The main activity of the company is production of sheet and block foam rubber in a periodic way. Produced foam rubber is used as stuffing material in the production of upholstered furniture, sports mats, children's modular products, medical mattresses, as well as for other purposes. Our company offers for sale not only the produced foam rubber, but also a set of production equipment with a full range of chemical components for this type of activity. Our specialists with many years of experience,will hold the whole range of services for installation, commissioning, learning Your staff and the release of final products on the proposed equipment. If necessary, our company offers on favorable terms for you supply of chemicals including transportation.
We have been cooperating since 2003 with the following organizations:
- LTD " DAUIzolan"Vladimir
- LTD " Furniture groups", Nizhny Novgorod
- LTD " NVP Vladipur", Vladimir
- LTD " Semi-product plant", Nizhny Novgorod
- LTD " HH pace", Nizhny Novgorod
- LLC NPP " Elastoprom"Penza

Equipment

The equipment is manufactured according to the design principles of imported (German) equipment, with the exception of complex expensive electronics, all critical components and assemblies are simplified and strengthened in accordance with domestic working conditions.
Performance
Allows you to produce up to 60 cubic meters of foam rubber in an 8-hour work shift.
Components
Blend setting
Designed for the manufacture of PPU blocks.
Overall dimensions 1400x1000x2730 mm.
- Supply voltage 3x380 V
- Maximum power consumption - 3 kW
- Mixer capacity allows to produce a range of densities from 16 kg/cu.m. to 25 kg/cu.m.
Form - mobile with floating lid
Cutting horizontal installation
- Designed for cutting PPU blocks into sheets of a given thickness (from 3 to 220 mm). Overall dimensions 4460x2500x2700 mm. Characteristics: - Supply voltage 3x380 V - Maximum power consumption - 5 kW

Technology and Components

This activity uses six-component system. The main ones are: polyester component and isocyanate component T-80. The apparent density of the resulting foam depends on the amount of basic components and water in the formulation. Surfactants and catalysts provide a balanced foaming and curing process.
The process of obtaining PU foam at batch plants consists of the following technological stages:
- preparation and tempering of raw materials
- preparation of the activator mixture and component A
- preparation of component C.
- dosage
- production of blocks and their aging
- cutting blocks into sheets of a given thickness
In the manufacture of blocks of elastic PPU the room temperature must be maintained at a particular temperature. When aging, PPU blocks are installed on the floor at a distance of no closer than 0.2 m from each other. Standing takes place for at least 12 hours, then the finished blocks are sent for cutting. During the aging process, the processes of chemical transformation of the starting materials into non-volatile polymeric products are completely completed, reactive compounds are bound, and the block is cooled.
Requirements for production facilities
- The area of ​​the molding shop (pouring) should be 30 - 35 sq.m, the temperature regime is 20 - 28 C, the ceiling height is at least 3 m
- Availability of exhaust ventilation in the molding shop. An umbrella measuring 1.2 mx 2.2 m is installed directly above the mold where foaming takes place. Fan motor at least 3 thousand revolutions per minute, air duct diameter 0.3 m
- The room for sawing and storage must have an area of ​​at least 200 sq.m, without reference to temperature regime
In total, the total area of ​​the premises required for the placement and operation of this production should be at least 230 sq.m.

Services

Departure of specialists for the organization of the entire turnkey mini-production to the address of the customer.
- Installation and commissioning of equipment
- Project of the premises under this species activities
- Selection of all the necessary attributes used in the production of PPU
- Technology training
- Delivery of chemical components
- Release of finished products
- All further consultations on customer issues

Profitability

At least three people (a technologist and two workers) must be involved in this production process. In the manufacture of foam rubber of any density, from 15 to 30 blocks are produced in one shift. Per month(24 working days) produced on average 500 blocks. Let us calculate the cost of one block of foam rubber with a density of 22 kg/cu.m. According to the technology, the required amount of raw materials for the manufacture of one block is 50.17 kg. The cost of a six-component system for the production of foam rubber is 2.8 $ per 1 kg(1 kg contains all the necessary components in the required proportions). Therefore, the cost of one block for raw materials will be: 50.17 kg x $2.8 = $140.47. The block obtained on this equipment has the following dimensions: width - 1000 mm, length - 2000 mm, height 1100 mm.
Thus, 110 cm of foam rubber (110 sheets of 10x1000x2000 mm in size) are for sale. On average, in January 2009, the cost of one sheet of foam rubber with a density of 22 kg / m 3 10x1000x2000 mm in size is 2,1 $ , therefore 110 sheets x 2.1 $ = 231 $ . Let's determine the difference between the sale price and the cost of one block for raw materials: 2 31 $ - 140,47 $ = 90,53 $ . With an average employment of working personnel in the production process, up to 500 blocks per month with income 25 - 30 thousand $. Electricity costs are 2000 - 2500 kW per month at the above rates of work. Wage employees have a piece rate, on average it is 3 $ for the production of one block of PPU. Current expenses for the needs of production activities are 400 - 500 $ per month. This equipment allows to produce up to 35 tons of foam rubber per month, subject to the continuous operation of production

WATERPROOFING SPB

foam production technology.

Equipment. Components. Reviews.

What is foam rubber?

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

The principle of operation of the filling plant.

The main unit of the filling machine is the mixing chamber into which the polyol and additives enter. There they are quickly mixed and, already in a homogeneous state, enter the second mixing chamber, where they are even more rapidly mixed with isocyanate. 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 filling can be done in several stages, observing the technology of polymerization of each of the layers using intermediate primers.

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

To date, foam rubber manufacturers operating in our country cannot fully satisfy the demand for this product, so it has to be imported from abroad. Shipping costs significantly increase the cost of products, so consumers prefer to buy material made by domestic manufacturers. The production of foam rubber in Russia brings a lot of profit. How to organize such a business, we will understand in this article.

Business features

Modern foam rubber is significantly different from the material that was produced several decades ago.

Among its advantages I would like to highlight:

• High moisture resistance;
• Mold resistant;
• High degree of heat and sound insulation;
• Elasticity.
• The most important advantage of the product lies in its low cost.

Like any other material, foam rubber also has disadvantages. First of all, the production of such products is considered environmentally harmful, therefore, high requirements are placed on security systems at enterprises for its production.

In addition, polyurethane foam is a combustible material. When ignited, it begins to release harmful substances that can lead to poisoning. To eliminate this drawback, manufacturers use special impregnations, but usually they do not provide the desired effect.

Manufacturing technology

For the production of foam rubber, one of two methods can be used:

1. Continuous;
2. Periodic.

The simplest, periodic method. It is perfect for aspiring entrepreneurs. This foam rubber production technology does not require special knowledge and the use of sophisticated equipment. Everything chemical reagents mixed in a foaming machine, after which it is sent to a special form. In it, the material is no more than half an hour. Further, the finished product is cooled for 3 days and cut to size.

Particular attention in the manufacture of foam rubber should be given to the temperature regime. V industrial premises the temperature should not fall below +18 degrees. This requirement does not apply to the warehouse, utility rooms and cutting area.

In addition, you need to correctly determine the dosage of the components. There is no room for error in this matter. The production process must be controlled by an experienced chemical technologist. A video of foam rubber production will help you to get acquainted with the production process in more detail.

Scheme: foam rubber production

Raw material

For the manufacture of foam rubber, polyisocyanates and polyols are used, which are produced by petrochemical enterprises. To establish the smooth operation of the production line, it is necessary to conclude long-term contracts for the supply of high-quality raw materials. In this case, your company will not be idle without work and suffer losses.

In addition, a room should be allocated for a warehouse for raw materials in order to have a reserve in case of force majeure situations. In addition, if you buy material in large quantities, manufacturers can significantly reduce the price, which will allow you to save money and reduce the cost of production.

Range

Consider the main types of foam rubber:

• Increased rigidity. For the manufacture of this material, special polyols are used, which give it increased strength. Such foam rubber is used for the manufacture of seats and mattresses;
• Latex highly elastic foam rubber. This type of product is presented in a wide range. It is much more elastic than other types of polyurethane foam. Material with such properties is used in the furniture industry for the manufacture of pillows, mattresses and other products. It is durable and resistant to dents;
• Material for molding various elements. To achieve an orthopedic effect, many manufacturers use spring blocks with multilayer filling in the manufacture of upholstered furniture. Synthetic flooring materials, for example, block elastic polyurethane foam, can significantly reduce the cost of products;
• Foam rubber. This material is made from rubber. It is produced in the form of molded elements or sheets. Foam rubber has excellent sound and heat insulation properties, as well as durability and high hygiene.

Equipment

The finished foam rubber production line can be used regardless of the method of organization of the enterprise.

It consists of the following units:

• foaming machine;
• Thermal camera;
• Device for cutting material;
• dispenser;
• Form block.

To make production waste-free, you should also buy a crusher for processing edges and defective material. In addition, you will need a packaging device, with which the foam is rolled up and packed in polyethylene.

Staff

To work at the enterprise, it is not necessary to hire qualified personnel. It is enough to find one experienced chemist-technologist. Other employees may receive special training. Usually such courses are offered free of charge by equipment suppliers.

2 people are required to service the cutting and pouring equipment. You also need to hire 3 workers for loading and unloading.

Financial calculations

To start a plant for the production of foam rubber will require large capital investments. Since the profitability of such a business is quite high, and the demand for foam rubber is constantly growing, start-up capital will be back in 5-6 months.

The purchase price of foam rubber production equipment is quite high. You will spend approximately 17 thousand dollars to purchase it. For installation and staff training, you will have to pay another $7,000.

To improve performance, you must also purchase:

• Thermal camera - 6 thousand dollars;
• A set of dosing devices - 6.5 thousand dollars;
• Band saw machine - 5 thousand dollars.

Thanks to such additional investment you can increase the productivity of the enterprise by 2.5 times, but only if the periodic method is applied.

A fully automated line will cost 6.5 million rubles. This is the main equipment for the production of foam rubber, to which you will also have to purchase additional accessories:

• Packing machine - 7 thousand dollars;
• Crusher for foam rubber crusts - 2 thousand dollars;
• Equipment for waste processing - 9 thousand dollars.

To the cost of equipping the workshop should be added:

• Payment for the rent of the premises;
• Employee salaries;
• Purchase of components for the production of foam rubber;
• Fare;
• Payment of utility bills.

According to preliminary calculations, the net income of such an enterprise is about 220 thousand rubles a month. According to experts, the profitability of such an enterprise is at least 15%.

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Sales of finished products

Furniture factories that use foam rubber as padding for upholstered furniture can become your regular customers. They are the main consumers of this material, since they purchase 70% of the total volume of products on the market.

In addition, foam rubber is used in construction for heat and sound insulation. Shoe manufacturers also buy this material in small quantities. In the medical industry, foam rubber is used to make fixing splints and prostheses. finished products can be sold to manufacturers of audio equipment for the manufacture of headphones, microphones and other devices.

Foam rubber can also be taken to hardware stores. Such goods are bought by individuals in small batches. Factories for the production of children's toys often use this material for stuffing various products, so you can try to conclude contracts with such enterprises.

As you can see, various types of polyurethane foam are in great demand, so there are usually no problems with its sale.

conclusions

The enterprise for the production of foam rubber is enough promising business. This is especially true for the production of molded products. Such material is used for stuffing furniture, as well as backs and seats in car seats. From waste, you can organize the production of rugs, insulation or sponges for washing dishes. This will allow you to get a good additional profit.

Foam rubber is a synthetic material that is made from flexible polyurethane foam. This name of this material has already taken root, because in Soviet times it was supplied by the Scandinavian company Porolon.

Since foam rubber is a soft foam material with almost 90% air cavities, it has excellent elastic and breathable characteristics.

It is used as shock-absorbing and insulating material for packing fragile items, furniture filler, making soft toys etc. In addition, due to its soundproofing properties, foam rubber is used for soundproofing.

Since chemically active substances are used for the production of foam rubber, such as polyol, isocyanate, then its manufacture, foam rubber is considered environmentally unsafe, since the fumes during the chemical reaction of these materials are toxic and dangerous to humans.

For the manufacture of foam rubber, foam stabilizers and special catalysts are used, thanks to the first foam rubber under the influence external factors such as air and moisture decomposes into safe components and can be easily disposed of.

The main disadvantages of this material include: not long service life and a high degree of flammability. The last disadvantage is solved by introducing manufacturing process the use of specific additives, with the help of which the so-called nonflammable foam.

foam manufacturing technology

The technological process for the production of foam rubber is based on carrying out a chemical reaction to mix its components in a special device for foaming. After that, the prepared mass is poured into a special form for solidification.

The whole technological process can be divided into the following successive steps:

• delivery of the mixture components to the foam rubber production site;
• preparation of components for the manufacture of foam rubber, control of their characteristics (temperature, viscosity, quality, and so on);
• filling in the constituent components;
• mixing of raw materials in a foaming machine, in a given mode, to achieve certain characteristics material;
• filling the resulting foam with a special movable (collapsible) matrix (form);
• a process of waiting for a chemical reaction to form foam in the upper part of the matrix, which can be on the order of 20 minutes;
• disassembly of the matrix (form) and extraction of a semi-finished product from it;
• cooling the material and waiting for the end of its active chemical processes;
• waiting for the final solidification of foam rubber (about one to three days);
• cutting foam rubber, according to a perky template;
• storage of the finished product.

Equipment used to make foam

One of necessary conditions production of foam rubber, is the exact observance of a given recipe, since the chemical reaction, which is the basis for the preparation of the mixture, is carried out at the molecular level.

In addition, the quality and temperature that the ingredients have before mixing is equally important. The equipment that is used to produce this material must ensure not only the correct dosage, but also the temperature characteristics of the starting material.

Therefore, most devices that carry out pre-treatment and dosing are equipped with various sensors and automated systems, which are designed to provide control over the performance of the ingredients.

Depending on the degree of automation and the complexity of the equipment used for this, the price of the line for the production of foam rubber, as well as the quality of the goods that are produced with it, directly depend. The lines of equipment used for the manufacture of foam rubber are of the same type. The difference in configuration depends only on the method of production of foam rubber.

Video: foam production process

Depending on the volume and serial production, there are continuous and periodic methods of its manufacture. They differ in the method of foam extraction, in continuous production, foam extraction is carried out constantly and the foam material is fed to the mold, which is made in the form of a transport line.

Among the main devices that are used in the manufacturing process of foam rubber can be identified:

Also, some highly automated lines may include various packaging units and machines for the manufacture of tape or shredded foam rubber, for use as fillers.

Since the production of foam rubber refers to processes associated with emissions of toxic and harmful substances, a prerequisite for the construction of a production line is the presence of special devices that allow not only forced ventilation of the premises, but also monitor the degree of air pollution.

foaming machine

Foaming machine is the key in foam rubber production line.
Typically, the design of such devices provides for the presence of such main components and mechanisms:

1. Block for storage, pre-mixing and supply of mixture components.
2. High pressure block for foaming the mixture.
3. Node of automatic process control.
4. Cooling block.
5. Spray device.

If you pay attention to which companies are most often opened today, then here you can undoubtedly name jewelry, alcohol, automotive and furniture. Let's take a look at the furniture. It consists of simple and light materials, but with an interesting design, it can be very expensive. Thus, the furniture brings a high income with minimal costs. As a result, equipment for the production of foam rubber is considered relevant for the acquisition.

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

The material is used in the manufacture of:

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

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

On the this moment There are two main methods that are used in the manufacture of foam rubber: continuous and periodic. Small firms use the second technology, as it is simple, and the cost of buying equipment and maintaining it is 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 device;
• configuration block (forms);
• 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 twist sheets and a film wrapping 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 the production of foam rubber of various brands and is capable of producing up to 30 m 3 of foam rubber per shift, 1.3 million rubles will be required.

There is an option where you can order a mini-factory in China. The output of such a line is not less than 50 m 3 of finished material per shift. Issue price 1.6-1.8 million rubles. This option is more profitable. To effectively build a process, you will need 7 employees who will work 8 hours per shift. Capital costs for the organization of the line for the production of foam rubber will amount to approximately 1.78 million rubles.

Those who decide to engage in this activity must issue an IP. Find suitable premises where the workshop will be located with total area 200 m2. Find buyers among enterprises and firms that are engaged in the production of furniture and other goods where foam rubber is used.

The loading of the line is closely related to the demand of buyers for upholstered furniture. It will be possible to receive the largest revenue 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 associated with seasonal customer requests. 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 in the production of foam rubber

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

In the manufacture of foam rubber sheet, the cost will include the cost of raw materials for production and the energy used.