The Russian market for the production of pipes from various plastics has expanded significantly in recent years. This is due to simple production technology, as well as high demand for this product. Plastic pipes have a wide range of applications. They are used in sewer and heating systems, in water and gas supply systems, as well as for arranging “warm floors”. Such a wide range of applications is explained by the quality characteristics of plastic pipes:
- they are durable, do not rust, do not rot;
- withstand temperatures up to 160 -170? C;
- do not change the taste of water;
- there are no lime deposits on them;
- shelf life is about 50 years;
- five to seven times lighter than metal pipes.
Pipe manufacturers are improving technology and expanding their range, because competition in this type of production is quite high. For a successful business selling pipes, you need to produce high-quality products at an affordable price.
Technology and raw materials
For the manufacture of plastic pipes, various raw materials are used: high and low pressure polymers, polypropylene, polybutene, polyvinyl chloride, etc. Their production is environmentally friendly and uncomplicated, it is based on extrusion. Extrusion is the extrusion of pipes from molten plastic using a special machine (extruder). There are several types of extruders: screw, screwless and combined. The operating principle of a screw extruder resembles a meat grinder or juicer. In screwless ones, the main working part is the disk; they are used when necessary to produce pipes from mixed materials. A combined extruder combines both a screw part and a disk. The most commonly used are screw extruders. They come in single- and double-stage, specialized and universal, single- and double-screw, equipped with and without a degassing chamber, with screws rotating in one or opposite directions, etc.
The production of plastic pipes occurs as follows. The raw material in granules is poured into the receiver hopper of the extruder, where it melts under high temperature. Next, the mass is extruded through the forming head of the extruder, which determines the parameters of the future pipe. After the initial forming, the drawing machine pulls the workpiece into a primary cooling bath, where under pressure it is finally formed using a sizing mold. Next, the pipe is cut and either stacked (large-diameter pipes) or coiled (small-diameter pipes).
Equipment and raw materials
A full-cycle plastic pipe production line, in addition to the extruder, includes a pipe cutting machine, a raw material supply system, calibration and cooling baths, a mixer, a pulling device, a conveying belt, a vacuum former and a storage tank for laying pipes.
Productivity depends on the pipe size: pipe diameter - 20,25, - 80 kg/h, pipe diameter - 32,40,50 - 100 kg/h, pipe diameter - 63,75,90,110 - 130 kg/h. The line can produce about 1000 meters of pipes per day, depending on the diameter. The lines have different parameters, so you can order machines for your business, or you can save money and buy used equipment. The lowest cost of such a set is about 400 thousand rubles.
Granulated polymers are purchased for raw materials. It is important to be demanding about its quality and shelf life. Polyethylene and polypropylene are very advantageous materials due to their almost unlimited shelf life. Polypropylene copolymer is one of the best materials for making pipes. Its cost is about 50-70 rubles per kg. Low-density polyethylene (HDPE) is also often used for production; its cost is lower - about 32 rubles per kg and more. The best option would be to arrange supply from one plant, because changing raw materials will also require changing equipment characteristics.
Premises and staff
For the production of plastic pipes, any premises outside the city that has a convenient entrance, in which you can locate a workshop, a large warehouse, a bathroom, and staff quarters, are suitable. All equipment can be located in a workshop with an area from 40 sq.m to 200 sq.m. To service it you will need at least 3 people per shift. Technologists, machine operators, and auxiliary workers should be hired. The average salary for a technologist is about 50 thousand rubles, for workers - about 25-30 thousand rubles.
Requirements
To open production, you will need to obtain permits from the gas service, fire inspection, sanitary and epidemiological station, local branch of the State Supervision Service, local executive authorities, etc.
According to GOST 18599-2001, the conditions for transportation and storage of plastic pipes are as follows.
It is allowed to transport pipes by any type of transport in covered bodies (cars). To protect the pipes from dust and external influences, they must be closed with plugs and placed in packaging. The weight of the pipe coils together with the packaging should not exceed 1.25 tons, the length of the pipes should not exceed 5.5 m.
Pipes are stored in warehouses in a horizontal position away from sunlight and heating devices. The height of the stack when storing pipes for more than 2 months should not exceed 2 m. When storing for up to 2 months, the stack height should be no more than 3 m. Pipes can be stored for no more than 12 months. Shelf life – 2 years from the date of manufacture.
Investments and sales
The initial investment required to open the production of plastic pipes, when purchasing used equipment and 100 tons of raw materials, will be about 8-9 million rubles (including six months' salary and rent). A business pays for itself in about 1.5-2 years. Profitability can vary greatly (from 2 to 20%), due to competition.
The average price per linear meter of pipe on the market depends on its parameters: if a pipe with a diameter of 63 mm costs about 90 rubles, then with a diameter of 800 mm it costs about 14 thousand rubles. When searching for consumers, you should remember the areas of application of plastic pipes mentioned above. You can establish contacts with local pipefitting and installation companies and have custom pipes made to order.
Kristina Cherukhina
- portal of business plans and manuals
Production of plastic pipes: 7 product advantages + 9 areas of application + procedure + market and industry analysis + 4 main types of products + raw materials + 6 suppliers + technology + premises and equipment + personnel + sales + cost items + possible profit.
In recent years, the attention of many entrepreneurs has been attracted by the production of plastic pipes. Companies open their own workshops where they produce PVC products.
What is the reason for its popularity? In improving production, growing demand and widespread use of polymer, cylindrical products. Due to the emergence of more and more new players in the market, fierce competition has formed.
But by offering a high-quality product at an attractive price for customers, you can bypass many of them.
Why make pipes from plastic?
Plastic production will bring a stable profit to the business owner. Plastic is a material that, since 2010, has been considered superior to others in construction and other fields.
This boom was caused by its convenience and practicality, minimal resource consumption and other operational characteristics. Pipes made from plastic also have a number of advantages, which to this day make these products in demand on the market.
Plastic cylindrical products are also characterized by:
- resistance to high temperature (maximum 170°C), rotting, dynamic loads, abrasion;
- light weight;
- fire safety and safety for drinking water supply;
- seismic resistance;
- flexibility;
- economical operation.
Although the fashion trends for plastic have slowed down a bit, pipes made from this material are still being sold successfully. This is one of the reasons that the business of their production has good returns and is promising.
Excellent sales volumes are also influenced by the widespread use of plastic pipes. The list is really large, but we will list the main areas.
- sewer systems;
- water pipes;
- cable channels;
- heating;
- transportation of liquids in industrial production;
- intra-house networks;
- drainage systems;
- installation of watering and irrigation systems;
- gas distribution, etc.
The future entrepreneur will have difficulties when entering the market, since there is a lot of competition in this area. However, this should not “discourage” such activities as the production of plastic pipes.
If you produce a wide range of good quality products at an attractive price, and are willing to compete for end consumers using available resources and proactive strategies, gaining a strong position will be an achievable goal.
Procedure for starting a plastic pipe production
As in any entrepreneurial activity, first of all you need to do something, which will become your guide to action, help you avoid many mistakes and indicate what financial support is needed to start production.
Before writing it, the entrepreneur should already have ideas about the plastic pipe market and the competitive environment, which are formed during the analysis (we will return to this in more detail). Of course, you will have to delve into the production technology, think about where and how you will buy raw materials and equipment.
No less important is the issue of labor resources and production space, and the formation of an assortment. In addition, the production of plastic pipes requires registration and the choice of a tax regime.
Because pipe production occurs with, it is classified as harmful. Therefore, it is necessary to comply with international law regarding the care of the environment and ensure its safety.
All types of products must also have certificates of conformity. The company must implement a Quality and Environmental Policy.
1. Analysis of the market and the polymer pipe industry.
The Russian market for plastic pipes is to some extent limited and narrowed in volume due to a lack of raw materials and final demand. The problem is counterfeit goods and savings on production costs.
In 2016, sales of plastic pipes had stable dynamics. If compared with 2014, it will be negative.
Consumption remained at 425 thousand tons. Enterprises that updated and expanded production capacity produced more plastic products, and although consumption increased by 2016, supply exceeded demand.
The production of pressure plastic pipes predominated (60%), non-pressure pipes were produced least of all (19%), and corrugated products accounted for 21%. At the same time, record supplies of domestic raw materials (75 thousand tons of polypropylene of various types) became an incentive to increase production.
There is a tendency for foreign companies involved in the supply of pipes to be squeezed out of the market. In this industry, the consumption level of polyethylene pipes exceeded 62%.
The main production facilities are involved in the production of large-diameter PE pipes intended for use in water supply and gas distribution. There is the toughest competition here and there is practically no import.
In 2016, there was a decrease in import supplies of equipment used in the production of plastic pipes. China remains the main supplier. It provides Russia with 70% automatic lines.
The main issue for plastic pipe manufacturers is the supply of raw materials. Moreover, few pipe business owners are confident that a decrease in the price of raw materials will increase the production of plastic pipes.
By 2020, production volumes of polypropylene and polyethylene are expected to increase by 30%.
The competition is:
- Cheboksary Pipe Plant;
- Polymer piping systems;
- Polyplastic Group;
- Techstroy;
- About Aqua;
- Politek;
- PC Contour;
- Hemcor;
- Pieplough et al.
In general, the production of polymer pipes in Russia can be called oligopolistic, since the main part of the market is occupied by 8 large enterprises. And although these positions are only becoming stronger, conditions are being created for small and medium-sized companies to actively develop their business.
Production efficiency is achieved through the use of new technologies, the introduction of innovations, and the production of unique plastic products. This creates the need to purchase expensive equipment.
The reform of the housing and communal services sector and the modernization of infrastructure have a great influence on the development of the market.
2. Type of plastic pipes: what products to produce?
To decide on the assortment that an entrepreneur will produce and sell, you should understand the types of plastic pipes:
PE pipes They transport water well for drinking and household needs, and are used for drainage. Such products are produced with a length of at least 12 m and a diameter of 1.6-16 cm. Products can be found under the brands PE 63, 80, 100, 100...etc.
The production of polyethylene pipes has its own characteristics:
- use of advanced technologies,
- lower cost,
- less expensive packaging.
The degree of polymerization allows the production of products of different pressures.
PVC pipes are produced in a non-pressure type, they are not afraid of low temperatures and other climatic changes, and are durable. These items are intended for the installation of underground pipelines, sewage systems, and the removal of gaseous media whose temperature does not exceed 45°C.
Also used in construction because... have good economic performance. Their diameter is 11-63 cm, and their length is up to 12 m. They are painted white and orange.
Polypropylene products Due to their multi-layer nature and high hardness class, they cope well with drinking water supply. PP is also purchased for modernizing the heating system and technological installations. The diameter range is 2-11 cm. They are supplied in lengths from 2 to 4 m.
Metal-plastic pipes are considered the best option for home use,
because they are easy to install. However, with mechanical deformation, PP quickly breaks, and the connecting elements are not resistant to high temperature changes in water.
The color of the products indicates their area of application. Thus, blue products are used to supply cold water. White pipes are needed in the installation of hot pipelines and heating. Products with a red color are used for laying heated floors. Yellow pipes are used in gas supply.
The cost of pipes depends on their parameters, i.e. on thickness, diameter, length, layering. In addition, the pricing policy is formed based on the technical characteristics of the product (pressure and temperature of the environment that it can withstand).
The most popular are polyethylene pipes of grades 80, 63 and 100. Prices range from 15 to 860 rubles.
3. What raw materials are purchased for the production of plastic pipes?
In order for the production of polymer pipes to be carried out without problems, it is necessary to worry about the supply of raw materials. In the future, polymer supplies should occur regularly.
Used as raw material:
- polybutylene (PB),
- polyethylene (PE),
- polyvinchloride (PVC),
- polyamide (PA),
- polypropylene (PP) and other propylenes.
Raw materials are purchased in the primary grade in granulated form.
The type of production will influence the choice of raw materials. When purchasing it, pay attention to expiration date and quality. The most commonly purchased copolymer is polypropylene. This composite allows for the production of durable products.
The backup option is secondary raw materials, also known as waste. This will produce low-pressure plastic pipes, which are designated HDPE.
At the stage of preparing production for launch, the workshop owner must find suppliers. You can sign supply agreements both with Russian enterprises engaged in the production of polymers and with foreign ones. The price for domestic primary raw materials is up to 80 rubles/kg, prices for secondary materials are from 30 to 40 rubles/kg.
List of leading Russian manufacturers of polymer granules for plastic pipes:
- Polyplastic— produces recycled polyethylene and other polymer materials at an affordable price.
- Roekoplast– a company producing LDPE and HDPE granules.
- Polymer Club– carries out the production of raw materials for the manufacture of pipes, packaging, films, etc.
- AST Promplast– produces and sells LDPE granules.
- GlavTehProm– is a trading and production company in the field of polymers, rubber goods, and ATI.
- TD Plastics Group– supplier and manufacturer of synthetic polymers.
Production technology: how to make plastic pipes?
The production of plastic pipes is carried out using relatively simple technology. The principle of extrusion is used, when pipes of the required shape are extruded from softened plastic using special equipment - an extruder.
The production process begins with loading raw material granules into the machine hopper. It crushes and liquefies the plastic. The formed mass is squeezed into tanks.
The plastic blanks are immediately given the required shape. They are then pulled out and dipped into a cooling tank, where, through pressure and calibration, the “semi-finished products” are processed and given a finished appearance.
The last stage of production consists of cutting plastic products. They are twisted in coils or stacked if they have a large diameter.
Location of an enterprise for the production of polymer pipes
You will need to rent a room outside the city with an area of 40-200 square meters. m. It is necessary that convenient transport access be provided to the workshop. There are no increased power requirements.
Be sure to allocate a large space for storage. A room for personnel (production, administrative) and a bathroom are also required.
In addition, the room must have:
- water supply,
- sewerage,
- ventilation,
- heating,
- fire protection system.
Rent a room with high ceilings. This is due to the bulkiness and height of the machines. High humidity is not allowed in the workshop. Therefore, it is better to buy a hygrometer and monitor this parameter.
Equipment for plastic pipes – we equip production.
To produce plastic pipe products, an entrepreneur must automate the production process by means, the main one of which will be an extruder.
This is a machine designed for plasticization, and it comes in various types.
Screw They work on the principle of a meat grinder. Screwless The devices are used for the production of plastic pipe products from mixed raw materials. Combined The machines are equipped with both disk and screw mechanisms.
Typically, in the production of plastic pipes, screw-type equipment is used; it is considered the simplest, and also has its own classification:
To figure out which extruder is needed in your case, it is better to contact a specialist.
Or you can buy an automated line for production, which will consist of the following elements:
Equipment for plastic pipes is purchased from Russian suppliers, as well as imported. Those who have a limited budget have the opportunity to purchase used machines. The prices for new cars are considerable - from 2 to 4.5 million rubles.
Personnel of the enterprise for the production of plastic pipes
To participate in production, 3 workers (shift) will be required. This is an operator, technologist and assistant. A technologist is entitled to a salary of at least 50 thousand rubles, and an operator – up to 30 thousand rubles.
Regardless of whether they have experience working with such equipment or not, instruction must be provided.
If you yourself cannot control the production process, you will still need to hire a manager. The company must have an accountant and a sales manager. It is advisable to hire a cleaner.
If you intend to install standard equipment and increase production volumes, you may need to increase staffing to 6 people per shift.
If you plan to provide production with transport logistics, you should take into account that these are additional costs, and special requirements are imposed on vehicles.
Having formed a team, it also needs to be retained. To do this, it is necessary to create a healthy psychological climate in it, introduce it, provide normal working conditions, and social guarantees.
It is important to motivate employees with rewards, which will help achieve their goals in a shorter time.
Sales of plastic pipes
If you do not pay serious attention to product sales and do not think about it in advance, the production of plastic pipes will become unprofitable. It is necessary to make a lot of effort to find your clients, wholesale customers and conclude profitable contracts with them.You need to offer plastic products:
- construction bases and shops;
- to private individuals;
- various companies;
- Housing and communal services, etc.
We will have to develop all kinds of discounts, make special offers, and hold promotions. To position your brand, don’t skimp on advertising. Use methods available in the real environment (media, television, radio, outdoor advertising, distribution of leaflets, etc.) and on the Internet.
Creating your own website will be an excellent solution, because this way you will expand your audience and give customers the opportunity to order pipes online.
The production process of polymer pipes.
What properties do polymer pipes have?
Equipment for the production of.
How much can you earn in the production of plastic pipes?
First, let's decide on the investments needed to get started. The minimum amount will be 2 million 260 thousand rubles. For a large enterprise you need to have 8-9 million rubles.
Expenditure:
- registration, obtaining permits – from 15 thousand rubles;
- rent – from 50 thousand rubles;
- taxes – from 20 thousand rubles;
- utilities - from 30 thousand rubles;
- equipment – 2-4.5 million rubles;
- raw materials - from 200 thousand rubles;
- Payroll – from 250 thousand rubles;
- advertising – from 55 thousand rubles.
Profit will depend on the type and characteristics of the plastic products produced and pricing policy. In general, it is quite possible to count on 300-400 thousand net profit per month. Profitability reaches 18%, and costs will pay off within 2-3 years.
With the right approach to activity planning, market analysis, and the purchase of high-quality raw materials and equipment, the production of plastic pipes will become a profitable business area.
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Pipe products made from polyvinyl chloride have found wide application in many areas of modern life. The reason for its demand is the excellent quality of the products. How are PVC pipes produced, and what raw materials and equipment are used for this?
They are used when laying pipelines designed to move almost any media - gases, liquids and chemicals. PVC pipes and PVC connecting elements for them are used in the construction of residential buildings and industrial enterprises.
When constructing houses, plastic products are used for laying utilities, including external sections of highways - these are sewer and water supply networks, as well as drainage structures.
Such pipes are resistant to aggressive environments, they can be used in different temperature conditions, and they are easy to install. Pipelines laid from them have a long service life.
Materials for the production of PVC pipes
The raw material for the manufacture of PVC pipes is granular polymer. They are produced using the extrusion method.
In order to impart certain properties to pipe products, the following is added to the components:
- catalysts- chemicals that accelerate the polymerization process;
- inhibitors– cause a delay or slowdown in reactions;
- stabilizers– special substances that provide polymers with stability and inhibit their aging;
- plasticizers– refer to special additives that impart plasticity and elasticity to polymer materials;
- antistatic agents– they are introduced to prevent the occurrence of a charge of static electricity;
- pigments– impart the required color to an already manufactured product.
In addition to the above additives, polymer raw materials sometimes include other components that affect the properties of the final product.
Equipment for the production of polyvinyl chloride pipes
To organize the workflow, you will need equipment for the production of PVC pipes, including:
- Bunker, where prepared raw materials are poured.
- Extruder– thanks to this device the extrusion process is carried out.
- Baths. Refers to installations in which products are cooled and calibrated.
- Scissors guillotine or disc cutters - they are used to cut pipes.
In addition to this equipment, depending on the type of products being manufactured, PVC pipe manufacturers may use additional mechanisms and devices, for example, a hydraulic stacker.
Pipe production technology
The process of producing PVC pipes is simple, it is not labor-intensive, does not consume energy and is environmentally friendly. All equipment necessary for organizing production can easily be placed in an area of no more than 100 square meters.
The extrusion production line operates in a continuous and complete cycle consisting of the following stages:
- Extrusion.
- Pipe calibration.
- Cooling of products in bathrooms.
- Pipe extraction.
- Cutting products to the required length.
- Stacking of finished products.
The technology for manufacturing products at the PVC pipe plant is as follows:
- Granular plastic raw materials are poured into a hopper that has a screw-shaped auger and heating elements.
- During rotation in the bunker, the raw material is heated to the required temperature.
- The polymer, in a molten state, is fed into the extrusion head.
- To form a product, molds are used that have a certain outer and inner diameter.
- After extrusion is completed, a plasticized product blank is obtained.
- Then the pipe is fed into a vacuum calibrator (bath) for calibration. The equipment for this process is a three-meter closed container, inside of which a vacuum is created using a vacuum pump.
- The workpiece, having passed through the calibrator diaphragm, moves to the next chamber. It is a cooling bath where there is rarefied air.
- To evenly stretch the product, a pulling device is used, which can be of a caterpillar or belt type.
- Products are cut using a guillotine or circular saw.
- At the final stage of the technological process, the finished products enter a device called a stacker, which places the manufactured products on special racks.
Scope of use of PVC pipes
Pipe products made by extrusion can be used for arranging:
- pipelines supplying household gas;
- water supply systems;
- structures for drainage of wastewater and precipitation;
- technological lines designed for transporting chemicals;
- highways used for production purposes.
PVC pipes can perform a protective function when installing electrical wiring and communication cables.
Depending on the purpose, PVC pipe products can be non-pressure or pressure. In the first case, the pipes serve to move liquid through them by gravity, and in the second, the contents are supplied under pressure. Currently, the production of non-pressure PVC sewer pipes has become widespread.
Features of the installation process
The work of laying pipes made from PVC is simple and does not require the purchase of special equipment.
Installation is carried out in two ways:
- By connecting into a socket using rubber seals and silicone grease.
- By gluing products using special adhesives. The resulting connection is reliable, since the polymer molecules penetrate from one to another connected product.
When organizing the production of PVC pipes, the costs of purchasing equipment and other activities usually pay off within one year.
Polyvinyl chloride (PVC) pipes today are widely used in various sectors of the economy, mostly, of course, in construction. This type of pipe has replaced metal pipes and is increasingly pushing them out of the market. It is not surprising that today more and more people are investing in the development of this business. The main cost item is the line for the production of plastic pipes, but high productivity and low cost of consumables quickly pay for the investment.
Plastic pipes are suitable for: water supply, sewerage and heating
The high demand for plastic pipes is due to a number of distinctive characteristics:
- they are not subject to corrosion;
- lightweight – 5-7 times lighter than metal analogues;
- not affected by high and low temperatures;
- limescale is not deposited on them;
- long service life - up to 50 years;
- they do not affect the taste of the water.
Such quality advantages allow the use of pipes in heating and sewer systems, water supply and gas systems.
Plastic pipe manufacturing technology
The process of producing PVC pipes is quite simple; it will require raw materials - granular polymers and a PVC pipe production line. One of the best materials is polypropylene copolymer. Using an extruder, the granules are melted under high temperature. The polymer mass is extruded using the forming head of a screw extruder. The operating principle of this mechanism resembles a meat grinder. This is the initial stage of molding, which is followed by the process of drawing the workpiece and its further cooling. In special baths, the workpiece undergoes a final molding process under high pressure using a calibrating device. The dimensions for molding are set automatically before the process begins. The final stage in the production of plastic pipes is their cutting and laying.
Mechanisms that make up a production machine
The assembled line is a collection of units and components with a total length of 18 to 60 meters. All elements are interconnected and consistently carry out technological processes. Manual labor is used at the stages of loading raw materials and receiving finished products, as well as for debugging automated systems of the line for the production of plastic PVC pipes. Production line composition:
Pulling device - bunker for raw materials;
- pipe head;
- baths;
- cutting unit;
- other additional devices and accessories.
A hopper is a container with a dispenser into which the raw materials are placed. Often the hopper is replaced with a funnel, and the raw materials are weighed separately, manually.
The extruder consists of a vertical gearbox with a thrust bearing, an electric motor, a plasticizing cylinder, a barrier screw, and an electrical cabinet with an automated control system. Characteristics:
- dimensions – 1900*1400*900;
- weight – 950 kg;
- productivity – 30 – 75 kg/h;
- power – 30 kW.
Extruder for making PVC pipes The pipe head includes two thermal control zones and is intended for the initial formation of the diameter of the future product - from 16 to 63 mm. It will additionally require matrices of the appropriate caliber.
Baths for cooling – one vacuum-water, the second water. The baths are made of stainless steel, filled with water, and equipped with water and vacuum pumps. The length of each bath is 4 m.
The pulling device of the line for the production of plastic pipes is a single frame with a movable and stationary traverse. This unit is equipped with a meter counter and a cutting device. The cut is carried out with a roller according to the diameter of the pipe. The pulling mechanism is driven by pneumatics; it is possible to regulate the pulling speed - from 1 m/min to 5 m/min.
If the production involves the production of soft products from polyethylene, then the line is supplemented with a winder. The coil is installed, its diameter is adjusted as needed, and the winding process is carried out using a pneumatic cylinder.
Manufacturing of corrugated pipes
The corrugated pipe has a relief surface, which in longitudinal section resembles a ridge. This type of plastic pipes is widely used in construction for carrying out engineering systems - sewerage, water supply, electrical, ventilation. The advantages of this type of product are versatility of use, lightness and compactness during transportation, plasticity, and low cost. The manufacturing process is similar to the technology of ordinary plastic pipe and is carried out using a corrugated pipe production line. This line is complemented by a special device - a corrugator, which sets the general nature of production. The corrugator is located near the extruder head and consists of two halves with a channel for the flow of cooling water; at the working area, both halves merge, forming a closed space.
The workpiece from the extruder enters the working space, where under air pressure it is pressed against the surfaces and hardens, and a certain shape is set - a corrugation. Next, the pipe is ready for winding. Unlike the PVC pipe production line, baths are omitted here; cooling occurs in a corrugator. Main characteristics of the line:
- dimensions – 9*1.9*2.5 m;
- power – 65 kW;
- weight – 2.5 t;
- speed – 1 – 12 m/min;
- productivity – 60 – 80 kg/h;
- diameter of the finished product – 16 -63 mm;
- cost – 2,800,000 rubles.
Profitability of plastic pipe production
Calculation of production profitability will be considered using the example of manufacturing PVC pipes 50 * 1.8 mm, weighing one meter - 0.6 kg.
The technical capability of the line is production of 80 kg/h, which is 133 m3/h. Provided that the equipment is fully loaded, 95,760 m3 will be produced per month. This will require 34 tons of raw materials, the price per 1 kg will be 44 rubles (SG-5 brand, China), which for the monthly norm will be 1,496,000 rubles. The salary for four workers, two per shift, will be 70 thousand rubles. Products can be sold at a price of 50 rubles per 1 m2 - with full sales of monthly output, the revenue will be 2,300,000 rubles - net profit - 750 thousand rubles. This amount will be reduced by the amount of rental premises, utility bills, transport and organizational expenses - approximately 200 thousand. There remain 550 thousand rubles, which will cover capital investments monthly. With a starting capital of 4,500,000 rubles for the purchase of a line for the production of plastic pipes, the payback period will be 12-18 months. To do this, it will be necessary to ensure full sales of finished products, and it is better to work on pre-orders, then there will be no excess production.
Video: Production of polypropylene pipes
Plastic pipes are a popular product that is widely used in construction, agriculture and water supply. The demand for them has been and remains high today. At the same time, their production technology is quite simple and accessible for a startup to implement. Today we’ll look at a business idea for manufacturing plastic pipes.
A few words about technology and raw materials
Plastic pipes are made from various materials (PVC, polybutene, polymers), but the process of their creation is simple and does not pollute the environment. Pipes are produced by extrusion, that is, extrusion from molten plastic.
There are several types of extruder:
- Screw.
- Combined.
- Screwless.
The first option resembles a meat grinder in its operation. The screwless one operates with a disk, while the combined one combines the principle of the two types listed above. Study the specialized literature in detail and talk to experts to choose the best option for your business.
Operating procedure
Pipe production is divided into stages:
- Introduction of raw materials into the receiving hopper: plastic granules, which begin to melt at high temperatures.
- The newly formed composition is passed through the extruder head, taking on the shape and dimensions specified by the manufacturer.
- The pipe enters the container of the pulling machine. High pressure ensures final processing - giving shape and diameter.
- Pipes are cut, stacked or wound into coils.
Equipment and production
To organize the plant’s workflow, you will need to purchase:
- Extruder.
- Slicing unit.
- Apparatus for transporting raw materials.
- Container for calibration and cooling.
- Mixer.
- Pulling device.
- Conveyor.
- Former with vacuum installation.
- Storage and stackers.
The productivity of the workshop depends on the characteristics of the pipes (diameter). The average is 1000 meters of pipes/shift. The indicator may vary depending on the characteristics of the equipment. Check the information in advance before purchasing units.
The raw materials for making pipes are plastic granular polymers. Choose the source material responsibly and pay attention to its expiration date. To produce quality pipes, use propylene copolymer, polypropylene or polyethylene. These are high-quality raw materials at a low price.
Advice! When changing raw materials, you need to change the equipment settings. To avoid wasting time, purchase several lines or initially determine the working material.
Premises and staff
The plant is located outside the city on an area with free access. The equipment occupies from 40 to 200 sq. m of area, the rest of the premises is intended for staff (locker rooms, kitchens, bathrooms), storage of finished products and raw materials.
The staff of one shift includes the following positions:
- Technologist.
- Support workers.
- Production line operators.
Decor
To operate an enterprise, you need to obtain permission from the gas service, fire safety inspection, Gosnadzorohrantruda, and SES. Study the rules for storing finished products and other organizational issues so that in the future there will be no problems with executive authorities.
Rough calculations show that the investment for the purchase of used equipment and the purchase of raw materials in the amount of 100 tons is 8-9 million rubles. The calculations include rent for the premises for a period of six months. Business profitability varies between 2-20%, which is due to competition. The payback period of the project is 1.5-2 years.
Search for buyers based on the demand for the product. These can be utilities, wholesale and retail stores. Send a business proposal to construction companies.
Eventually
Before opening a business, immediately make a list of potential buyers and study the market in your region. There are often problems with implementation. This approach will help prevent a negative development scenario and determine in advance the feasibility of production.
