure.

The fan can be purchased separately by choosing the same BP model as for the pre-blower hopper. Also, for loading / unloading of raw materials at the bottom, it will be necessary to install a venturi conical pipe with an upper receiver (5 thousand rubles). Its ends are connected to the sleeves of pneumatic conveying, supplying light granulate under pressure. Accordingly, a compressor will also have to be included in this circuit.

4. Molding equipment for the production of foam.

These blocks are not standardized and can have a variety of designs. It all depends on the quality of the metal and the design features. The loading of expanded and cooled polystyrene is carried out either manually or through pneumatic tubes. Typically, the shapes have dimensions of about 1x2 m, their width ranges from 200 to 750 mm, but you can order the manufacture of blocks with other parameters.

The processing of the loaded foam with steam takes place within only 2-6 minutes. To control processes, it is possible to connect an electric drive to the mold cover (about 25 thousand rubles). A fully automated unit with vacuum cooling and unloading is much more expensive.

5. Cutting.

It uses various tables and trimming, cutting the foam block into separate sheets of the desired size. The simplest models of equipment are able to process 10-12 m3 / h, with an increase in the number of separating strings, the productivity of the tables also increases (up to 30 m3 / h). However, the accuracy of cutting is the same for everyone - 1 mm. And to save raw materials and recycle polystyrene residues, you should purchase a special crusher. It will create a truly waste-free production scheme.

Equipment	Model	Consumption kW	Price, thousand rubles
Pre-foamer	PN-01	2	109
Hopper with fan	PB and BP 80-75 No. 3.15	0,7 – 2,2	16
Bag insert 30 m3	—	—	14
Steam generator	PGND-35	35	131
Block form	Bf-0.5	—	116
Slicing table	S-05-07 Combi	4	145
Waste crusher	D-01	1,2	39
Remote Control	PVN-01 Dispenser	—	65

Mini-factories

You don’t need to assemble the technological chain in parts - it’s much easier if it is a ready-made mini-line for the production of polystyrene. It is easier to set up and maintain, and the difference in price between a complete set and a set of individual machines is usually small, although not always in favor of the first option. Let's make a small overview of the available offers in this market segment and compare the characteristics.

1. Penoceh-1000.

Mini-plant of the German brand AEG with a capacity of 7 m3 / h (56 cubic meters per shift). It is equipped with additional units: silos for storing raw materials, a crusher for preparing waste for recycling and a packaging machine. It produces polystyrene blocks with a density of 9-25 kg / m3 and a size of 1040x2040x630 mm.

2. LLC Equipment and technology.

Voronezh company, offering inexpensive finished lines in two performance options: 40 and 100 m3. The package already includes a machine for vertical and horizontal cutting of foam blocks, installation supervision with commissioning and staff training (30 thousand rubles) is included. Forms are delivered in sizes of 1000x2000x (50-400) mm, produced by the foam brand line: from M15 to M35.

3. Foam leader.

It supplies mini-factories for the manufacture of expanded polystyrene in volumes from 20 to 400 m3 / cm. To organize production at home, the most modest line producing 2.5 m3 / h of finished products will be enough. Along with a set of equipment are block molds measuring 1000x1000x600 mm and the installation of hot cuts. The power consumption of the mini-workshop is 25 kW.

True, in the basic version there is no steam generator, although a drive with a volume of 2.5 m3 is provided. However, you can not only buy equipment for the production of expanded polystyrene from the same Penolider, but also choose a suitable boiler, focusing on the availability of energy. This will increase costs by another 108-338 thousand.

You can save 40-50% if you buy a used second-hand line for polystyrene foam or just agree with the manufacturer on the minimum configuration. But saving some of the money, you will have to spend more time assembling and launching the chain. Here, everyone chooses what is more important.

The production of building materials has always brought a good income. This also applies to polystyrene. Today this material is in great demand in the domestic market. If you decide to open your own business and make a good fortune, pay attention to the business plan for the production of foam. To implement this idea, you do not need a large start-up capital, as for example in the case of, so any novice entrepreneur can do this.

registration

It’s impossible to open a workshop in a large room and install bulky equipment in it. The production of polystyrene at home should in any case be legalized. This will allow you to sell goods by bank transfer in large quantities. And this is a significant advantage.

At the start, you can register an IP and pay a single tax. To open a full-fledged company and pay taxes in full at the stage of formation is too expensive. This can lead your business to bankruptcy. When the company begins to expand, you can open an LLC and work on a simplified tax system.

Location

To choose the right geographical location of the enterprise, you need to conduct a thorough market research. The most favorable for doing business are those regions in which the offers of this product do not fully cover the demand. In such a place, you can safely launch your commercial project.

Do not forget to clearly work out and include in the business plan the ways of marketing the finished material. This is a very important point on which the profitability of your enterprise depends in many respects. In addition, the seasonality of the business should be taken into account. At a time when demand for products is falling, it is possible to switch to the production of foam products. This will allow you to ensure a stable year-round income.

The main consumer of foam is. Each of them is already collaborating with other manufacturers. You need to draw their attention to your product with low prices, but at the same time good quality. To ensure stable sales of products, it is necessary to find regular wholesale customers, for example, and conclude agreements with them.

Room

The building in which the equipment for the production of foam will be located has special requirements. The mini-factory should consist of three rooms, which are isolated from each other by special fireproof shields:

Production hall - 70 sq. M. meters;
Warehouse - 50 square meters. meters;
Warehouse for raw materials - 10 square meters. meters.

Water and electricity should be supplied to the workshop. The ceiling height in this room should not be less than 5 meters.

As for the location of the workshop, it is best to find a room outside the city. Renting there will be much cheaper, which will significantly affect the payback time of a business.

Schematic: Styrofoam Production Equipment

Necessary equipment

Starting a small business is much easier than a large business. If you are limited in finances, you can open a mini foam production with a production capacity of 50 square meters. meters of material per shift. It will cost you much cheaper.

A complete foam plastic production line consists of the following units:

Pre-foaming agent - 250 thousand rubles;
Machine for secondary foaming - 40 thousand rubles;
Steam generator - 80 thousand rubles;
Block form - 150 thousand rubles;
Fan for drying - 20 thousand rubles;
Steam battery - 85 thousand rubles;
Crusher - 55 thousand rubles.

This equipment does not require special maintenance. You can install it on your own. But, as in any other business, there are some nuances that can further negatively affect the cost of the product. Therefore, it is better to entrust the installation of equipment to specialists.

One block mold for the production of polystyrene will not be able to provide high performance. It is advisable to purchase two units at once. If you plan to produce products in large volumes, buy a cutting table equipped with an electric cutter.

Employee staff

Do not think that a modern polystyrene machine does not need maintenance personnel. To ensure the continuous operation of the enterprise, it is necessary to form a staff.

To work in one shift, you will need 1 technologist and 4 workers. In addition, the staff should be a person who is engaged in cleaning the premises. To solve issues related to taxation and accounting, you need to hire a competent specialist.

Costs

One of the most important steps in drawing up a business plan for mini-foam production is the calculation of costs:

Equipment - 900 thousand rubles;
Salary to employees - 100 thousand rubles;
Additional costs (rental of premises, payment of electricity, etc.).

If your company will work in two shifts 5 days a week, the initial costs will pay off in literally 3-5 months. This applies only to the purchase of equipment and raw materials. The cost of renting the premises and the salary of employees will be monthly.

Calculation of the cost of production

One cubic meter of material costs about 1 thousand rubles. The total cost of its manufacture is 600 rubles. Accordingly, if a foam plant produces 50 cubic meters of products per day, you will make a profit of about 450 thousand rubles a month.

The profitability of such a business reaches 20%. These are excellent indicators that are difficult to achieve in any other direction of entrepreneurial activity. If you are looking for a profitable business idea, the production of polystyrene is an ideal option in order to open your own profitable business.

Raw materials and technology

Polystyrene foam is made from special expandable polystyrene foam. Its cost largely depends on the manufacturer and the fraction. The price of raw materials for the production of polystyrene varies between $ 2 per 25 kg.

When purchasing expanded polystyrene, pay special attention to its quality. Domestic raw materials can be bought at a low price, but this can negatively affect the quality of the finished product. Imported polystyrene foam allows you to get high-quality material with a small amount of marriage. Recently, the main raw materials purchased in China.

Pay attention to the quality of polystyrene, as well as the duration of its storage. The older the raw material, the longer the foaming process will take and the more difficult it will be to achieve the density of the foam bead.

What is needed for the production of expanded polystyrene?

Raw materials (expanded polystyrene foam);
Steam (temperature about 110 degrees);
Electricity (voltage 980 W);
Cold water;
Equipment.

Production technology

When the starting material enters the pre-foaming agent, the granules are inflated and turn into balls. If necessary, this process is repeated. After foaming, the granules increase in volume. This technology for the production of foam is used for the manufacture of material of low strength.

What do you need for self-made foam?

So, you have in your hands a complete business plan, there is an idea of \u200b\u200bthe amount of work required investments. The next task is to buy equipment for the production of foam products. Installation required:

1. Pre-foamer. At this stage, a preliminary whipping of polystyrene granules is carried out under the influence of steam to a predetermined density level: 5-50 kg / cu. m. They differ in parameters:

material of manufacture (carbon or stainless steel);
performance;
volume of the chamber and receiver for granules;
operating principle (continuous or cyclic);
the presence of a built-in steam generator, hopper, feed dispenser.

2. Intermediate container with an insert bag for secondary foaming. This block is necessary to obtain a foam with a density of up to 6-8 kg / cu. m. The dimensions of the frame are determined by the technologist.

3. Receiving hopper with a built-in or plug-in fan with the option of heating the air. It is aged and dried. They differ in useful volume and power.

4. A block form in which, under the influence of steam, polystyrene beads are sintered into a monolith. Cooling can be vacuum or natural, control - through the remote control.

5. To speed up the process, a vacuum pump and compressor are required. Delivered separately depending on the power and the specified density of the final product.

6. Table for curly cutting of foam into sheets of the desired size and thickness. They differ in configuration; as additional options, range finders, transformers for heating strings, face saws for tongue-and-groove and others are often present. For profile molded products (skirting, platband, columns, slate insulation), instead of a table, a complex 3D machine is used. Management is carried out through a special computer program.

7. A packaging machine wrapping finished products with shrink film or polyethylene.

8. Crusher with exhaust fan, grinding waste from cutting foam. Subsequently, they are again put into production.

9. Steam generators and accumulators providing continuous operation of pre-foamers.

This may also include scales, condensate drains, transformers, pneumatic conveying pipes and the like.

Estimated price of equipment

Table 1. The cost of a kit with a capacity of 40 cubic meters. m. per standard shift (8 hours)

View	Quantity	price, rub.	Total RUB
Steam generator	1	85 000	85 000
Pre-foamer with dispenser	2	80 000	160 000
Receiving hopper	1	15 000	15 000
Heated receiver fan	1	14 000	14 000
Hopper bag	2	8 000	16 000
Venturi pipes	2	3 000	6 000
Fans	2	11 000	22 000
Block shape electric drive	1	125 000	125 000
Vacuum pump	1	50 000	50 000
Intermediate Hopper Bag	1	5 000	5 000
Polystyrene cutting machine	1	20 000	20 000
Pneumatic crusher	1	45 000	45 000
Steam accumulator	1	90 000	90 000
Pneumatic conveying pipes for 2 hoppers	1 set	24 000	24 000
TOTAL			677 000

The minimum configuration will cost half the price. The warranty on the Russian and Chinese products is 1 year.

To reduce costs, many novice businessmen prefer to buy used equipment from sellers of used units. For example, in Germany the state provides loans at a rate of 2-5% per annum plus tax incentives to modernize the production base. Accordingly, it is profitable for them to sell 4-year-old plants at cost minus depreciation.

So, used cars Kurtz, Heitz, Hirsch cost about 70,000 rubles, but at the same time the buyer receives European quality, metal parts with Teflon coating and a sufficiently large resource - at least 5 years. Whereas applying a protective coating to the Russian block form increases its price by 25,000 rubles.

Styrofoam production steps

The manufacture of foam includes the following phases:

Foaming polystyrene granules (preliminary, double, triple);
Drying;
Maturation for up to 24 hours;
Forming in a single block;
Drying up to 30 days;
Cutting into plates of specified sizes;
Recycling waste.

The whole process takes no more than a few days. Despite the fact that the product has a steady demand, investments pay off in a year and a half. For this reason, many are interested in the question of whether it is possible to organize the production of polystyrene at home. This idea is quite feasible, but a garage or an outbuilding on a summer cottage does not meet safety standards.

Firstly, the height of the ceilings in the room should be at least 4-5 m. Secondly, the availability of water supply, sewage, an electric power source of 380 W, a good ventilation or exhaust system is mandatory. And thirdly, the storage warehouse for finished products must be protected from fire, moisture and direct sunlight, all this is detrimental to quality.

In addition to the purchase, installation and commissioning of equipment, the search and training of workers, and the rental of premises, it will be necessary to obtain permits from various authorities (sanitary and epidemiological surveillance, fire protection and others). After all, the manufacture of polystyrene foam at home is a process associated with the release of toxic fumes, fire hazard, toxic waste. It is better to approach the matter responsibly and acquire a turnkey ready-made business for the production of foam in the industrial zone. At the same time, an established supply and sales network, trained personnel and relevant documentation are transferred to the buyer.