What is needed for the production of profiled sheets. We are launching a plant for the production of corrugated sheets. General cost estimate for project implementation

The production of corrugated sheets is considered a highly profitable and quite promising direction in business. But there is high competition in this area, since such material is produced by both large enterprises and private individuals.

Making a business plan

Before you begin to develop a business plan for the production of corrugated sheets, you need to objectively assess the prospects of the region.

This can be done using the following parameters:

• The presence of large enterprises that produce metal profiles. To enter into competition with them, large investments will be needed. In addition, you will have to spend a lot of money on advertising and significantly reduce product prices in order to attract buyers. As a result, production may become unprofitable. This strategy may soon lead you to bankruptcy;
• Availability of raw material suppliers in the region. If you buy blanks directly from the manufacturer at wholesale prices, the production cost will be much lower;
• The assortment, sales volumes, and prices offered to consumers by existing manufacturers;
• Demand for products in your region. This parameter can be assessed by the volume of private and commercial construction.

Registration

These products do not require mandatory certification. Conscientious manufacturers produce corrugated sheets in accordance with GOST 24045-94.

Enterprise equipment

As in any other form production activities To open an enterprise, you need to select equipment for the production of corrugated sheets. The automatic line consists of several units. Its total cost largely depends on technical capabilities, as well as power and performance. If you purchase expensive units, you can use them to make any profile height and bending angle. In addition, you can paint the sheets and apply a polymer coating to them.

Scheme: production of corrugated sheets

You will have to spend approximately more than 1 million rubles to purchase equipment for the production of corrugated sheets and metal tiles. It is advisable to find a supplier in your area to save on transportation and maintenance costs for the production line.

Purchasing equipment in the manufacturing sector is always expensive. If you cannot afford to start this type of business yet, you can try to start with a simpler activity. Alternatively, you can start or open a small business in .

Room

The choice of premises must be taken very seriously. Finding a suitable option will not be difficult, since such production can be opened anywhere - in the city or outside it.

Pay attention to access roads, utility networks, as well as areas for unloading material for the production of corrugated sheets and loading finished products. For a small enterprise, a premises with an area of ​​over 100 square meters is sufficient. meters. If you are planning to open a factory, rent a premises with an area of ​​250–350 sq. m. meters. To optimize costs, you can rent production space outside the city.

Most likely, the premises will require repairs, so this expense item should be included in the business plan. The finishing of a mini-workshop usually costs about 500 thousand rubles.

Staff

The greatest demand for corrugated sheets is observed in the warm season, when the building sector. During this period, the company can organize two work shifts. To do this, you will have to hire additional temporary employees.

Advertising and sales of products

Promoting any product on the market is almost impossible without effective advertising campaign. Thereby manufacturing process will develop and generate stable income.

In order for corrugated sheet plants to operate continuously and successfully, it is necessary to find reliable ways to sell the products. It can be implemented through shopping facilities, dealers and distributors.

Seek help from specialists who can help you find new markets. An affordable advertising strategy must be outlined at the very first stage of organizing production, that is, when developing a business plan. To ensure a stable income, try to enter into an agreement for the supply of products with large trading enterprises.

Expenses

When drawing up a business plan for a future enterprise, you need to calculate everything financial expenses. Determine one-time and monthly costs to evaluate the feasibility of a commercial project. Organization own production corrugated sheeting will entail the following costs:

• Purchase of equipment – ​​1 million rubles;
• Rent of premises for a year – 300 thousand rubles;
• Workers' salary – 450 thousand rubles;
• Transport and advertising – 120 thousand rubles.

If we talk about the payback of the project, it largely depends on the following factors:

• Technical capabilities;
• Presence of competition;
• Demand for products.

Successful production pays for itself in literally six months.

Making profiled sheets at home

Many novice businessmen, whose financial capabilities do not allow them to purchase a line for the production of corrugated sheets, are interested in how to produce this material using manual equipment.

Do manual machine for the production of corrugated sheets you can do it yourself. But such equipment is extremely rare. A manual sheet bender is inexpensive, so it’s easier to purchase a ready-made universal unit. Products manufactured on such equipment are in no way inferior in quality to factory ones. Poor performance manual labor usually compensated by high quality.

If you use a machine to produce corrugated sheets with your own hands, you should remember that you should purchase raw materials for these purposes High Quality. It is better to buy equipment from well-known manufacturers with an impeccable reputation.

The process of making corrugated sheets

General conclusions

Competently organized business the production of corrugated sheets is a highly profitable business that brings excellent profits. Before you start work, you need to calculate all costs and expected profits. At the same time, take into account all the features of this area of ​​business activity.

The main advantages of such a business are as follows:

1. Small initial investment;
2. High profitability;
3. Great demand for products;
4. Fast payback.

If you are planning to open large enterprise, for example, by

• Capital investments: 2,190,000 rubles,
• Average monthly revenue: 2,880,000 rubles,
• Net profit: 160,000 rubles,
• Payback: 14 months.

Purpose of the business plan: Attracting investor funds to organize a workshop for the production of corrugated sheets capable of producing up to 720 sq.m. finished products per hour.

1. Organizational and technical planning

1.1. description of the project.

After analyzing proposals for sales of corrugated sheets in the city “N”, it was revealed that all the presented material is imported to us from neighboring regions; there are no products of our own production for sale.

In this regard, opening a company with the above-mentioned specialization is a promising direction for starting a business. Competitive advantages:

• the presence of metallurgical plants in the region and, as a consequence, the possibility of purchasing rolled metal at manufacturer prices, excluding transportation costs.
• low cost of transportation costs for delivery of finished products

1.2. Necessary equipment for the production of corrugated sheets

To equip the workshop you need to purchase the following:

1. Main line
2. Forklift

Production Line

It is planned to purchase a PS-8 line for the workshop, manufactured by Lipetsk Roll Forming Equipment Plant LLC, Lipetsk. This line is designed for the production of corrugated sheets from rolled steel with galvanized or polymer coating. The maximum width of rolled steel used is 1250mm. Line productivity is up to 720 m2 per hour.

Line cost: 900,000 rubles.

Crane beam, lifting capacity 10 tons

To reduce costs, the possibility of purchasing a used crane beam is being considered. Maximum price: 200,000 rubles. Initial negotiations with the owner have been carried out, an agreement on the purchase has been reached.

Forklift

To transport finished products to the workshop, you need to purchase a forklift. To reduce costs, the possibility of purchasing a Doosan forklift manufactured in 2003 is being considered, the cost is 300,000 rubles. Excellent condition. Initial negotiations with the owner have been carried out, an agreement on the purchase has been reached.

1.3. Location.

The workshop will be located in its own premises. Area 270 sq.m. The premises are located in the industrial part of the city, have convenient access roads for freight transport, and have all the necessary communications.

Repair costs:

1. Repair the floor to install the line - RUB 200,000.
2. Replace electrical wiring, install additional lines - 100,000 rubles.
3. Replacement of windows - 100,000 rubles.
4. Others - 100,000 rub.

1.4. Staff.

Staff of 4 people: 1 foreman and 3 workers to work in the workshop. It is planned that the workshop will operate in one shift (8 hours), 24 shifts per month. During the season, it is possible to increase the number of shifts per month.

1.5. Sales markets.

Sales of finished products are planned to be carried out in the following directions:

1. Industrial enterprises. The exit is planned to be carried out through participation in ongoing auctions and tenders posted on various electronic platforms.
2. Specialized stores. Sales of products will be carried out by concluding supply agreements with various construction stores. (Preliminary negotiations with the owner of the “Y” chain of construction stores have been held, and there has been a positive reaction).
3. Distributors and dealers.

1.6. Organizational form

It is planned to choose the form “Limited Liability Company” as the organizational and legal form of doing business.

• Investor's share in the authorized capital: 50%.
• Project developer's share: 50%

It is planned to choose the General Taxation System as a form of taxation.

2. Project implementation plan

2.1. Schedule of the main stages of the project implementation

2.2. General cost estimate for project implementation

To start the workshop you need investment in the amount of 2,190,000 rubles, investment structure:

• 1,490,000 - investor funds
• 700,000 personal funds of the project initiator

In addition to these investments, the project initiator provides premises belonging to him for the location of the workshop.

2.3. Project financing schedule

3. Planned indicators of the economic activity of the workshop

3.1. Production plan production output in tons.

The production of building materials is seasonal business, sales peak in the spring and summer.

3.2. Calculation of planned revenue

After the workshop reaches its design capacity, the average monthly revenue will be 2,880,000 rubles.

• Output per shift 500 m2 (8 hours)
• Price per 1 m2: 240 rubles
• Daily cutting/24 shifts: 120,000
• Monthly output: 2,880,000

3.3. Cost price

The cost of corrugated sheet production includes the cost of rolled metal, as well as the cost of electricity.

One ton of sheet metal can produce 270 square meters of finished products.

3.4. General expenses.

3.5. Calculation of workshop profitability

4. Calculation of project payback.

• Project start date: August 1, 2012
• Project launch: October 4, 2012
• Reaching operational break-even: December 2012
• Reaching planned capacity: January 2013
• Full payback of the project: March 2014
• Project payback period: 14 months.

Addition

Do you need a detailed business plan with calculations? Check out the offer of "BiPlan Conslating". There are 2 versions available for download on the site: paid and free, the paid version contains all the necessary calculations for obtaining a loan and subsidy. .

Video

Profiled sheets are not a new material on the construction market. Domestic entrepreneurs have successfully mastered this business. The production of profiled sheets of various sizes and shapes exists in many regions of the country. If it is not yet in your area, then you can safely open a production workshop.

• Step by step plan discoveries
• What equipment to choose to start producing corrugated sheets
• What is OKVED for business?
• What documents are needed to open
• Which tax system to choose
• Do I need permission to open?
• Production technology
• How much can you earn from a professional sheet?

Among the consumers of this building material will be organizations producing temporary outbuildings (houses, garages). Corrugated sheets are used for covering roofs, erecting fences and fencing. Most often, they are separated from construction sites or other objects for a short period of time. Due to its low cost, lightness and ease of installation of the material, it is becoming increasingly in demand among builders.

Profiled sheets are divided into several classes:

Often the surface is coated with polymers of different colors. This gives the product an aesthetic appearance. The production technology is based on the use of rolling equipment. After the product has been developed and its type, color, thickness and profile shape have been approved, raw materials for production can be purchased. Durable sheet steel is usually chosen as it.

Step-by-step opening plan

1. Assessment of the product market.

Availability of factories producing metal profiles. If there is no similar production in an area up to 200 km away, but the product is imported into the region, you can successfully occupy a market niche by reducing the price through transportation;

Rolling metal production in the region. Which will provide raw materials at the manufacturer’s price, with minimal costs for delivery, the cost of the profiled sheet, accordingly, is significantly reduced;

Studying the cost, variety of product types and sales volumes of existing manufacturers.

1. Premises and equipment for the production of profiled sheets.
2. Raw material base.
3. Staff.
4. Sales market. The climate of the region, the volume of industrial, suburban, homestead construction and more.

What equipment to choose to start producing corrugated sheets

The simplest equipment for production is mechanical sheet benders. They make a product using the cold stamping method. The sheets are pre-cut to the required sizes. If a PVC coating is provided, it must already be applied. Mechanical equipment involves the use of human hands, so it is not usually used in mass production. However, it can be noted that mechanical machines make it possible to produce profiled sheets of steel with a thickness of 1 mm. The length of the product can reach up to 2 meters. The mechanics allow you to bend the wave up to 150 degrees. Despite the simplicity of the entire process, usually polymer-coated material for handmade do not use. As a result mechanical impact it may get damaged.

In mass production, equipment powered by pneumatics, hydraulics, and other technologies is used to produce profiled sheets. It allows you to work not only with steel, but also with copper or aluminum. The bending angle on such machines reaches 360 degrees, and the manufacturing accuracy is much greater.

The operating principle of pneumatic equipment is based on the fact that a punch acts on the workpiece and presses it into a special matrix. The thickness of the material can be 1.5 mm, and the length of the finished product is 2.5 meters.

Hydraulic equipment works on the same principle as pneumatic equipment. Its accuracy and performance are much higher. This type of machine is complemented by CNC. Control by software significantly increases the yield of finished products and reduces the amount of defects. The operator can preset the shape of the die and punch. The speed of work is also selected.

Large industries use rolling mills. The cold rolling method is also used here. The equipment consists of the following components:

All technology looks like this. A steel roll is installed in the unwinder. From there the material is fed to the rolling mill.

In addition, it is necessary to purchase a number of additional equipment and auxiliary mechanisms. Working with metal involves lifting heavy rolls to a height. For this purpose, loaders, winches and other lifting equipment are used. In addition to the workshop premises itself, you need to decide on the space for warehouses: finished products and raw materials. Products, like blanks, are quite bulky and require certain storage areas. IN production premises you need to maintain the temperature above +4 degrees. This is necessary for high-quality formation of polymer-coated profiled sheets.

What is OKVED for business?

According to the classifier of types, this business of business corresponds to: clause 27.33. − production of bent steel profiles. Then, for the sale of products, that is, the wholesale sale of other building materials - 51.53.24, namely 52.46.73 - Retail metal and non-metallic structures, etc.

What documents are needed to open

When registering a company (LLC), you need: an application for state registration, the Charter in two copies, and, if there is one founder, then the Decision on establishment. Protocol of founders' meetings and agreement on the foundation of the company, if the company is founded by several participants. Scanned copies of such documents are also presented when opening a bank account. Then a receipt for payment of the state duty. And some other documents as required by the registration authority.

Which tax system to choose

When registering an LLC, the general taxation system is applicable.

Do I need permission to open?

The production of corrugated sheets is not subject to mandatory licensing and special certification, but it is recommended to regulate the production process in accordance with GOST 24045-94.

Production technology

• Galvanized steel in a blank roll is installed on an unwinding device and fed at a certain speed by a continuous belt.
• A program of profiled sheet parameters is set on the line (only the width does not change), the length is, as a rule, no higher than 12-13 m.
• Several paired shafts provide the desired geometry and thickness of the corrugation.
• A press with guillotine shears cuts a strip of metal. The resulting profiled sheet arrives at the receiving table.
• The sheets are stacked in bundles on the receiving table.

How much can you earn from a professional sheet?

We summarize monthly income and expenses associated with production in the table:

Net profit minus expenses will be 309,917 rubles per month. If we consider that investments in production and equipment amounted to about two million rubles, then full payback can be expected in 8-9 months.

Corrugated sheets are increasingly used in construction. The material is durable, not afraid of corrosion, easy to install and inexpensive. It is not difficult to produce corrugated sheets, and the constantly growing need for it allows us to consider the business promising.

Corrugated sheeting is a cold-formed profile sheet with trapezoidal corrugation. Corrugated sheets are made from galvanized steel sheets (possibly with a polymer coating) using the cold rolling method.

It is widely used in modern construction, V last years becoming the most popular. The use of corrugated sheeting is based on its structural strength, ease of installation and relative cheapness. In addition, corrugated sheeting is not subject to corrosion and is durable.

Areas of application of corrugated sheets

Corrugated sheeting is used for:

• roof decking;
• construction of prefabricated buildings;
• fencing devices;
• cladding of walls and partitions;
• permanent formwork devices, etc.

Ease of manufacture, relatively low cost and constant need for construction allow us to consider the business of producing corrugated sheets as quite promising.

What is needed to open a corrugated sheet production enterprise?

Product Description

Corrugated sheet metal used in roof construction has the following thicknesses: 0.5 mm, 0.55 mm, 0.7 mm, 0.8 mm, 1.0 mm. The most in demand are thin steel 0.5 mm, 0.55 mm and 0.7 mm.

The trapezoidal profile determines the height of the corrugated sheet, which can be from 15 mm to 130 mm. The length depends on the application and is usually determined by the customer; the width depends on the source sheet and ranges from 970-1900 mm

Equipment

There are 2 options to solve the problem production equipment. A domestic line for the production of profile sheets with minimum productivity costs about 1 million rubles.

You can save a lot by purchasing separately used machines, of which it actually consists:

• Machine for unwinding rolled galvanized sheets RUB 100,000;
• Guillotine shears – RUB 100,000;
• Profiling machine – RUB 300,000.

Total: 500,000 rubles.

Accessories (used, in good working order):

• Crane beam with lifting capacity up to 10,000-180,000 rubles.
• Forklift – RUB 280,000.

Total: 960,000 rubles.

Industrial premises

Any room with a total area of ​​400 square meters or more is suitable. m in the urban industrial zone. The main thing is the availability of convenient access roads for receiving raw materials (galvanized sheets) and shipping manufactured corrugated sheets.

Standard premises requirements:

• Production facility 250 km. m;
• Warehouse for raw materials and finished products 100 -120 sq. m;
• Administrative, household and sanitary premises - 30-50 sq. m.

Staff

The minimum number of employees is 4 people, including a foreman who performs the duties of a production manager.

Economics of production:

• Cost of 1 sq. m of galvanized sheet depending on the thickness: 160-200 rubles per sq. m. m;
• Based average productivity per shift up to 600 sq. m of corrugated sheeting we get a monthly volume of 15,000 sq. m;
• The cost (minimum) of a square meter of corrugated sheeting is 250 rubles. Gross income for the month will be: RUB 3,750,000;
• Monthly salary: 100,000 rubles;
• The minimum monthly profit of the workshop will be: 3,750,000-3,000,000-100,000 = 650,000 rubles.

The calculations do not take into account expenses for renting premises and electricity, advertising expenses, taxes and other expenses, since it is impossible to predict the exact sales volume in a specific assortment and cost. The above calculations showed the general economic picture of corrugated sheet production, from which we can conclude that the payback period, taking into account the seasonal unevenness of production load, will be 1.0-1.5 years.

Sales of products

Before making a decision to organize the production of corrugated sheets, market research should be conducted to study the demand for products, the presence of competitors, identify a liquid assortment, etc.

It would be correct to conclude contracts for the supply of products even before the start of the preparatory period in order to predict financial condition production and payback in the foreseeable future. Please note that roofing and other construction works differ in seasonality and it is impossible to count on year-round constant production load.

Possible addresses for the sale of corrugated sheets:

• Specialized construction organizations;
• Construction stores;
• Building materials databases;
• Network of distributors and dealers.

Production of corrugated sheets: step by step guide+ list of equipment + business plan for starting your own business in Russia.

In one children's fairy tale, three little pigs built themselves houses from various materials. As you know, all but one were blown away by the evil gray wolf.

Well, if the pig brothers had used corrugated sheets, then all three would probably have remained alive and well, the children’s psyche would not have suffered, and the happy ending would have begun with the phrase: “And they bought machine for the production of corrugated sheets…».

IN real life Many people have already realized the advantages of this material, thanks to which the demand for corrugated sheeting began to grow from year to year.

Demand creates supply. This means that the production of corrugated sheets looks very attractive, as an idea for serious business.

For a business to flourish, the attitude towards it must be appropriate - the result of the fairy tale with the “swine” squatter construction is an example for you.

A thriving manufacturing business needs to be built like a house - systematically and step by step, with a strong foundation and reliable calculations. We will analyze these steps (develop a business idea, create a plan, purchase equipment for the production of corrugated sheets, etc.).

Production of corrugated sheets: product description and industry overview

Let’s assume that we have chosen the area of ​​future business – the production of corrugated sheets on our own machine.

Now we need to carry out what experts call preliminary marketing research, for our production of corrugated sheets.

Simply put, we need to understand what we will produce (corrugated sheeting), how to sell it and to whom.

Also in this section we will look at the level of competition in the production of this building material, assess the scale of corrugated sheet production in the country, etc.

Only having sorted this out will it be possible to move on to the next step - direct planning, review of equipment for the production of corrugated sheets, etc.

What is corrugated sheeting?

This word comes up quite often these days, although not all ordinary people can immediately understand what exactly it means.

"Profile" stands for "profiled flooring", and means that a flexible sheet of metal was given a “profile” (longitudinal bends were added using special equipment for the production of corrugated sheets). This makes him look like an accordion.

Such a profiled sheet, or corrugated sheet, turns out to be rigid and quite strong. This is not a concrete wall, but it is no longer a plywood board.

Correctly processed during production using special equipment, corrugated sheeting is not afraid of temperature changes, it is difficult to damage without additional equipment, and most importantly, this solution is often temporary, but strong and relatively cheap.

If you need to quickly fence off, for example, a future construction site, then you can do this with corrugated sheeting in a couple of hours. The only equipment you will need is a hammer and nails or screws with a driver. Most of the time will be spent on installing the posts, and not on attaching the corrugated sheeting itself.

It is used not only as a fence, but also for a wide range of other construction needs. It is used to make sheds, industrial and retail premises, where the equipment can be stored, and in residential buildings roofs are often covered.

In principle, corrugated sheeting can be used to cover any surface, which has long been used in the West.

The possibilities of its use are determined by the main types of corrugated sheets:

• wall;
• roofing

In addition, the profiled sheet can be of different thicknesses and flexibility, coated with different paints/enamels, etc. This makes corrugated sheeting very versatile.

It is equally important that the profiled sheet is lightweight - you can save on installing load-bearing structures.

We will take as a basis the indicators for the Central District of Russia. It’s worth starting with what scale of activity you see for your production.

It is believed that only medium business for the production of profiled sheets, therefore it is recommended to register the enterprise as a limited liability company (LLC) and on the general taxation system, so that there are no problems with the tax authorities later.

1. Standards for production.

All production of profiled sheets is regulated state standards(GOST and TU).

Although the product is not subject to certification, if checked, the quality of your profiled sheet must comply with GOST 24045-94.

All corrugated sheets are divided into three OKVED codes:

Also, at the very beginning, you need to decide on the sales channels for the profiled sheet: will you establish my retail network or sell goods wholesale to intermediaries(it is best to negotiate with large networks construction supermarkets about the supply of profiled sheets).

Or maybe you decide work under government orders, while there is such a possibility (large construction sites require a lot of profiled sheets).

It’s better to try to create your own “branded” base store selling profiled sheets, and negotiate with suppliers to expand sales channels.

If everything goes well with this, then you can state procurements come with your own corrugated sheet, although you can work there without connections with very variable success.

2. Raw materials for corrugated sheets.

The second most important aspect in launching production of profiled sheets after distribution channels is building a supply chain of raw materials: in order to have something to sell, you must first figure out what to make your profiled sheets from.

Otherwise, the situation will be similar to “the skin of an unkilled bear” from that proverb, where they began to divide it ahead of time.

To produce corrugated sheets, you will need rolled steel of the highest and first categories, which are divided into three main types according to GOSTs.

The metal for the profiled sheet can be purchased both in the form of ready-made cut blanks and in the form of rolls. How to choose what's right for you?

It's simple:

• the cut sheets are profiled manually (on a special pressing machine);
• The rolls are profiled and cut on a special assembly line.

An important point is that the quality of steel and its coating can be very different, since raw materials can be supplied by both domestic and foreign manufacturers.

Chinese raw materials are the cheapest, and European ones (Germany, Great Britain, Slovakia, etc.) are the most expensive.

The quality of Ukrainian metal is approximately equal to that of Russia, although you need to look at which manufacturing plants you compare.

Kazakhstan recently entered the market, where a similar plant of the Mittal Steel concern operates in Ukraine.

What is convenient about the current situation with a wide variety of manufacturers and suppliers of blanks for the production of profiled sheets is that you do not need to repaint the sheet yourself. And this is a serious saving on equipment and premises.

Only really large enterprises have a paint shop.

3. Equipment for the production of corrugated sheets.

Before moving on to an overview of the requirements for personnel and premises, it is worth describing necessary equipment for the production of corrugated sheets.

It would seem that for such a simple type of building material it is enough to buy a machine for the production of corrugated sheets, but this is just a misconception. High-quality corrugated sheeting requires the use of serious technologies in automatic or semi-automatic modes.

So, if you intend to work on a large scale, then you will need an automated line for the production of profiled sheets.

This option is the simplest, but not the cheapest - it will cost you somewhere between 1,100,000 - 1,500,000 rubles (depending on the manufacturer and configuration).

It is simple because you only need to know the appropriate GOST - 24045-94 (production of corrugated sheets with a polymer or galvanized coating). It will already include all the necessary equipment, including programs for computerized systems.

Then it will only be necessary to hire an operator to produce the profiled sheet.

In a more complex version, you will have to buy and install all the equipment for the production of profiled sheets yourself.

It may be possible to do this cheaper (which is not a fact), but the rate of production of corrugated sheets in such a semi-automatic mode will be clearly lower.

However, if you intend to make some kind of analogue of the European “ family business”, where usually only a couple of people are employed (father and son or two brothers), then this option will suit you quite well.

4. Production of corrugated sheets: ribbon of happiness.

We will consider a business plan with an automated belt for the production of corrugated sheets, because the transition to modern technologies already almost total in all areas. There is nowhere to go back.

In addition, thanks to the Chinese, this method has also become cheap (although you need to “keep your eyes open” with them so that the resulting products comply with Russian GOST standards, and not their Chinese counterparts).

Large production volumes of profiled sheets can reduce production costs.

For a small automated production of profiled sheets, you will need the following equipment (includes both the line itself and related equipment for the production of corrugated sheets):

In the table dedicated to equipment for the production of corrugated sheets, we indicated the amount of 1,700,000 rubles.

But you need to be prepared for the fact that due to inflation and devaluation, the real price of the equipment may be an order of magnitude higher - about 2,000,000 rubles.

However, it may also be lower if you are ready to buy a used machine for the production of corrugated sheets. Then you can meet 1,500,000 rubles.

However, this will be risky, both from the point of view of safety and from the point of view of the quality of your profiled sheet - no one will buy a sheet of corrugated sheet with defects.

If we move away from extremes, then the same 1,700,000 rubles are spent on the production of profiled sheets, so we will not change the amount in the calculations, but you must decide in advance: new or used equipment for the production of corrugated sheets will suit you.

Such a line will be able to produce about 500 meters of profiled sheets with a thickness of 0.4-1.5 mm and a roll width of 1,250 mm in one 8-hour shift. A month (with 24 shifts) can produce about 12,000 meters of finished corrugated sheeting.

5. Premises for the production of corrugated sheets: warehouse.

In fact, you need two premises - the workshop itself, in which you need to place all the above equipment for the production of corrugated sheets, and a warehouse where the finished profiled sheet will be stored until sale.

Let us immediately note that the storage and packaging of corrugated sheets is regulated by a separate GOST - 15150, so the premises must be suitable.

So, finished profiled sheets must be packed in bundles, tied with a special belt (most often in the form of wire or plastic cord), then put it all in a special wooden container.

To top it all off, special gaskets need to be installed at the corners of the package with corrugated sheets so that the sheets do not touch each other or the outer surface.

If the profiled sheet is scratched, it will lose its presentation. If the presentation is damaged, the buyer of your corrugated sheet may refuse to accept the goods - you will incur losses.

By the way, GOST requires that all these packs of corrugated sheets in the warehouse be almost tightly secured - this is important from the point of view of the safety of your employees (if a heavy stack collapses, then your worker will not be envied).

Packs can be stored in two layers only if the weight of the upper tier does not exceed 3,000 kg per 1 sq.m.

6. Workshop.

We described the warehouse, and the requirements for the corrugated sheet production workshop itself are not particularly different from the requirements for other similar enterprises.

To accommodate an automatic line, the premises must have an area of ​​at least 300 sq.m., of which about 100 sq.m. will be for the finished products warehouse, and another 50 sq.m. for the raw materials warehouse.

There remains 150 sq.m. for the workshop itself. It is recommended (but not required) that the workshop have separate entrances and exits - this will allow the smooth import of raw materials and the export of finished goods without stopping loading, that is, to establish a conveyor production of corrugated sheets.

The workshop must be connected to a 380V power line, have a water supply, and be heated (according to the manufacturers’ requirements automatic lines and equipment for the production of corrugated sheets, their uninterrupted operation is possible only at temperatures above +10°C), etc.

That is, in fact, everything public utilities must be established.

Among special conditions for a workshop for the production of profiled sheets - a flat concrete floor. It is needed for the smooth movement of a forklift and other special equipment loaded with your corrugated sheets.

This is also regulated by safety requirements.

7. Personnel and other equipment for corrugated sheeting.

The standard staff for automated production of corrugated sheets consists of 5 people: a foreman, an equipment manager and three workers.

The second option is 1 director, 2 workers and 1 senior foreman. Shift work - 1 shift (8 hours), and a standard 24 shifts per month.

In fact, one person can control the equipment from the remote control. The only difference is how much profiled sheeting you will produce - the more corrugated sheeting, the more auxiliary workers you need to load it from the line to the warehouse.

The total salary fund for the production of profiled sheets is about 120,000 rubles (including taxes).

8. Technology for the production of profiled sheets.

The personnel installs a roll of galvanized or polymer-coated steel at the beginning of the belt. The end of the roll is fixed in the drum, which automatically unwinds it.

A special guillotine cuts the metal first into large pieces, which are profiled by special shafts, and then into smaller pieces at the end of the line. The height of the shafts (and therefore the depth of the profile) is set from the remote control.

All this goes to the receiving table, where your workers put the metal into bundles and take it to the warehouse. That, in fact, is all production.

A very important but optional piece of equipment is a car. Most often, it is not included in business plans (and we will not), because... It is assumed that the customer will pick up the corrugated sheets himself.

However, it’s better to have a car - delivery will be your advantage over your competitors.

How does the production of corrugated sheets work?

Let's take a look at the competitors and take a closer look at everything:

We calculate the costs and profits for the production of corrugated sheets

So we got to the most important thing - calculating the business plan estimate. However, everything here is somewhat more complicated than in simpler production.

Different thicknesses of sheets for different brands make it difficult to accurately predict the volume of products. Also, the price is greatly influenced by the polymer coating or galvanized - up to a third of the cost.

1) Cost.

Let's take the most cheap option– thin (0.45 mm) galvanized profiled sheet of grade C-8 (this means that the profile height will be 8 mm) with an area of ​​1 sq.m.

To find out the cost of 1 meter of finished products, you need to apply the following formula:

multiply the thickness (0.45 mm) by the width, then by the specific gravity of the steel sheet:

0,45 * 1250 * 7,85.

In our example, we get 4.42 kg of finished products from one roll of galvanized raw materials.

With a roll width of 1,250 mm, after profiling, the finished sheet will have an area of ​​1,195 mm. 4.42 kg/1.195 m = 3.70 kg/m2 - this is our 1 linear meter of corrugated sheeting, the base value for determining the total cost of production.

It turns out that from 1 ton of workpiece you can get approximately 270 square meters. m of finished galvanized steel corrugated sheet.

The calculation formula here is as follows: 1 t (1,000 kg) divided by the weight of our linear meter (3.7 kg).

The cost of 1 meter of product is calculated as follows: the cost of 1 ton of workpiece (50,000 rubles) is divided by the resulting area (270 sq.m.). We get about 185 rubles/1 sq.m.

Taking into account inflation and the renewed rise in metal prices, this figure may be at the level of 200 rubles.

2) Revenue.

• For sale 1 sq. m of galvanized corrugated sheeting grade S-8 for about 240 rubles.
• The automated line is capable of producing 500 sq.m. per shift. m of corrugated sheets.
• It turns out per month (24 shifts) - 12,000 sq.m.
• We multiply 240 * 12,000, we get revenue in the amount of 2,880,000 rubles per month.
• Taking into account inflation, it can be up to 3,000,000 rubles.

Minus the cost (2,223,000 rubles), we get a net profit of approximately 650,000 rubles.

From 650,000 rub. subtract:

• salary (74,000 rubles);
• utilities and electricity (17,000 rubles);
• services of an external accountant (5,000 rubles);
• logistics (90,000 – 95,000 rubles);
• don’t forget about rent (45,000 rubles);
• taxes (according to the optimistic scenario - 100,000 rubles).

“Net” comes out to about 338,000 rubles, although in reality the range can be from 300,000 to 350,000 rubles per month.

3) Payback.

If we take as a basis the amount of 1,700,000 rubles (our capital investments for the purchase of equipment for the production of corrugated sheets, etc.), then The payback period can be only 6 months.

For the manufacturing sector, this is very, very fast.

In addition, do not forget that the corrugated sheeting itself is quite simple - press the buttons on the remote control (ready-made programs are already installed there), and the automation itself will rivet the products according to your requirements.

Your employees just need to have time to ship finished products and load blank rolls.

Let us also add that this indicator is relevant for the production of thin (8 mm) corrugated sheets.
But the thicker it is, the higher its selling price.
Yes, the cost is also higher. But let us remind you that S-20 and S-18 are the most popular grades of corrugated sheets in Moscow and St. Petersburg, respectively.
In addition, corrugated sheeting with a polymer rather than galvanized coating, which accounts for almost 50% of all sales on the Moscow market, costs a third more than galvanized sheeting, as we previously wrote.

That is, by working in some Orel (according to Rosstat, there is the lowest salary in Russia in 2016), but by arranging supplies to Moscow or the Moscow region, you can increase your income to approximately 4,000,000 - 6,000,000 rubles per month.

As you can see, everything is in your hands. The main thing is not to forget about the regional factor when setting up your business, purchasing equipment for the production of corrugated sheets.

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home » Earn money online » What is needed for the production of profiled sheets. We are launching a plant for the production of corrugated sheets. General cost estimate for project implementation