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How to open a foam rubber production. Foam Rubber Business Foam Rubber Components

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 is 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:

Continuous production technology.
Periodic production technology.

The batch foam production method is simpler, which is why it is ideal for small businesses and beginners in this 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:

Foaming apparatus.
Thermal camera.
Foam cutting machine.
Dosing device.
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:

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.
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.
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:

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.
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.
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.
The density level of PPU is measured in kg / cubic meter. And this is the main indicator of quality.
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.
Comfortable elastic foam. This parameter distinguishes furniture foam rubber marking HR.

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

Standard (ST).
Highly elastic (HR).
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.

When planning to start your own manufacturing business, it is better to give preference to the production of products that are in high demand, regardless 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 is early spring (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.

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.

When opening your own production of 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, closely located potential customers should be taken into account. 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 appropriate 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 the better the work of 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

Foam rubber is a synthetic material that is made from flexible polyurethane foam. This name of this material has already taken root, since in Soviet times it was supplied by the Scandinavian company Porolon.

Since foam rubber is a soft foam material with almost 90% air cavities, it has excellent elastic and breathable characteristics.

It is used as a shock-absorbing and insulating material for packaging fragile items, furniture filler, soft toys, and the like. In addition, due to its soundproofing properties, foam rubber is used for soundproofing.

Since chemically active substances are used for the production of foam rubber, such as polyol, isocyanate, then its manufacture, foam rubber is considered environmentally unsafe, since the fumes during the chemical reaction of these materials are toxic and dangerous to humans.

For the manufacture of foam rubber, foam stabilizers and special catalysts are used, thanks to the first foam rubber, under the influence of external factors such as air and moisture, it decomposes into safe components and can be easily disposed of.

The main disadvantages of this material include: not long service life and a high degree of flammability. The last drawback is solved by introducing into the production process the use of specific additives, with the help of which the so-called nonflammable foam.

foam manufacturing technology

The technological process for the production of foam rubber is based on carrying out a chemical reaction to mix its components in a special device for foaming. After that, the prepared mass is poured into a special form for solidification.

The whole technological process can be divided into the following successive steps:

delivery of the mixture components to the foam rubber production site;
preparation of components for the manufacture of foam rubber, control of their characteristics (temperature, viscosity, quality, and so on);
filling in the constituent components;
mixing of raw materials in the machine for foaming, in a given mode, to achieve certain characteristics of the material;
filling the resulting foam with a special movable (collapsible) matrix (form);
a process of waiting for a chemical reaction to form foam in the upper part of the matrix, which can be on the order of 20 minutes;
disassembly of the matrix (form) and extraction of a semi-finished product from it;
cooling the material and waiting for the end of its active chemical processes;
waiting for the final solidification of foam rubber (about one to three days);
cutting foam rubber, according to a perky template;
storage of the finished product.

Equipment used to make foam

One of the necessary conditions for the manufacture of foam rubber is the exact observance of the given recipe, since the chemical reaction, which is the basis for preparing the mixture, is carried out at the molecular level.

In addition, the quality and temperature that the ingredients have before mixing is equally important. The equipment that is used to produce this material must ensure not only the correct dosage, but also the temperature characteristics of the starting material.

Therefore, most devices that carry out preliminary preparation and dosage are equipped with various sensors and automated systems that are designed to provide control over the performance of the ingredients.

Depending on the degree of automation and complexity of the equipment used for this, the price of the line for the production of foam rubber, as well as the quality of the goods that are produced with it, directly depend. The lines of equipment used for the manufacture of foam rubber are of the same type. The difference in configuration depends only on the method of production of foam rubber.

Video: foam production process

Depending on the volume and serial production, there are continuous and periodic methods of its production. They differ in the method of foam extraction, in continuous production, foam extraction is carried out constantly and the foam material is fed to the mold, which is made in the form of a transport line.

Among the main devices that are used in the manufacturing process of foam rubber can be identified:

Also, some highly automated lines may include various packaging units and machines for the manufacture of tape or shredded foam rubber, for use as fillers.

Since the manufacture of foam rubber refers to processes associated with emissions of toxic and harmful substances, a prerequisite for the construction of a production line is the presence of special devices that allow not only forced ventilation of the premises, but also monitor the degree of air pollution.

foaming machine

Foaming machine is the key in foam rubber production line.
Typically, the design of such devices provides for the presence of such main components and mechanisms:

Block for storage, pre-mixing and supply of mixture components.
High pressure block for foaming the mixture.
Node of automatic process control.
Cooling block.
Spray device.

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 consumables 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 insignificant, 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, it is necessary to purchase the following additional 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 of 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. 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 of ownership: Individual entrepreneur (find out)
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. In January, it is most optimal to engage in equipment maintenance, as there are practically no orders in this month.
Number of staff 7 people
Working hours: 8 hours per shift, 23 shifts per month.
Number of teams: 1

Capital expenditures

The total amount of 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.

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.

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 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

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 often.

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

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.