Features of the production of foam blocks with your own hands

Mini-plant for the production of foam blocks - how to properly organize your business

Production of the simplest building materials is the most favorite direction of development in small business. In such an area, a miniature plant for the creation of foam blocks can be an incredible find, or otherwise, become a real disappointment. Everything will depend on how correctly the production scheme of foam blocks is chosen at home. So, consider the production of foam blocks with your own hands.

How to get profitable production of foam blocks?

At the very beginning, when drawing up a business plan for the production of such material as foam blocks, you need to do 3 main things:

1. To the maximum deeply understand all the intricacies of the production technology for a foam block, and it depends on the quality, which block is the most popular, and what is required to make the production process not only profitable, but even less costly than from the next of kin.

2. Find a team of at least two people who are technically savvy and know about making foam blocks with their own hands, in practice.
3. And the most important thing is to find potential buyers for the creation of foam blocks and at any cost to get them to want to buy foam blocks from their production.

Good advice! If you can complete all the points, then you can safely apply to the bank for a loan to purchase a ready-made foreign miniature plant for the production of foam blocks.

The presence of all the components, as well as a correctly drawn up cost estimate and calculation of foam block production and a business plan, this will help very quickly attract impressive capital to your miniature plant. To be able to fulfill all the points, sometimes a year of hard work is needed, but you can make your own small miniature plant profitable and bring in a decent income after six months.

You will need to start with the simplest thing - production technology.

How to organize work

Before proceeding with the calculation of the income and expenses of foam block production, it is required to hone the technology to a high level of quality of materials. At the same time, it is not at all worth buying used equipment of factories. Most often, in production they get rid of broken and ineffective equipment, and only in rare cases, due to financial difficulties, they sell idle equipment at low cost.

Purchase of equipment

For this reason, almost all equipment for your own plant will need to be found and purchased in parts.

For the main line of the plant you need:

1. A foam generator in order to prepare a foam filler, with an average the price of a device in good condition can be about 18,000 rubles.
2. An air compressor with a pressure of 8 atm and a flow rate of at least three hundred liters will cost up to 22,000 rubles.
3. Creation of a home-made concrete mixer for three hundred liters will cost 25,000 rubles. In the first 5 to 10 months of manufacturing, the capabilities of a self-made tank will be enough. As soon as free funds appear for additional equipment of the miniature plant, the tank can be exchanged for a purchased product.

4. A pump for pumping a mixture costs up to 50,000 rubles, and just like a compressor, this is the most expensive and complex part of the plant, and therefore it is impossible to save on the quality of such equipment.
5. Set of forms for pouring concrete mix. It is required to purchase molds with ready-made trays made of metal with low fineness, counting the volume of molds for the production of a personal mini-factory, and the maximum cost is 33,000 rubles.

So, the total price goes to 135,000 rubles. If we take into account the storage tanks for sand, water, foaming agent and cement, the total cost of the first line is up to 150,000 rubles.

Production technology and material consumption

The method of manufacturing a mini-plant for the production of foam blocks is simple. The foam generator is filled with a special mixture with the addition of a foam agent. It is best to use the ready-made composition SDO-m or similar. Do-it-yourself products based on rosin and sodium alkali are better not to use yet. The components of the concrete composition are filled in and mixed with special care with the simultaneous supply of foam and air by installing a compressor.

After "foaming" the mass of foam concrete, a solution of sodium chloride is given, mixed, and the foam is poured into molds with a screw pump, and then sent for setting for a couple of days. To create a cubic meter of D600 aerated concrete, an average of 305 kg of cement, 205 kg of sand and only 1.65 liters of foam are required when combined with a stabilizer. As a result, it turns out that for a miniature plant with a capacity of 10 cubic meters of foam concrete, the expenditure for the production of a daily batch of materials is 16,500 rubles of the D600 brand, and for the D1000, 20,000 rubles are required.

Calculation of profit and costs, production planning in the future

For 30 days of production of foam blocks, a small factory will be able to produce approximately 240 cubic meters of building material.

With wholesale prices for foam blocks of 1800 rubles for grade No. 600 and 2,600 rubles for grade No. 1000, the projected profit is 200 and 600 rubles per cubic meter of the block sold. For a production volume of 240 cubic meters, the total surplus price, taking into account the discount on wholesale sales and delivery, is 40,000 rubles and 100,000 rubles. In the first month, you can stamp all 240 cubic meters with your own hands, with only one assistant at half the rate.

His salary will be 15,000 rubles, which means that your income will decrease to 25,000 and 85,000 rubles, respectively.

From this amount, funds should be allocated to compensate for hidden costs on the second line of the miniature factory.First of all, you need to organize the disassembly of the form, cleaning and restoration. To have 1 set with molds for pouring every day, and it turns out that one person in production will have to deal with the preparatory stage of the molds and laying out the blocks in finished form.

Transferring 10 cubic meters of finished blocks with a weight of 12 tons is a physically difficult task, and therefore you need special equipment, a lift and carts, with a total price of up to 20,000 rubles.

In addition, you need to think about a warehouse in which it is allowed to lay out a stock of at least 2 weeks of material for maturation, that is, 120 cubic meters of a foam block. At a minimum, a shed or shed with an area of ​​one hundred square meters is required. Erection of a simple canopy will cost you 110,000 rubles.

The main additional expenses for the first couple of months of foam block production are:

• Expenses for additional equipment of a miniature plant with a new concrete mixer - 105,000 rubles.
• Attracting an additional worker to work 24,000 rubles.

• Purchase of transport and lifting equipment and erection of a canopy is 125,000 rubles.
• Block cutter.

As a result, for the normal functioning of the plant, additional capital investments in the amount of 255,000 rubles will be required. In order to cover such costs, stable production and release of the material is required for 6 months.

How to improve the production of foam blocks

The example shown proves that a miniature plant does not always have a high degree of profitability, and in certain cases they are unprofitable.

Even in the most common approximation, to cover the cost of improving equipment and wages, it is required to sell 240 cubic meters or even four wagons of material for the railways every month. In conditions of strong competition, it is possible to sell this number of foam concrete only in the summer, with incredible construction. For this reason, the initial cost of foam block production at the plant needs to be reduced with a simultaneous increase in quality to the factory one.

There are several main methods to improve the return on investment for a mini foam block plant:

1. Agree with cement and sand suppliers on a stable supply of material throughout the new year subject to free shipping.
2. To find the main buyers of building materials in the person of private developers, teams that are engaged in building houses from foam concrete.

   If the amount of purchased material has been exceeded and increased to 400 cubic meters, the production of the plant can be transferred from semi-handicraft to semi-industrial.

3. Based on the attracted funds or loans, the production line of the foam block is purchased according to an improved steaming scheme. The line price is up to 5,000,000 rubles, and the production price of one block is reduced by 15%.

The use of the semi-industrial steaming method makes it possible to reduce the consumption of cement and at the same time increase the strength of the block. It turns out that with a decrease in the level of profitability, the plant will be able to increase production with a stable profit.

The complex of measures produced makes it possible to move from the sale of small single batches to the planned sale. Instead of low quality aerated concrete castings, production can be divided into two - creating a cast slab and cutting blocks of the required size for a specific order.

Conclusion

The present perspective of the development of small factories for the production of foam concrete is very large. The main limiting factors will be the relatively low quality of the material, and it turns out that there is a high risk of not ensuring the minimum sales level. At that time, the purchase at the initial stage of the line for creating a foam block will become unprofitable until a client is found.

( 1 grade, average 1 of 5 )