Business plan for organizing a powder coating workshop. Business idea for powder coating of metal products. Powder coating - is there any prospects for this business?

Exotic lovers can discover interesting powder painting business– with its help they make high-quality decorative painting of various glass and metal surfaces. What are the advantages and how to organize a powder painting business, read further in our material.

Advantages of powder coating

1. Cost-effective. Powder painting does not require solvents. In addition, if it does not settle when sprayed, it can be used for a second procedure. Thanks to this, it is possible to reduce losses to 5%.

2. Ease of use. Powder paint is completely ready for use and can be easily removed from equipment.

3. Speed. There is no need to wait for the powder paint to dry before placing the items in the oven.

4. Durability. When applied, an elastic polymer layer is formed, which perfectly adheres to the surface being painted, protecting it from corrosion and the effects of electricity.

5. Eco-friendly. No solvents - no harmful substances when painting.

6. Decorative. Powder painting can be done in any shade and any texture.

How to start a powder coating business

If it is not possible to organize a large-scale painting enterprise, you can limit yourself to manual painting. In any case, you will need a separate room and special equipment.

Powder painting equipment

1. Camera. Powder painting takes place in a special chamber - it is thanks to it that unused paint can be collected again for a repeat cycle. The size of the chamber is selected to suit the needs of the enterprise.

2. Stove, gun. At the initial stages, you can use an oven instead of a stove, but for large-scale production you need to purchase special equipment. Instead of a gun, you can use a compressor with a high pressure filter.

3. Recuperator, transport system. A recuperator is needed to collect unused paint. Can be replaced with a cyclone type vacuum cleaner. A transport system will be needed to work with large powder coating objects. In any case, the room must have appropriate wiring and grounding.

Technology

1. Preparing a product for powder coating is the most labor-intensive and responsible process. Old paint, traces of corrosion and other substances are removed mechanically or chemically. The choice of method and means depends on the type of product on which it will be carried out. powder painting.

2. To insulate the product and better adhesion to the paint, chromating and phosphating are carried out. Iron phosphate is used for steel, zinc is used for electroplating, and chromium and manganese are used for aluminum. Oxides are removed by chemical and abrasive cleaning. After which the products must be rinsed well.

3. Passivation – treatment with chromium and sodium nitrate compounds. Then the product is washed and dried.

4. Powder painting itself, which is carried out in a chamber using special spray guns.

5. Formation of coating. After painting, the product is polymerized in an oven. Within half an hour the product heats up and the paint turns into a film. Duration and temperature depend on the type of product. After this treatment it is dried and painting is completed.

Scope of application

This method is used for forged, aluminum, galvanized products. It is used in various fields: from medicine to the automotive industry. It allows you to paint even clay and wood.

Organizing your business

Despite the fact that starting a business will require a lot of money, such services are also quite expensive. Therefore, the costs will be recouped quickly. You can start with small items in a small garage. And when the necessary skills and funds appear, move on to more serious orders. Over time, it will become easier for you to develop your own powder coating business.

*Calculations use average data for Russia

Overview of the powder coating market for metal products

Currently, powder coating or polymer coating is becoming an increasingly popular method of final processing of finished metal products of any type in many industries.

But not every company producing metal industrial goods is equipped with the appropriate equipment: some do not have enough production space, some do not want to invest money in additional equipment, and some want to hire additional workers, who are also suitably qualified, or retrain those already employed.

Be that as it may, often the painting of a finished metal product is carried out by a third-party specialized organization, which essentially does not produce anything, but is profitable enough to attract the attention of a novice businessman.

Indeed, by providing services for painting metal products, the management and owner of such an enterprise do not risk the invested funds at all: an organization of this type will definitely not be left without work, moreover, there are many complex production issues - how, what and in what volumes to produce, where to sell what is produced or how to ensure uninterrupted operation of a plant or factory - this type of business simply does not arise - it is enough just to replenish stocks of powder dyes and other consumables in a timely manner and comply with the terms of contracts with clients.

In principle, such simple tasks can be handled not only by a novice entrepreneur who is hearing about powder coating chambers and polymerization ovens for the first time, but also by a third-party manager who can be hired in order not to deal with such essentially minor issues.

In general, in this, as in some other types of business, the entrepreneur is only required to organize the enterprise itself: purchase equipment, hire workers and provide advertising and marketing policies. But even these, in general, basic things can be entrusted to professionals: managers, advertising and personnel specialists, etc. The main thing is to have an appropriate amount of starting capital, which will serve as an investment in starting a business, and, after waiting for some time (from six months to a year), during which the break-even point will be overcome, work on expanding this business or live as a rentier - whatever soul.

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It should be remembered, however, that powder coating and polymerization services are highly oriented, for the most part, to the availability of suitable customers rather than other factors: geographical location, size of the settlement, etc.

For confident work and successful development, it is necessary to have a sufficient number of manufacturing enterprises, producing such goods that reach the end consumer either in painted form or with a layer of polymer (polymers) applied to the surface (and sometimes having undergone both processes: powder coating and the formation of polymer coatings on metal products).

So, before investing money in organizing a powder coating business, you should not just ask, but carefully study the availability of manufacturers of the corresponding metal products in the region.

You should not rely on private orders, even in major cities: yes, individuals sometimes they resort to such services (especially car owners), but even with large-scale small orders the enterprise will not last long - it needs larger production volumes.

Only the presence of a large number of manufacturers of metal products requiring powder coating can give a painting business the right to exist.

Of course, there is also the factor of customers from other regions, but most likely you should not count on this: firstly, similar enterprises may exist in neighboring regions, fortunately their opening does not involve large investments and costs, and secondly, such a large-scale An advertising campaign that will help manufacturers of metal products from another region learn about your company will be disproportionately expensive compared to the effect achieved.

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So there is only one way to get clients from other regions: to ensure your own local presence, that is, to open your own enterprises for powder coating of metal products in these regions.

Powder coating equipment

The most important equipment in a metal powder coating plant is, of course, the powder coating chamber. And not even one, but several: depending on the planned production volumes and the approximate dimensions of the objects being painted: the typical size of the working space (LxWxH, mm) is approximately 2000x1100x1700, but for painting large-sized products you will need special chambers: up to 11 m long, up to 2 m high .5 m.

The powder coating chamber with a recovery system is designed for applying polymer powder coating to the metal surface of products. It is a metal frame covered with polymer-coated steel sheets.

The recuperator is used to catch powder paint that has not settled on the product. The powder paint deposited on the recuperator filters is dumped into the hopper; the paint from the hopper (screenings) can be returned to the painting cycle.

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As you can see, a powder coating chamber is not a technically complex design and its cost depends directly on its size: a standard chamber costs from 60 thousand rubles, cameras of specific (non-standard) sizes are somewhat more expensive. However, there are also cheaper ones - the so-called single-post (i.e., designed to be serviced by one worker) or dead-end cameras that are approximately half the price (about 30-35 thousand rubles) of those indicated.

Actually, powder paint sprayers are used directly for painting - tools designed for applying powder paint to products in an electrostatic field, or automatic application chambers.

Sprayers differ only in the size of the container with powder paint: small manual ones with a container capacity of up to half a liter and portable trolley units with a reservoir of up to 50 liters.

Usually, several copies of each type are purchased: at least one manual one for each employee, plus several spare and replaceable (when using dyes of several colors at the same time) and 3-4 (for an enterprise with an average volume of production, more precisely, the services provided) manual spraying units.

The cost of the first type of sprayer is about 9-11 thousand rubles, installation will cost about 4.5 thousand euros (which, converted into rubles at the current exchange rate, is about 190 thousand rubles). A domestic analogue will cost about 50 thousand rubles, but the quality of such a product and its work may be low.

An automatic application chamber is essentially a powder coating chamber equipped with built-in sprayers: painting metal products in such a chamber does not require the direct presence of a person in them.

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Typically, manual sprayers are used for small parts or small jobs, as well as for painting parts in different colors, while an automatic camera can quickly and evenly spray one large color or several more. small parts. So it is advisable to equip the enterprise with 2-3 automatic cameras.

The cost of each of them is approximately 100 thousand Ukrainian hryvnia (UAH), which when converted into rubles at the current exchange rate is about 370 thousand rubles.

For polymerization - the formation of polymer coatings on already painted metal products - special polymerization ovens are used.

There are three types of ovens: electric, gas and infrared. The most common - electric ones separately cost from 130 to 180 thousand rubles. (dead end option) or from 280 to 535 thousand rubles. (pass-through option), however, when purchasing some automatic paint application chambers, you can do without these costs: many of them are like a mini-line, or a full-cycle automatic machine and are equipped with built-in polymerization ovens.

However, it is still worth purchasing one or two separate ovens: in some cases, painting of the product is not required - only polymerization (for example, when undergoing manual painting earlier or ordering only polymerization, i.e., the client provides already painted parts).

As mentioned above, all cameras in mandatory are connected to recuperators - special devices that allow you to collect powder paint that has not settled on the surface of the product.

Each recuperator will cost approximately 90 thousand rubles, which significantly increases the cost of powder coating chambers (both simple and automatic; however, some models of the latter have a built-in recuperator), however, without using a recuperator, you will not be able to collect the waste that has not settled on the product. paint, and therefore reuse it.

Loss of paint will cost a decent amount - quite comparable to the cost of the recuperator. In addition, it is possible to organize the collection and supply of powder paint directly from the hopper directly to the spraying installation, i.e. arrange a closed painting cycle.

In addition, for hanging and transporting products through all technological cycles of the powder coating section in mechanized or manual mode, a plant for powder coating of metal parts requires its own transport system.

It consists of transport carts, monorails, supports, spacers, load-bearing columns, transport storage units, transverse movement links, longitudinal and transverse trusses and beams, carriages, traverses, etc. standard parts for this system.

Accordingly, a mechanical (manual, in which parts are moved around the workshop by the muscular power of workers) transport system will cost only 25 thousand rubles. However, it is suitable only for small enterprises that do not undertake painting of large parts or large orders, or have limited production space.

Medium and large companies require an automatic transport system, the organization and installation of which will cost at least 110-175 thousand rubles.

TO additional equipment can be attributed to a vibrating sieve (cost - about 35 thousand rubles), designed for sifting (separating large fractions and foreign inclusions from the main composition of the material) fine bulk products, in this case - powder paint with lumps and recycled paint (screenings) and industrial water-mud-vacuum cleaner for collecting it (10-19 thousand rubles).

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They are used to paint medical equipment, roofing materials, household appliances, objects made of ceramics, plaster and glass, furniture. Powder coating of wheels is becoming increasingly popular among car enthusiasts. Organizing a business These works in specialized centers are quite expensive today. If you want to try yourself in this business, then if you have the financial resources, you can get started. Of course, the powder coating line ( automated system) is not affordable for everyone, but thanks to our recommendations you will be able to replace some elements with other tools at first. Start with small items. These could be plaster figurines, ceramic tableware and much more. Try painting something in your home first (start with something you don't mind ruining).

New business ideas

Powder painting itself, which is carried out in a chamber using special spray guns. 5. Formation of coating. After painting, the product is polymerized in an oven.
Within half an hour the product heats up and the paint turns into a film. Duration and temperature depend on the type of product. After this treatment it is dried and painting is completed.

Scope of application This method is used for forged, aluminum, galvanized products. It is used in various fields: from medicine to the automotive industry.

It allows you to paint even clay and wood. Organizing your own business Despite the fact that starting a business will require a lot of money, such services are also quite expensive. Therefore, the costs will be recouped quickly. You can start with small items in a small garage.

And when the necessary skills and funds appear, move on to more serious orders.

Powder coating - is there any prospects for this business?

For industries where more than 50,000 m² of surface is covered per year, continuous powder coating production lines are used. Despite the difference in production volumes, the equipment in both cases is the same and differs only in power.
The set of basic equipment for powder coating includes (prices are as of January 2017):

Spray chamber (from 100 thousand rubles) and recuperator (from 80 thousand rubles). A special chamber where the main paint application process takes place.
The chamber is equipped with filters and a recuperator to capture unsettled paint and return it to the production cycle. As a rule, the walls of the chamber are coated with a special antistatic agent.
Sprayer and feeder for powder coating (from 60 thousand rubles).
The sprayer is designed for applying paint to the product to be painted.

Your own business in powder coating of metal products

Powder coating is becoming increasingly popular today. What is this? This modern technology, designed to produce high quality decorative and protective coatings.

The work uses polymer powders (hence the name “powder”). They turn into coating due to exposure to high temperatures.

Because of this peculiarity of the procedure, powder coating of metal and glass is most common. Advantages This process has a number of positive aspects.

These include: - Cost-effectiveness. The fact is that such paint can be reused if it does not settle when sprayed on the surface being treated. Thus, material loss is no more than 5%.

By the way, this figure for conventional paints will be 8 times higher - about 40%. Also in this case there is no need for solvents.

— Ease of use.

business plan

The most commonly used method for applying paint is electrostatic spraying. In this case, powder coating guns are used.

These tools are also called sprayers or applicators. This device is a pneumatic sprayer that applies an electrostatically charged substance to a previously grounded part.

Formation of the coating We move on to the next stage of work. The paint is applied, now you need to form the coating. First of all, the product is sent to the oven for polymerization. Such chambers can be different: vertical, horizontal, again, dead-end or pass-through, single-pass and multi-pass. The mentioned equipment for powder coating ensures heating of the surface to a certain temperature - 150-220 oC. The treatment lasts about half an hour, resulting in the formation of a film.

Business plan: powder coating of metal products.

Instead, at first you can use a cyclone-type vacuum cleaner. In this case, you need to first check the power of the electrical network in the room and make sure that there is grounding. If you plan to work with large items, then you should also consider purchasing a transport system. In it, the workpieces are moved on special trolleys that move on rails.

This is how a powder coating line is built. Such equipment improves the productivity of the process, ensuring its continuity.

Powder coating technology The process of performing the work itself is divided, as you can already understand, into several stages:

We will talk about each stage separately. Preparing the product, or rather its surface, for processing.
Application of paint in powder form.
Polymerization, i.e.

Although this method coloring was developed in the 50s of the XX century, it still does not lose its relevance and popularity. Process powder coating consists of applying powder paint (that’s why it is called “powder paint”) onto the part to be painted, followed by polymerization. The popularity of the method is based on the unsurpassed decorative and protective properties of the resulting color layer. The only serious limitation of the technology used is the heat resistance of the processed product. During the paint application process, the resulting layer must be polymerized, which is achieved by heating the product to high temperatures. Therefore, only heat-resistant products made of steel, ceramics, glass, MDF and similar materials are allowed for powder painting.

The scope of use of this technology is quite extensive. In addition to decorative functions, this coating has utilitarian protective functions. The fact is that powder paint coating can withstand high temperatures, pressure and chemically aggressive environments, which makes its use indispensable in processing various parts of equipment and cars (shock absorbers, discs, decorative elements etc.).

Powder coating technology and process

The process of applying powder paint and forming a layer takes place in several stages using special equipment. Schematic diagram powder coating is as follows:

The surface of the product is cleaned of grease, dirt and oxides. This is usually achieved through a series of chemical procedures.
Using a special gun (applicator), a layer of colored powder (paint) is applied to the surface of the product. Paint is applied using an electric field. The paint particles in the applicator are charged with a positive charge, and the surface of the product being painted is charged with a negative charge. Due to this, paint particles are attracted to the product and a reliable and monolithic layer of paint is obtained over the entire surface of the product. The paint application process is carried out in a special painting chamber equipped with a recuperator and an air purifier. The fact is that particles of non-settled paint can be reused (which is impossible when using liquid paints), so these particles are collected in the recuperator from the chamber air.
The finished product is sent to a polymerization chamber (oven) where, due to high temperature, the powder paint melts into a liquid polymer, which reliably wets the surface. After drying, a final solid colored film is formed, which performs decorative and protective functions.

Commercial benefits of powder coating

Decorative functions. A wide variety of shades and resulting textures makes it possible to apply not only matte or glossy colored films to the processed products, but also to imitate various materials(painting for marble, granite, etc.).

Service life. As we have already noted, the polymer coating is very durable and stable. Therefore, the operation of polymer-painted products can reach several decades without updating the paint layer.

Simple, reliable and cost-effective technology. Due to the fact that solvents are not used (as with traditional liquid painting), the mass of dry paint settles on all products with the same density - the final layer on all products is almost identical in its performance characteristics. High efficiency is due to the fact that paint losses do not exceed 5% (reuse of non-settled paint particles). The cost of raw materials is not high. The main expense is the electricity used to apply and bake the paint.

Powder coating equipment and its cost

Powder coating equipment is classified according to production volume. For small volumes (businesses) compact installations are used. For industries where more than 50,000 m² of surface is covered per year, continuous powder coating production lines are used. Despite the difference in production volumes, the equipment in both cases is the same and differs only in power.

The set of basic equipment for powder coating includes (prices are as of January 2017):

Spray chamber (from 100 thousand rubles) and recuperator (from 80 thousand rubles). A special chamber where the main paint application process takes place. The chamber is equipped with filters and a recuperator to capture unsettled paint and return it to the production cycle. As a rule, the walls of the chamber are coated with a special antistatic agent.
Sprayer and feeder for powder coating (from 60 thousand rubles). The sprayer is designed for applying paint to the product to be painted. Feeder - prepares and sends a mixture of powder paint and air to the spray gun. Sprayers are of two types − electric charge paint occurs in the sprayer itself due to an external power source ( electrostatic), the electrical charge of the paint is carried out due to friction ( tribostatic). Both types of sprayers are used equally.
Polymerization chamber (from 150 thousand rubles). A heating chamber where the powder paint applied to the product is heated and melted into a polymer layer.

The total cost of equipment for a powder coating workshop is up to 500 thousand rubles.

Powder coating as a business idea

Due to the advantages of powder coating, the demand for this service is steadily growing among both private and legal entities. The main direction of earning money in this business is painting various metal products - car rims, metal structures various applications(forged gratings, railings, metal frames of stairs, etc.), metal sheets and products ( metal doors, instrument cases, safes, boxes, containers, stands, stands, souvenirs, etc.). The cost of powder coating for 1 m² is from 100 rubles, for 1 linear meter – from 40 rubles. On average, the monthly profit at 40% equipment utilization, excluding consumables and cost of work, is 200-500 thousand rubles. Provided that professional equipment is used, with which it is possible to achieve stable painting quality. Also, advertising promotion of the business occurs periodically.

*Calculations use average data for Russia

Overview of the powder coating market for metal products

Currently, powder coating or polymer coating is becoming an increasingly popular method of final processing of finished metal products of any type in many industries.

Earn up to
200,000 rub. per month while having fun!

Trend 2020. Intellectual business in the field of entertainment. Minimum investment. No additional deductions or payments. Turnkey training.

It should, however, be remembered that powder painting and polymerization services are highly oriented, for the most part, to the availability of appropriate clients rather than to other factors: geographical location, size of the locality, etc.

For confident operation and successful development, it is necessary to have a sufficient number of manufacturing enterprises producing such goods that reach the end consumer either in painted form or with a layer of polymer (polymers) applied to the surface (and sometimes having gone through both processes: powder coating and the formation of polymer coatings on metal products).

So, before investing money in organizing a powder coating business, you should not just ask, but carefully study the availability of manufacturers of the corresponding metal products in the region.

You should not rely on private orders, even in large cities: yes, individuals sometimes resort to such services (especially car owners), but even with mass small orders the enterprise will not last long - it needs larger production volumes.

Only the presence of a large number of manufacturers of metal products requiring powder coating can give a painting business the right to exist.

Ready ideas for your business

So there is only one way to get clients from other regions: to ensure your own local presence, that is, to open your own enterprises for powder coating of metal products in these regions.

Powder coating equipment

The powder coating chamber with a recovery system is designed for applying polymer powder coating to the metal surface of products. It is a metal frame covered with polymer-coated steel sheets.

Ready ideas for your business

Actually, powder paint sprayers are used directly for painting - tools designed for applying powder paint to products in an electrostatic field, or automatic application chambers.

Sprayers differ only in the size of the container with powder paint: small manual ones with a container capacity of up to half a liter and portable trolley units with a reservoir of up to 50 liters.

Ready ideas for your business

Typically, manual sprayers are used for small parts or low-volume jobs, as well as for painting parts in different colors, while an automatic camera can quickly and evenly spray paint one large part or several smaller parts in one color. So it is advisable to equip the enterprise with 2-3 automatic cameras.

The cost of each of them is approximately 100 thousand Ukrainian hryvnia (UAH), which when converted into rubles at the current exchange rate is about 370 thousand rubles.

For polymerization - the formation of polymer coatings on already painted metal products - special polymerization ovens are used.

As mentioned above, all cameras must be connected to recuperators - special devices that allow you to collect powder paint that has not settled on the surface of the product.

Medium and large companies require an automatic transport system, the organization and installation of which will cost at least 110-175 thousand rubles.

Additional equipment includes a vibrating sieve (cost - about 35 thousand rubles), designed for sifting (separating large fractions and foreign inclusions from the main composition of the material) fine bulk products, in this case - powder paint with lumps and recycled paint (screening ) and an industrial water and mud vacuum cleaner for collecting it (10-19 thousand rubles).

9464 people are studying this business today.

In 30 days, this business was viewed 383,046 times.

Calculator for calculating the profitability of this business