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How to organize own production foam rubber

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

Brief business analysis:
Costs of setting up a business:from 20 thousand dollars
Relevant for cities with the population: no limits
Industry situation:average level of competition
Difficulty of organizing a business: 3/5
Payback: 8 – 18 months

Production of foam rubber and its use

Despite the fact that every year the volume of foam rubber production in Russia increases on average by 7%, in order to meet the demand of all consumer companies of this material it is necessary to import it from abroad. Considering the bulk of foam rubber and its relatively low weight, logistics costs often exceed the cost of the material itself. Taking these factors into account, each new mini-factory immediately acquires regular wholesale customers who want to save on components for their products.

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

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

In addition, during construction and repairs they use special sound-proofing foam, which has slightly different properties.

Foam production technology

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

Components for making foam rubber

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

Methods for producing polyurethane foam

There are two main methods for producing foam rubber:

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

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

With the continuous method, the mixture is poured onto a belt and rises as it moves. Upon reaching the end point of the conveyor, the material is already shaped, cut into blocks and moved to the final forming room.

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

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

Acoustic polyurethane foam has the highest density, which ensures sound insulation of rooms. Often, foam rubber crumbs are used in its production.

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

For industrial production of polyurethane foam, the following types of equipment will be required:

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

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

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

Premises and personnel for organizing production

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

Considering the increased harmfulness of production, it is necessary to ensure high-quality ventilation of the room. It is also necessary to maintain a certain temperature regime - at the moment of pouring the working mixture into the mold, the temperature should not fall below +18°C, otherwise it will affect the technical properties of the finished material. To make it easier to maintain the temperature, it is recommended to isolate the pouring shop from other rooms. Other operations such as curing, cutting and storage can be carried out at lower temperatures.

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

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

Profitability and business prospects

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

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

WATERPROOFING SPB

Foam rubber production technology.

Equipment. Components. Reviews.

What is foam rubber?

Foam rubber is a two-component polyurethane foam. Since foam rubber is polyurethane foam with a very low density, it is logical that the components for it are also polystyrene and isocyanate. The properties of the final product directly depend on the formulation (volume and mass ratio of components, additives, plasticizers, thinners). Usually, when making products on one casting machine, the same isocyanate is used, and the second component, the polyol, is selected depending on the technical specifications. And the additives are poured into it. What additives and additives are needed for a particular product are given by the technical department or laboratory of the component manufacturer's plant.

Operating principle of the filling installation.

The main unit of the filling machine is the mixing chamber into which the polyol and additives are supplied. There they quickly mix and, already in a homogeneous state, enter the second mixing chamber where they mix with the isocyanate even faster. And then all this mass is fed into the mold. The larger the foam block hopper, the more components must initially be moved. Most often, pouring into the mold is done once. But if there is a need to make products from two or more types of foam rubber, then pouring can be done in several steps, following the technology of polymerization of each layer using intermediate primers.

When pouring foam blocks, the surface of the mold is treated with a special compound to prevent sticking. Or, before pouring the components into the mold, polyethylene is placed. Polyethylene is one of the few materials to which polyurethane foam does not stick.

Foam rubber is currently one of the “long-lived” materials: polyurethane foam (or PU foam for short) was first developed back in the 1930s, and produced in the 1940s. This is a proven and reliable softening and supporting material used to provide elasticity to products (for example, upholstered furniture) and thermal insulation.

However, its production in Russia does not cover the needs, so foam rubber is often imported from abroad. Therefore, the production of foam rubber may become sufficient profitable business, taking into account the fact that foreign manufacturers will not be able to compete with domestic ones for the simple reason that transporting this material, especially over long distances, often costs more than the transported material itself - after all, foam rubber takes up a large volume with low weight, even if transported in a special compression packaging.

In addition, the production of foam rubber (in relatively small volumes) does not require significant costs for equipment and large production areas, and therefore is perfect for a novice entrepreneur.

However, this point can become a significant obstacle for the local manufacturer: the same territorial restrictions are imposed on him as on foreign manufacturers - the production of foam rubber is actually a very customer-oriented production, the sales market for which is relatively small and quite specific.

The main sales niche is occupied by those industries that produce fragile and suffering from mechanical influences goods such as electronics ( e-books, GPS navigators, etc.) that require a soft pad to protect them from breaking.

Such productions willingly purchase fairly large quantities of foam rubber as packaging, or more precisely, cushioning material. In second place are manufacturers of upholstered furniture, who use foam rubber as padding for inexpensive and mid-price products, which make up the bulk of such products in a medium-sized enterprise: armchairs, sofas, etc., as well as construction companies, sometimes using foam rubber as sound, heat and vibration insulation.

In approximately equal (relatively small) volumes, foam rubber is purchased by shoe manufacturers, who use it as one of the components of shoe insoles, and by manufacturers of audio equipment - microphones, headphones and some types of audio speakers.

A very small volume of foam rubber sales is made up of other clients, among which it should be noted manufacturers of some medical products, such as fixing splints (for example, a collar splint), some prostheses, etc. products. Of course, we should not forget about the sales network for individuals: supermarkets and building materials stores can also purchase a certain amount of products.

So, when opening your own foam rubber production, you should correlate the expected production volume with the expected sales volume, taking into account all potential buyers available in the region and not taking into account the possibility of sending the produced goods outside the zone, which does not imply a competitive cost of the transported foam rubber plus transportation costs with analogues from other manufacturers.

Foam production technology

The production of foam rubber is considered environmentally hazardous and, in some cases, harmful to health. The fact is that for its production polyol, aromatic diisocyanates are used - mainly toluene diisocyanate (toluene diisocyanate) or methylene diphenyl diisocyanate (diphenylmethane diisocyanate), some catalysts and foam stabilizers.

Some of these components are toxic when evaporated, but they decompose into non-hazardous ingredients under the influence of moisture and air - which is why the production workshop must be supplied with running water and well ventilated, and workers must have respirators.

The actual production of foam rubber, as well as any other polyurethane foam, can be classified into two categories: volume, i.e. plant capacity and the production method used - continuous or batch.

Actually, both categories are related: as a rule, the continuous method is used for large production volumes (over 2000 tons per year), although some medium-sized (500-2000 tons per year) enterprises also use it; The periodic method is used by some medium-sized (with a capacity of 500-2000 tons per year) and all small (up to 500 tons per year) enterprises.

The foam production process itself is as follows. Liquid chemical reagents - a composition for producing foam rubber - are dosed into a mixer of a certain volume, then quickly mixed in a foaming machine (in accordance with mixing modes, on which the main characteristics of foam rubber depend - density, compression stress, relative residual deformation during compression, breaking stress, relative elongation at break) and is poured into a movable mold with hinged walls.

After mixing the reagents, a chemical reaction occurs in the mold, which leads to the formation of foam and its rise to the top edge of the mold. The block of foam rubber obtained in this way is kept in the mold for the time allotted by the technology (approximately 15-20 minutes), then the mold is disassembled, and the block is moved to the room for final formation (cooling of the blocks and completion of chemical reactions in them).

After 1-3 days, the finished foam rubber is cut into sheets of the required thickness (usually from 5 to 150 mm) on a horizontal band saw. Sheet foam rubber is sold.

The methods for producing foam rubber differ next moment: with the continuous method, the pouring machine supplies a measured amount of components into the mixer, from where the mixed composition is poured not into a mold, but into a special moving conveyor, where foaming occurs. A continuous layer of material is cut into blocks of the required length. After curing, the blocks are cut into sheets of the required thickness.

Equipment for the production of foam rubber

Equipment for the production of foam rubber using the continuous and periodic methods is not fundamentally different and consists of a foaming machine, a mold (for periodic), a conveyor (for continuous), a horizontal or vertical band saw and a set of kits for dosing components, servicing machines, pumps, etc. Only the power of the equipment is different, i.e. its performance.

Ready Production Line for low capacity (from 100-140 to 500 tons per year) with the possibility of expansion it will cost $16,700, which when converted into rubles at the current exchange rate is about 510 thousand rubles, and taking into account installation and personnel training - $24,700 ( about 755 thousand rubles).

To further expand production, you will need: a thermal chamber for tempering raw materials, accelerating the final formation process - $6,000, or about 180 thousand rubles; additional automatic set of dosing devices and containers - $6,200, or about 190 thousand rubles; as well as an additional vertical bandsaw machine - $5,000, or about 153 thousand rubles. After these investments, the production of foam rubber will increase approximately 2-2.5 times, but it should be remembered that the production method will remain the same, i.e. periodic.

A fully automated set of equipment for the production of foam rubber using a continuous method will cost slightly more – 6,200 thousand rubles. However, in addition to the basic equipment, there is also additional equipment, which should be purchased as soon as possible if it is not possible to purchase it immediately.

Such machines include, for example, a machine for rolling and packaging sheets in plastic film or paper costing $7,000, or about 214 thousand rubles; a crusher for processing foam rubber crusts into crumbs, which is used for stuffing relief products in the production of upholstered furniture, and is also used in the production of “recycled foam rubber” worth $2,000 or about 61 thousand rubles, as well as the actual set of equipment for processing waste foam rubber and obtaining recycled foam rubber worth $9,000, or 275 thousand rubles.

Premises and personnel required for the production of foam rubber

The basic requirements for the production premises are limited only to the height of the ceilings (which must be at least 3 m) and maintaining temperature regime at a level not lower than 18°C: if the air temperature in the block pouring area drops below 18°C, then the production of foam rubber is impossible.

The temperature limitation applies only to the block pouring area (30-50 sq.m.), which can be separated from the rest of the workshop into a separate room to easily maintain the required temperature. Further aging of the blocks can be done in a room with a lower temperature, and cutting and storing the finished product can be carried out at any temperature.

The total area of ​​the workshop for the production of foam rubber is 200-250 sq.m., including a living room for production workers and a small office for the technologist. The presence of 380V electrical wiring with a ground loop is mandatory, as is properly installed ventilation. In addition, band saws require a lightweight foundation.

Convenient access roads should lead to the workshop, and the area in front of it should provide an opportunity for unloading barrels of raw materials (200-250 kg).

To produce sheet foam rubber, a person is required who either has an education as a chemical technologist or has undergone appropriate training, which is often provided by manufacturers of foam rubber production lines. In principle, having a chemical education is a desirable, although not mandatory, criterion when selecting personnel.

In addition, to service the machines, 3 people are needed for the filling machine and 2 people for the cutting machine, and for loading and unloading goods and raw materials and other work - 2-3 general workers. The qualifications and education of production workers are not of great importance.

Prospects for business development in the production of foam rubber

The main direction of development of the foam rubber business is the production of molded products. Such products are now used mainly for seats and backs of car seats, as well as in the furniture industry - in the segment of expensive upholstered furniture.

In addition, an option that requires practically no additional costs is the production of rugs, sponges, strips for window insulation, children's toys, “hangers” for clothes, etc. household goods.

We should not forget about the introduction of new technologies: in the West, instead of foam rubber, non-flammable polyurethane foams (which are produced by introducing special additives) have become widespread.

Video about the production of foam rubber

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 during production. In fact, you can make foam in basic laboratory conditions in a chemistry lesson. Today, you and I encounter foam rubber everywhere every day in its various manifestations. Cover with foam rubber upholstered furniture, make sound insulation, insulate doors, etc. Elastic polyurethane foam (PPU) is found in our kitchen, in the bathroom, in the children's room, in our furniture and in many other things that a person encounters 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 equipment package is quite affordable for small businesses.

Equipment for the production of foam rubber

Foam rubber is produced using two production technologies:

1. Continuous production technology.
2. Batch production technology.

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

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

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

Batch technology in the production of elastic polyurethane foam

The batch production technology is as follows:

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

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

Profitability of a business idea

Let's calculate the profitability using the example of one standard portion of foam rubber produced by the 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, the output is a block of foam rubber, which should be cut into foam sheets (2000x1000x10mm). The retail price of one such sheet is $2. We should have at least 100 sheets (because 2 of them will most likely be defective).

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

Properties in high-quality foam rubber

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

The main parameters for assessing the quality of foam rubber:

1. Durability of elastic polyurethane foam. At this stage, the level of ultimate strength is checked, which is determined by the level of elongation at break.
2. Elasticity. This indicator is directly dependent on the rigidity of the elastic polyurethane foam; the greater the rigidity, the less elasticity. This quality point is checked by measuring the height of the “jump” of the ball that falls on the sample.
3. Rigidity. This indicator is checked by compressing a sample of the product by 40% of the total length of the sample. Hardness depends on the pore size; the larger the size of the balloons, the higher the hardness.
4. The density level of polyurethane foam is measured in kg/cubic meter. And this is the main indicator of quality.
5. Percentage of permanent deformation. This parameter indicates the ability of elastic polyurethane foam to maintain its original performance throughout its entire service life. It is measured by squeezing a sample of polyurethane foam for a certain amount of time, and establishing a percentage of the initial values.
6. Comfort of elastic polyurethane foam. Furniture foam rubber marked HR is distinguished by this parameter.

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

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

The furniture industry mainly uses EPU with the HR marking. ST marked is also used for the production of furniture, but only for those that will not be subject to heavy loads.

Sales of manufactured products

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

Today, we can say with some confidence that the foam rubber production market is quite competitive. Therefore, you should not count on large factories and enterprises as consumer partners. But if you have small furniture enterprises in your city, you can easily compete with large competitors.

Manufacturing precautions

Elastic polyurethane foam itself is safe for humans, so it is allowed to produce upholstered furniture from it. Although the finished foam itself is not hazardous to health and meets all hygienic standards, its production process requires strict adherence to production precautions. Chemical components in contact with mucous membranes can cause irritation in humans. Isocyanate (an essential component) has Negative influence on the skin and respiratory tract. Therefore, the operator must wear a respirator, safety glasses and a protective suit. It is also necessary to equip the production premises with supply and exhaust ventilation, which is designed in accordance with safety standards. This will get rid of the unpleasant odor. And all harmful substances disintegrate under the influence of air into elements that are absolutely safe for humans. It is forbidden to pour non-recycled components down the drain, as this will cause clogging. environment. Unrecycled materials should be disposed of safely.

If you pay attention to which companies are most often opened today, then without a doubt you can name jewelry, alcohol, automobile and furniture. Let's pay attention to the furniture. It consists of simple and lightweight materials, but with an interesting design it can be very expensive. Thus, furniture brings high income with minimal costs. As a result, equipment for the production of foam rubber is considered relevant for purchase.

The material is widely used in the manufacture of furniture, toys, and sporting goods. Foam rubber is a material consisting of polyurethane. It is very elastic and resilient, since 90% consists of cells filled with air.

Material used in manufacturing:

• various furniture;
• soft toys;
• car seats;
• sporting and household goods.

Production volumes of upholstered furniture in Russian Federation are increasing every year. Annual increase by this segment market share is 10%. With the development of this industry, the demand for the materials needed also increases. The main one is foam rubber.

At the moment, there are two main methods that are used in the production of foam rubber: continuous and periodic. Small firms use the second technology because it is simple, and the costs of purchasing equipment and its maintenance are minimal. In addition, no specific education is required to make foam rubber; it is enough to take training courses offered by suppliers.

Equipment for the production of foam rubber

In order to start making foam rubber, you need to have:

• machine (automatic) for foaming;
• thermal chamber;
• machine for cutting blanks;
• dosing apparatus;
• configuration block (form);
• related materials (couplings, hoses, etc.).

In order to organize a full-fledged line, you should purchase additional devices: a waste crusher, a machine with which you can curl sheets, and a film packaging machine. The above types of equipment can be ordered separately, or you can purchase a complete line.

Necessary costs for the production of foam rubber

A set of equipment that produces 12 m 3 of material in one shift costs around 300 thousand rubles. If you order a line that includes all devices for producing foam rubber of various brands and is capable of producing up to 30 m 3 of foam rubber per shift, you will need 1.3 million rubles.

There is an option in which you can order a mini-factory in China. The production volume of such a line is at least 50 m 3 of finished material per shift. The issue price is 1.6-1.8 million rubles. This option is more profitable. To effectively build the process, you will need 7 employees who will work 8 hours per shift. Capital costs for organizing a line for the production of foam rubber will amount to approximately 1.78 million rubles.

Those who decide to engage in this activity need to register an individual entrepreneur. Find suitable premises, where the workshop will be located with a total area of ​​200 m2. Find buyers among enterprises and firms that produce furniture and other goods that use foam rubber.

Line load is closely related to customer demand for upholstered furniture. The largest revenue will be generated during the peak time of furniture sales (autumn and from February to April). The rest of the time there will be a decrease in revenue due to seasonal customer demands. There are very few orders in January, this is primarily due to the holidays. This is the best time to spend Maintenance equipment.

How much can you earn from producing foam rubber?

Revenue is best calculated assuming that the line is 50% loaded. When producing foam rubber with parameters of 20 mm thickness and density 25 kg/m3, the price for large orders will be 150 rubles/sheet, and the retail price will be 250-270 rubles. As a result, we can create the following table.

When producing a sheet of foam rubber, the cost will include the cost of raw materials for production and the energy used.