How to open a business for the production of corrugated board. Business plan for organizing the production of corrugated board

So, you have decided - let's start corrugated board production plant. What to do for this, where to start and how much will it cost to start a business? We will talk about this in this article.

Overall Market Analysis

The production of corrugated board is considered cost-effective and promising business despite high competition. The prospects of the direction can be assessed on the basis of the following parameters:

Features of the climate of the region, volumes different type construction, including long-term construction, etc.;
sales volumes, prices, competitive advantages, range of competitors;
is there a metallurgical plant in the area for the supply of raw materials;
are there factories in the area that specialize in the manufacture of metal profiles (the absence of a factory within a radius of 200 km gives good chances for business development).

Issues of organizing the work of the enterprise

Factory for the production of corrugated board it is best to register in the form of an LLC and stop at common system taxation. Among the OKVED codes, you must choose:

27.33 "Manufacture of bent steel profiles",
51.53.24 " Wholesale others building materials»,
52.46.73 " Retail metal and non-metal structures, etc.”

Production of corrugated board must comply with GOST 24045-94, but it is not necessary to certify it.

Sales market

So, we are launching a plant for the production of corrugated board. The question logically arises, where are we going to sell it? There are several options:

Production of products to order, including non-standard;
wholesale sales to enterprises of the corresponding profile;
retail and wholesale sales through dealers and shops.

Raw materials for production

The production of corrugated board requires the use of rolled products of the highest or first category. It includes:

Aluzinc coated steel (TU 14-11-247-88).
rolled steel with a polymeric protective and decorative coating (GOST 30246-94);
galvanized rolled steel (GOST 14918-80).

There are raw materials of different price categories on the market: both domestic, Chinese, and from European factories.

Manufacturing facility

The plant for the production of corrugated board must have a workshop with a total area of ​​300 m2, zoned for a warehouse finished products, raw materials and production area: 100 m2, 50 m2 and 150 m2 respectively. It is better to provide several exits so that loading and unloading can be carried out simultaneously.

Production of corrugated board must meet the following requirements:

The presence of a monorail, a beam crane and other special equipment, carrying capacity (from 5 tons);
room temperature from 4 C (if the line is running - from 10 C);
concrete flat floor;
industrial power grid;
communications and heating.

Equipment for the production of corrugated board

The production of corrugated board will require investments in:

1. Automated line for the production of corrugated board (1,430,000 rubles), which includes:

System automatic control;
reception table;
hydraulic cutting knife;
rolling mill;
uncoiler drum.

2. A beam crane, which has a lifting capacity of up to 10 tons. A used crane will cost 200 thousand rubles.

3. A forklift that will transport the finished corrugated board to the warehouse (300 thousand rubles).

The total equipment will require 1,700,000 rubles.

Staff

The production of corrugated board is carried out by a staff of four people who will work in an 8-hour shift:

One master operator (responsible for the machine for the production of corrugated board and work on it);
two auxiliary workers (loading and unloading);
one manager (sales, deliveries, contracts).

Technology for the production of corrugated board

The roll of steel is mounted on the unwinder so that one of its ends is fixed in the filling stand. Then you need to program the line. In this case, the width remains unchanged.

Steel is passed through several pairs of special working stands, in which it receives necessary form. Automated line for the production of corrugated board allows you to produce corrugated board without defects and quickly.

Then the sheet enters the press, where it is cut with guillotine shears and sent to the receiving table. Here the sheets are stacked and sent to the warehouse for storage.

Transport and storage requirements

All necessary requirements are fixed in GOST 15150. Sheets should be stored in packs tied with polypropylene tie-down straps. Below should be a wooden stand to which they are securely attached. Gaskets must be installed under the constriction and at the corners.

Unloading and loading is carried out with soft slings. Sheets are stored in one tier, you can outdoors.

Video plot of the technological process of corrugated board production:

Business plan for the production of corrugated board

Square meter S-8 corrugated board is made of galvanized steel 0.45 mm thick, weighing 4.42 kg/m2. The roll is taken with a standard width of 1250 mm. It should be borne in mind that after profiling, this figure will decrease. Let's say if the corrugation is 8 mm, then the sheet will become 1,195 mm wide. and weighing 3.70 kg. In total, 270 m2 of S-8 corrugated board with a cost of 185.93 rubles will be obtained from a ton of steel.

500 m2 of corrugated board is produced per shift, and 12 thousand m2 per month. A square meter costs 240 rubles, so you can earn 2,880,000 rubles per month. Taking into account the deduction, this will amount to 648,840 rubles.

In terms of costs, production will require approximately 338,923 rubles. per month:

Transport - 90,000 rubles;
taxes - 107,739 rubles;
accounting for outsourcing - 5000 rubles;
electricity - 5184 rubles;
utilities - 12,000 rubles;
rent - 45,000 rubles;
salary - 74,000 rubles.

Net profit will amount to 309,917 rubles per month. Accordingly, investments will pay off in about six months. All this says one thing: we are launching a corrugated board production plant!

In an environment where Western suppliers and manufacturers can be squeezed out of Russian market, there is no doubt about the prospects of business plans for construction topics. The production of corrugated board is no exception, it is about it that we will discuss today in our new publication.

Business plan for the production of corrugated board

The use of corrugated board in construction

Decking is one of the best building materials that is used in roofing works. In addition, fences, fences and much more are made from it.

This building material is represented by a profiled galvanized metal sheet. For its profiling, special equipment is used.

The main advantages of corrugated board:

Reliability, rigidity of the material, which provide a long period of its service;

Availability of prices to a wide range of consumers.

These advantages of corrugated board determine its demand in private and public construction. Therefore, it is natural to say that the production of this building material will definitely be a profitable, highly profitable undertaking.

Equipment for the production of corrugated board

As in other activities related to the production of building materials, to open a mini-workshop you will need special equipment - a production line, which consists of:

unwinding machine;

Guillotines;

profiling machine;

Control unit.

Such equipment of the mini-workshop will make it possible to receive from 1.8 to 3 km of material per month.

The costs associated with the acquisition of the line will amount to 1-5 million rubles. The cost of the line is primarily affected by the production capacity of the facility, its technical capabilities. If you do not be stingy and purchase an expensive line, the following operations will become available: adjusting the profile height, bending angle, coating the sheets with a polymer, which eliminates the need for additional processing, painting the sheets.

As experts assure, the best supplier will be the one closest to the production facility. In this case, the costs associated with transportation, installation and maintenance of the units will be noticeably lower than in the case when the supplier is far from the place of sale.

Production room

The choice and equipment of the premises should be deliberate. The beauty of such a business is that a production facility (mini-workshop) can be opened, as in outline locality, as well as outside of them.

Preference should be given to the premises to which it was initially provided with convenient access roads. The availability of serviceable utility networks and a loading and unloading area will allow to reduce the initial investment. The minimum area of ​​the production facility is 50 sq. m. But with this size of a mini-shop, it is unrealistic to establish a truly profitable business. The practice of small business has shown that a room with an area of ​​​​200-300 square meters will be the best.

The premises can be purchased as a property, or you can rent. Both cases have their pros and cons. For example, the acquisition of an object will involve a large initial investment. It is not uncommon for landlords to refuse to renew (conclude another) lease agreement, which is the reason for the closure of production.

Advice: if you want to reduce future costs associated with paying for rented premises, then you should pay attention to an object that is located outside the city.

It is unlikely that the selected premises will not require repair. Therefore, it is necessary to focus on the costs for its implementation. Basically, more than 500 thousand rubles are spent on repairs and decoration of the premises.

This is interesting: read our other articles -, lamps and.

Working staff

In the process of business planning, it is worthwhile to deliberately approach the formation of a workforce, since wage requires corresponding monthly expenses. To find out about the reasonable size of the working staff, it is necessary to be guided by the planned mode of operation of the mini-workshop in the process of compiling a list of vacancies.

If there is a one-shift mode of operation, then 5 employees will be sufficient for the operation of the mini-workshop. There is no need to train all employees in the nuances of working with the equipment. For successful production one trained specialist is enough.

There should be a couple of workers per unit, one of which will control the control unit, and the second will receive and stack the finished material.

Note that this production is characterized by seasonality. The professional flooring is in the highest demand from the beginning of the spring period to the middle of autumn. During this period, a two-shift mode of operation will be rational. And this will require additional workers (form of employment - on a temporary basis).

Sales and advertising of products

The development of any production is impossible without a well-designed and conducted advertising company. It minimizes (negates) the likelihood of a production process being interrupted.

Also, for the successful and continuous operation of the mini-workshop, it is necessary to have ways to sell products.

This type of building material is in demand among public organizations, specialized trade facilities, distributors and dealers.

In order to expand the client base, search for new distribution channels, increase brand awareness, it is necessary to outline the most cost-effective and effective advertising strategy at the stage of business planning.

You can use local TV, radio channels, periodic print media. Leaflets, pasted ads at stopping points, metro stations, at the entrances will be useful. In such a business, it is not bad to conclude supply contracts with large retail facilities.

financial business plan

Financial side business must be set out in the business plan.

Expenses in this type of entrepreneurial activity are associated with:

Equipping the production facility with aggregates - at least 1 million rubles;

Rent - from 250 thousand rubles. in year;

Salary - about 400 thousand rubles;

That is, to implement a business plan based on the production of corrugated board, you will need to spend at least 1.75 million rubles.

The payback period of the initial investment is primarily determined by:

technical capabilities production line;

Competitiveness;

Demand for building materials at the place where the business idea is implemented.

In the best case, the initial investment will be justified based on the results of 12 months of work.

If you are going to open a large-scale production, you cannot do without an analytical study of the corrugated board market in Russia. Please note that in 2013 we carried out, it is possible to refine it for your business, bringing the current changes for 2014.

This business plan is a visual aid for a budding entrepreneur who decides to start producing corrugated board. It can be used as a presentation for an investor, as well as an example for getting a loan from a bank. Here the procedure for opening a corrugated board production enterprise is described in detail, economic calculations and projected earnings of the company.

The purpose of the project is to substantiate the economic efficiency of the project and obtain Money for its creation and development.

Production of corrugated board: preparatory stage

In order to justify the expediency of opening a corrugated board production enterprise in the city (we take the abstract city N as an example), we conducted a study of the local market and found out that all the corrugated board that is sold in this territory is brought from other cities and regions. Own enterprise in the city is absent, in this regard, there is reason to believe that the opening of such a plant is an effective and cost-effective project. Competitive advantages v this case are the presence of metallurgical production in the city and, as a result, the purchase of materials for more low prices and also low cost of transportation costs.

It is recommended to choose a "Limited Liability Company" as the organizational and legal form of the future enterprise. The system of taxation is general.

Necessary equipment for starting production

Location of the future enterprise. Repair work

The enterprise for the production of corrugated board will be located in separate room 270 sq. m. It will be located in the industrial area of ​​the city and will be equipped with convenient access roads for loading manufactured goods onto vehicles. To open an enterprise in the premises, it is required to make repairs, costing 420 rubles, which includes repairing the floor, replacing electrical wiring and installing additional power lines, changing window structures and other expenses. Study repair work there will be a specialized company, which will be selected by competition. The winner and owner of the tender will be the firm that offers the most profitable terms execution of the transaction.

Work with personnel

The following employees are required to open a corrugated board production enterprise.

Employees of the enterprise will work on a standard 5-day working week. One shift is 8 hours. In total about 24 shifts per month. During the season it is possible to increase the number of shifts.

Sales of products

The manufactured products are planned to be sold as follows:

• Implementation in specialized stores with the conclusion of supply contracts
• Implementation industrial enterprises
• Implementation through a network of dealers and distributors

Project launch schedule

Stage name				September
Making an advance payment (30%) for equipment
Preparatory work for the location of production
Admission to power lines 380 V
Additional payment (70%) for equipment
Equipment delivery
Commissioning works
Purchase of rolled metal
Start of the enterprise

Startup cost schedule

Item of expenses	Amount of expenses, rub.	Source of financing
Purchase of equipment		Investor
Preparing the workshop for line placement		Own
Admission to power lines 380 V.		Own
Equipment delivery		Investor
Acquisition additional equipment(tools, loader, overhead crane)		Investor
Commissioning works		Investor
Purchase of rolled metal		Own

As can be seen from the presented graph, 2 million 340 thousand rubles will be required to open an enterprise for the production of corrugated board. Of these, the investor's funds will amount to 1 million 540 thousand rubles, the funds of the project initiator - 800 thousand rubles.

Project financing

Projected production level

As can be seen from the graph, the production of corrugated board is a seasonal business. The peak of demand falls on the spring-summer period.

Planned revenue

Production cost

	Consumption per day	Unit price	Price per shift, rub.	Price per month (24 shifts)
Rolled metal (in tons)
Electricity, (in kilowatts)
				2 242 833,6

The organization of a business for the production of corrugated board and metal tiles is a very relevant area today. The number of buildings under construction for various purposes is steadily growing every day. Moreover, buildings of supermarkets, all kinds of hangars, production shops, covered car parks - this is an incomplete list of objects in which the roof project provides for the use of profiled flooring for it, or corrugated flooring for short. This material is also used as temporary fences for construction sites, can also be used for fencing suburban buildings. To all of the above, we can add that metal tiles are used as roofing, its use is more suitable for private households, office buildings, various retail facilities and other buildings, both in urban and rural areas. As practice shows recent years, such production has a high profitability.

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Technological process

The process of production of metal tiles is in a certain way connected with the production of corrugated board. The method of obtaining corrugated board is based on the fact that a galvanized steel strip is rolled on a profile bending mill and subsequently cut into sheets of a given length. As a result, the output has steel sheets having waves in their profile, which gives an aesthetic appearance and rigidity to the sheets.

The production of metal tiles occurs in much the same way, a strip is profiled, and then, by cold pressure, transverse ribs are stamped, which gives the sheets the look of a classic tile.

The plan for creating a business has its own characteristics.

For the profitability of production and reaching the required level of sales of finished products, it is necessary to obtain high quality corrugated board or metal tiles.

This requirement is related to the equipment on which the products are manufactured. Modern lines for the production of corrugated board or metal tiles include a whole range of technological equipment. Different manufacturers of roll forming machines supply seemingly the same type of equipment, but in the end, right choice line radically affects the final consumer properties of products. Mill automation, roll banding accuracy and calibration, mill drive are global factors for obtaining the products required by the market.

The metal tile is usually made of steel strip with polymer coated, corrugated board is made from a conventional galvanized strip, sometimes from a polymer-coated strip. When purchasing equipment, this factor should be taken into account. In other words, the business plan must take into account what metal will be profiled.

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Drawing up a business plan for organizing the production of corrugated board

One of the key areas in the organization of production is a well-written business plan.

For successful work line of roll forming equipment will require a room of about 250-300 sq.m. The profile bending mill includes: decoiler, setting mechanism, looper, directly roll forming stands, guillotine shears. The production plan provides for a crane with a lifting capacity of 10-15 tons and a loader.

In the future workshop should be carried out preparatory work, general repair, the foundation for the mill, you should also obtain permission to use a three-phase electrical network.

The organization of the work of the workshop is planned in one shift, 8 hours. Number of shifts - 24 per month. For the full production and maintenance of equipment, 5 people are enough: maintenance personnel - 4 people and an accountant - 1 person.

The average power characteristic of the production line is 600 sq.m of corrugated board per day.

Approximate start-up costs

Planned production - 600 sq.m of corrugated board per shift. Initial material - galvanized steel with a polymeric covering. Wholesale sales of products are expected at a price of 230 rubles/sq.m.

As a result, daily production: 600 sq.m;

Price per sq.m: 245 rubles;

Price for 600 sq.m, that is, for a shift: 147,000 rubles;

Monthly production: 3,528,000 rubles.

Costs associated with the production of corrugated board:

Total: 380,000 rubles

Cost plan

As can be seen from the calculation, the approximate profit per month will be 437,000.

This is a theoretical calculation and does not include contingencies. Special permits, laboratory examinations of the quality of the manufactured corrugated board, design and installation may be required fire fighting systems security.

In this article:

Decking is a versatile material, indispensable in many areas of construction. Despite the fact that the manufacture of profiled sheets is no longer a novelty for domestic manufacturers, the popularity and demand for this building material increases every year in proportion to the increase in construction volumes.

Assessment of the situation in the regional corrugated board market

The production of corrugated board is a promising and highly profitable business. But competition in this area is also high, since profiled sheets are produced as metal-rolling plants in industrial scale and individual entrepreneurs.

Therefore, before opening the production of corrugated board, it is necessary to assess the prospects of the region according to the following parameters:

• the presence of large factories specializing in metal profiles. High competition will require large capital investments to enter the market, advertising costs and price reductions to attract potential buyers, so production may not be profitable. But if there is no large plant within a radius of 200 km, and the delivery comes from afar, there is an opportunity to quickly conquer the market by reducing the price by minimizing transportation costs;
• availability of metallurgical production in the region. The purchase of rolled metal blanks directly, at manufacturer's prices and with a minimum of transportation costs, will significantly reduce the cost of production;
• competitive advantages, prices, assortment and sales volumes of existing manufacturers;
• climatic features of the region, volumes of private, country, suburban construction, the presence of long-term construction and other prospects on which the choice of strategy, type of product and volumes of future production is based.

Organizational moments

As organizational form for a business producing corrugated board, an LLC on the general taxation system is recommended.

OKVED codes:

• 27.33 "Manufacture of bent steel profiles",
• 51.53.24 "Wholesale trade in other building materials",
• 52.46.73 "Retail trade in metal and non-metal structures, etc."

Profiled sheeting is not subject to mandatory certification, but it is recommended to adhere to the standards of GOST 24045-94 during its manufacture.

Sales market

The implementation of corrugated board is planned in the following areas:

• wholesale and retail sales through specialized stores, bases, dealers, building supermarkets;
• wholesale to construction and industrial enterprises through participation in tenders, at auctions;
• work "on order" for the manufacture of batches of profiled sheets of non-standard sizes.

Raw materials for the production of corrugated board

Profiled sheeting is made from rolled products of the first and highest category:

• galvanized rolled steel (GOST 14918-80);
• rolled steel with a polymeric protective and decorative coating (GOST 30246-94);
• coated aluzinc steel (TU 14-11-247-88).

Metal for the production of corrugated board in the form of rolled blanks (for automated lines) and finished sheets of rolled metal (for manual profiling) are offered by domestic manufacturers, China, South Korea, European factories (Slovakia, Germany, England, Ukraine).

Room for the production of corrugated board

To open production, it is planned to rent a workshop with an area of ​​300 m 2, divided into a production area (150 m 2), a place for storing raw materials (50 m 2) and a warehouse for finished products (100 m 2). It is desirable that there are several gates in the room (for receiving raw materials and unloading finished products).

The production workshop must be equipped in accordance with the following requirements:

• availability of heating and all necessary communications;
• connection to the line at 380V;
• smooth concrete floor;
• the temperature regime in the room is not lower than +4 C (and when the line is operating, it is recommended not lower than +10 C);
• availability of special equipment with a lifting capacity of at least 5 tons (crane, monorail).

Equipment for the production of corrugated board

Capital investment:

• automated line for the production of corrugated board according to GOST 24045-94 (galvanized and polymer-coated) - 1,200,000 rubles. The line is designed for steel profiling with a roll width of 1250 mm and a thickness of 0.4-1.5 mm, the exit length is unlimited. Delivery, installation, setup, training and signal launch of the line are included in the price; Line equipment:
  • drum-uncoiler;
  • rolling mill;
  • hydraulic cutting knife;
  • reception table;
  • automatic control system (ACS).
• Cathead, with a carrying capacity of up to 10 tons, used - 200,000 rubles;
• forklift for transportation of finished products from the workshop to the warehouse - 300,000 rubles.

Total: 1,700,000 rubles.

Staff

At the initial stage, it is planned to hire 4 people:

• 1 master operator (responsible for the operation of the automatic line);
• 2 auxiliary workers (loading / unloading raw materials and finished products);
• director (sales, contracting, establishing trade relations).

Planned 8-hour one-shift work (24 shifts per month).

Technology for the production of corrugated board

1) Material for the production of corrugated board (galvanized steel coil with or without coating) is installed on the unwinder. One end of the metal coil is fixed on the filling stand of the rolling mill and fed at a predetermined speed in the form of a continuous belt.

2) The line is programmed for the production of corrugated board according to the required parameters (only the width is unchanged), the length is any (usually, it does not exceed 12-13 m, since it is limited by the dimensions of the transporter).

3) In addition to the filling mill, the profiling mill has several working pairs of stands (shafts), each of which is equipped with a set of rolling rollers that provide the necessary geometry and height of the corrugation. Rolled metal strip, passing between the upper and lower shafts, acquires a programmed shape.

The advantage of automated manufacturing technology is that all the corrugations are rolled simultaneously, which makes it possible to obtain high-quality material without defects.

4) A guillotine shearing press cuts the rolled sheet, which enters the receiving table.

5) On the receiving table, finished profiled sheets are stacked in packs and sent to the finished product warehouse.

Requirements for storage and transportation of products

Transportation and storage of profiled sheets, including climatic features of various regions, is standardized by GOST 15150.

Profiled sheets must be packed for transportation in packs with a constriction from a tie-down strap (polypropylene, metal), laid on a wooden lining and securely secured from movement. Gaskets are laid at the corners of the packs at the points of contact between the corrugated board and the constriction so as not to damage the coating.

Loading and unloading is carried out using soft slings to reduce the risk of mechanical damage.

During storage and transportation, packs are placed in one tier. A two-tier layer is permissible only if the total mass of 1 m 2 of the upper level profiles does not exceed 3000 kg / m 2. Outdoor storage is allowed.

Business plan for the production of corrugated board

1) Calculation of the cost of 1 m 2 of corrugated board grade C-8

Raw material- galvanized steel, 0.45 mm thick.

Weight of 1 linear meter of roll calculated by the formula: Thickness * width * specific gravity metal 0.45 mm * 1250 mm * 7.85 g = 4,415.63 g (4.42 kg)

Roll width standard- 1250 mm, but after profiling the width decreases. So, for a profiled sheet with a corrugation height of 8 mm, the width of the sheet at the exit will be 1,195 mm, with a constant weight of 1 running/m at the inlet and outlet.

Weight 1 m 2 corrugated board brand S-8 calculated by the formula: 1 running meter(kg) / width of 1 linear meter / meter of finished corrugated board (m) 4.42 kg / 1.195 m \u003d 3.70 kg / m 2

Total, from 1 ton rolled steel 270 m 2 of S-8 grade corrugated board will be released (1000 kg / 3.7 kg / m 2)

The cost of 1 m 2 galvanized corrugated board grade C-8\u003d cost of 1 ton of raw materials / quantity of finished corrugated board: 50200 rubles / 270 m 2 \u003d 185.93 rubles

2) Revenue

For one shift, it is planned to produce 500 m 2 of corrugated board; monthly output– 12,000 m2

With a selling wholesale cost of corrugated board of 240 rubles / m 2, and 24 work / shifts per month, the projected revenue will be: 500 m 2 * 24 working days * 240 rubles / m 2 \u003d 2,880,000 rubles / month.

Profit: 2,880,000 - (185.93 * 12,000 m 2) \u003d 648,840 rubles / month.

3) Consumables

• rent (300 m 2 * 150 rubles / m 2) = 45,000 rubles / month;
• utilities (including heating) - 12,000 rubles / month;
• electricity (daily consumption for the production of 500 m 2 - 48 kW) - 1152 kW / month * 4.5 rubles = 5184 rubles / month;
• salary - 74,000 rubles;
• outsourcing (bookkeeping) - 5000 rubles / month;
• taxes payable - 107,739 rubles / month;
• transportation costs - 90,000 rubles / month.

Total: 338,923 rubles.

4) Net profit

Net profit: 648,840 - 338,923 = 309,917 rubles / month.

5) Profitability of corrugated board production

With the production of 12,000 m 2 / month, capital investments of 1,700,000 rubles will pay off: 1,700,000 rubles / 309,917 rubles / month = 6 months.