Pipe products made from polyvinyl chloride have found wide application in many areas modern life. The reason for its demand is the excellent quality of the products. How are PVC pipes made, and what raw materials and equipment are used for this?
They are used when laying pipelines designed to move almost any media - gases, liquids and chemicals. PVC pipes and PVC connecting elements for them are used in the construction of residential buildings and industrial enterprises.
When constructing houses, plastic products are used for laying utilities, including external sections of highways - these are sewer and water supply networks, as well as drainage structures.
Such pipes are resistant to aggressive environments, they can be used in different temperature conditions, and they are easy to install. Pipelines laid from them have a long service life.
Materials for the production of PVC pipes
The raw material for the manufacture of PVC pipes is granular polymer. They are produced using the extrusion method.
In order to impart certain properties to pipe products, the following is added to the components:
- catalysts- chemicals that accelerate the polymerization process;
- inhibitors– cause a delay or slowdown in reactions;
- stabilizers– special substances that provide polymers with stability and inhibit their aging;
- plasticizers– refer to special additives that impart plasticity and elasticity to polymer materials;
- antistatic agents– they are introduced to prevent the occurrence of a charge of static electricity;
- pigments– impart the required color to an already manufactured product.
In addition to the above additives, polymer raw materials sometimes include other components that affect the properties of the final product.
Equipment for the production of polyvinyl chloride pipes
To organize the workflow, you will need equipment for the production of PVC pipes, including:
- Bunker, where prepared raw materials are poured.
- Extruder– thanks to this device the extrusion process is carried out.
- Baths. Refers to installations in which products are cooled and calibrated.
- Scissors guillotine or disc cutters - they are used to cut pipes.
In addition to this equipment, depending on the type of products being manufactured, PVC pipe manufacturers may use additional mechanisms and devices, for example, a hydraulic stacker.
Pipe production technology
The production process of PVC pipes is simple, it is not labor-intensive, does not consume energy and is safe for the environment. All the equipment necessary to organize production of products can easily be accommodated in an area of no more than 100 square meters.
The extrusion production line operates in a continuous and complete cycle consisting of the following stages:
- Extrusion.
- Pipe calibration.
- Cooling of products in bathrooms.
- Pipe extraction.
- Cutting products to the required length.
- Laying finished products in stacks.
The technology for manufacturing products at the PVC pipe plant is as follows:
- Granular plastic raw materials are poured into a hopper that has a screw-shaped auger and heating elements.
- During rotation in the bunker, the raw material is heated to the required temperature.
- The polymer, in a molten state, is fed into the extrusion head.
- To form a product, molds are used that have a certain outer and inner diameter.
- After extrusion is completed, a plasticized product blank is obtained.
- Then the pipe is fed into a vacuum calibrator (bath) for calibration. The equipment for this process is a three-meter closed container, inside of which a vacuum is created using a vacuum pump.
- The workpiece, having passed through the calibrator diaphragm, moves to the next chamber. It is a cooling bath where there is rarefied air.
- To evenly stretch the product, a pulling device is used, which can be of a caterpillar or belt type.
- Products are cut using a guillotine or circular saw.
- At the final stage of the technological process, the finished products enter a device called a stacker, which places the manufactured products on special racks.
Scope of use of PVC pipes
Pipe products made by extrusion can be used for arranging:
- pipelines supplying household gas;
- water supply systems;
- structures for drainage of wastewater and precipitation;
- technological lines intended for transportation of chemicals;
- highways used for production purposes.
PVC pipes can perform a protective function when installing electrical wiring and communication cables.
Depending on the purpose, PVC pipe products can be non-pressure or pressure. In the first case, the pipes serve to move liquid through them by gravity, and in the second, the contents are supplied under pressure. Currently, the production of non-pressure PVC sewer pipes has become widespread.
Features of the installation process
The work of laying pipes made from PVC is simple and does not require the purchase of special equipment.
Installation is carried out in two ways:
- By connecting into a socket using rubber seals and silicone grease.
- By gluing products using special adhesives. The resulting connection is reliable, since the polymer molecules penetrate from one to another connected product.
When organizing the production of PVC pipes, the costs of purchasing equipment and other activities usually pay off within one year.
Production plastic pipes: 7 product advantages + 9 areas of application + procedure + market and industry analysis + 4 main types of products + raw materials + 6 suppliers + technology + premises and equipment + staff + sales + cost items + possible profit.
In recent years, the production of plastic pipes has attracted the attention of many entrepreneurs. Companies open their own workshops where they produce PVC products.
What is the reason for its popularity? In improving production, growing demand and widespread use of polymer, cylindrical products. Due to the emergence of more and more new players in the market, fierce competition has formed.
But by offering a high-quality product at an attractive price for customers, you can bypass many of them.
Why make pipes from plastic?
Plastic production will bring a stable profit to the business owner. Plastic is a material that, since 2010, has been considered superior to others in construction and other fields.
This boom was caused by its convenience and practicality, minimal resource consumption and other operational characteristics. Pipes made from plastic also have a number of advantages, which to this day make these products in demand on the market.
Plastic cylindrical products are also characterized by:
- resistance to high temperature (maximum 170°C), rotting, dynamic loads, abrasion;
- light weight;
- fire safety and safety for drinking water supply;
- seismic resistance;
- flexibility;
- economical operation.
Although plastic fashion trends have slowed down a bit, pipes made from this material are still being sold successfully. This is one of the reasons that the business of their production has good returns and is promising.
Excellent sales volumes are also influenced by the widespread use of plastic pipes. The list is really large, but we will list the main areas.
- sewer systems;
- water supply;
- cable channels;
- heating;
- transportation of liquids in industrial production;
- intra-house networks;
- drainage systems;
- installation of watering and irrigation systems;
- gas distribution, etc.
The future entrepreneur will have difficulties when entering the market, since there is a lot of competition in this area. However, this should not “discourage” such activities as the production of plastic pipes.
If you are making wide range products good quality at an attractive price, and are ready to fight for end consumers, using available resources and proactive strategies, gaining a strong position will become an achievable goal.
Procedure for starting a plastic pipe production
As in any entrepreneurial activity, first of all you need to do something, which will become your guide to action, help you avoid many mistakes and indicate what financial support is needed to start production.
Before writing it, the entrepreneur should already have ideas about the plastic pipe market and the competitive environment, which are formed during the analysis (we will return to this in more detail). Of course, you will have to delve into the production technology, think about where and how you will buy raw materials and equipment.
No less important is the question regarding labor resources and production areas, formation of assortment. In addition, the production of plastic pipes requires registration and the choice of a tax regime.
Because pipe production occurs with, it is classified as harmful. Therefore, it is necessary to comply with international law regarding the care of the environment and ensure its safety.
All types of products must also have certificates of conformity. The company must implement a Quality and Environmental Policy.
1. Analysis of the market and the polymer pipe industry.
The Russian market for plastic pipes is to some extent limited and narrowed in volume due to a lack of raw materials and final demand. The problem is counterfeit goods and savings on production costs.
In 2016, sales of plastic pipes had stable dynamics. If compared with 2014, it will be negative.
Consumption remained at 425 thousand tons. Enterprises that updated and expanded production capacities produced more plastic products, and although consumption increased by 2016, supply exceeded demand.
The production of pressure plastic pipes predominated (60%), non-pressure pipes were produced least of all (19%), and corrugated products accounted for 21%. At the same time, record supplies of domestic raw materials (75 thousand tons of polypropylene of various types) became an incentive to increase production.
There is a tendency for foreign companies involved in the supply of pipes to be squeezed out of the market. In this industry the level of consumption polyethylene pipes exceeded 62%.
The main production facilities are involved in the production of PE pipes large diameter, intended for use in water supply and gas distribution. There is the toughest competition here and there is practically no import.
In 2016, there was a decrease in import supplies of equipment used in the production of plastic pipes. China remains the main supplier. It provides Russia with 70% automatic lines.
The main issue for plastic pipe manufacturers is the supply of raw materials. Moreover, few pipe business owners are confident that a decrease in the price of raw materials will increase the production of plastic pipes.
By 2020, production volumes of polypropylene and polyethylene are expected to increase by 30%.
The competition is:
- Cheboksary Pipe Plant;
- Polymer piping systems;
- Polyplastic Group;
- Techstroy;
- About Aqua;
- Politek;
- PC Contour;
- Hemcor;
- Pieplough et al.
In general, the production of polymer pipes in Russia can be called oligopolistic, since the main part of the market is occupied by 8 large enterprises. And although these positions are only becoming stronger, conditions are being created for small and medium-sized companies to actively develop their business.
Production efficiency is achieved through the use of new technologies, the introduction of innovations, and the production of unique plastic products. This creates the need to purchase expensive equipment.
The reform of the housing and communal services sector and the modernization of infrastructure have a great influence on the development of the market.
2. Type of plastic pipes: what products to produce?
To decide on the assortment that an entrepreneur will produce and sell, you should understand the types of plastic pipes:
PE pipes They transport water well for drinking and household needs and are used for drainage. Such products are produced with a length of at least 12 m and a diameter of 1.6-16 cm. Products can be found under the brands PE 63, 80, 100, 100...etc.
The production of polyethylene pipes has its own characteristics:
- use of advanced technologies,
- lower cost,
- less expensive packaging.
The degree of polymerization allows the production of products of different pressures.
PVC pipes are produced in a non-pressure type, they are not afraid of low temperatures and other climatic changes, and are durable. These items are intended for the installation of underground pipelines, sewage systems, and the removal of gaseous media whose temperature does not exceed 45°C.
Also used in construction because... have good economic performance. Their diameter is 11-63 cm, and their length is up to 12 m. They are painted white and orange.
Polypropylene products due to their multi-layer nature and high stiffness class, they cope well with bridging drinking water. PP is also purchased for modernizing the heating system and technological installations. The diameter range is 2-11 cm. They are supplied in lengths from 2 to 4 m.
Metal-plastic pipes are considered the best option for home use,
because they are easy to install. However, with mechanical deformation, PP quickly breaks, and the connecting elements are not resistant to high temperature changes in water.
The color of the products indicates their area of application. Thus, blue products are used to supply cold water. White pipes are needed in the installation of hot pipelines and heating. Products with a red color are used for laying heated floors. Yellow pipes are used in gas supply.
The cost of pipes depends on their parameters, i.e. on thickness, diameter, length, layering. In addition, the pricing policy is formed based on the technical characteristics of the product (pressure and temperature of the environment that it can withstand).
The most popular are polyethylene pipes of grades 80, 63 and 100. Prices range from 15 to 860 rubles.
3. What raw materials are purchased for the production of plastic pipes?
In order for the production of polymer pipes to be carried out without problems, it is necessary to worry about the supply of raw materials. In the future, polymer supplies should occur regularly.
Used as raw material:
- polybutylene (PB),
- polyethylene (PE),
- polyvinchloride (PVC),
- polyamide (PA),
- polypropylene (PP) and other propylenes.
Raw materials are purchased in the primary grade in granulated form.
The type of production will influence the choice of raw materials. When purchasing it, pay attention to expiration date and quality. The most commonly purchased copolymer is polypropylene. This composite allows for the production of durable products.
The backup option is secondary raw materials, also known as waste. This will be used to make plastic pipes. low pressure, which stand for HDPE.
At the stage of preparing production for launch, the workshop owner must find suppliers. You can sign supply agreements both with Russian enterprises engaged in the production of polymers and with foreign ones. The price for domestic primary raw materials is up to 80 rubles/kg, prices for secondary materials are from 30 to 40 rubles/kg.
List of presenters Russian manufacturers polymer granules for plastic pipes:
- Polyplastic— produces recycled polyethylene and other polymer materials at an affordable price.
- Roekoplast– a company producing LDPE and HDPE granules.
- Polymer Club– carries out the production of raw materials for the manufacture of pipes, packaging, films, etc.
- AST Promplast– produces and sells LDPE granules.
- GlavTehProm– is a trading and production company in the field of polymers, rubber goods, and ATI.
- TD Plastics Group– supplier and manufacturer of synthetic polymers.
Production technology: how to make plastic pipes?
The production of plastic pipes is carried out using relatively simple technology. The principle of extrusion is used, when pipes of the required shape are extruded from softened plastic using special equipment - an extruder.
The production process begins with loading raw material granules into the machine hopper. It crushes and liquefies the plastic. The resulting mass is squeezed into tanks.
The plastic blanks are immediately given the required shape. They are then pulled out and dipped into a cooling tank, where, through pressure and calibration, the “semi-finished products” are processed and given a finished appearance.
The last stage of production consists of cutting plastic products. They are twisted in coils or stacked if they have a large diameter.
Location of an enterprise for the production of polymer pipes
You will need to rent a room outside the city with an area of 40-200 square meters. m. It is necessary that convenient transport access be provided to the workshop. There are no increased power requirements.
Be sure to allocate a large space for storage. A room for personnel (production, administrative) and a bathroom are also required.
In addition, the room must have:
- water supply,
- sewerage,
- ventilation,
- heating,
- fire protection system.
Rent a room with high ceilings. This is due to the bulkiness and height of the machines. High humidity is not allowed in the workshop. Therefore, it is better to buy a hygrometer and monitor this parameter.
Equipment for plastic pipes – we equip production.
To produce plastic pipe products, an entrepreneur must automate the production process by means, the main one of which will be an extruder.
This is a machine designed for plasticization, and it comes in various types.
Screw They work on the principle of a meat grinder. Screwless The devices are used for the production of plastic pipe products from mixed raw materials. Combined The machines are equipped with both disk and screw mechanisms.
Typically, in the production of plastic pipes, screw-type equipment is used; it is considered the simplest, and also has its own classification:
To figure out which extruder is needed in your case, it is better to contact a specialist.
Or you can buy an automated line for production, which will consist of the following elements:
Equipment for plastic pipes is purchased from Russian suppliers, as well as imported. Those who have a limited budget have the opportunity to purchase used machines. The prices for new cars are considerable - from 2 to 4.5 million rubles.
Personnel of the enterprise for the production of plastic pipes
To participate in production, 3 workers (shift) will be required. This is an operator, technologist and assistant. A technologist is entitled to a salary of at least 50 thousand rubles, and an operator – up to 30 thousand rubles.
Regardless of whether they have experience working with such equipment or not, instruction must be provided.
If you yourself cannot control the production process, you will still need to hire a manager. IN mandatory The company must have an accountant and a sales manager. It is advisable to hire a cleaner.
If you intend to install standard equipment and increase production volumes, you may need to increase staffing to 6 people per shift.
If you plan to provide production with transport logistics, you should take into account that these are additional costs, and special requirements are imposed on vehicles.
Having formed a team, it also needs to be retained. To do this, it is necessary to create a healthy psychological climate in it, introduce it, provide normal working conditions, and social guarantees.
It is important to motivate employees with rewards, which will help achieve their goals in a shorter time.
Sales of plastic pipes
If you do not pay serious attention to product sales and do not think about it in advance, the production of plastic pipes will become unprofitable. It is necessary to make a lot of effort to find your clients, wholesale customers and conclude profitable contracts with them.You need to offer plastic products:
- construction bases and shops;
- to private individuals;
- various companies;
- Housing and communal services, etc.
We will have to develop all kinds of discounts, make special offers, and hold promotions. To position your brand, don’t skimp on advertising. Use methods available in the real environment (media, television, radio, outdoor advertising, distribution of leaflets, etc.) and on the Internet.
Creating your own website will be an excellent solution, because this way you will expand your audience and give customers the opportunity to order pipes online.
The production process of polymer pipes.
What properties do polymer pipes have?
Equipment for production.
How much can you earn from producing plastic pipes?
First, let's decide on the investments needed to get started. The minimum amount will be 2 million 260 thousand rubles. For a large enterprise you need to have 8-9 million rubles.
Expense items:
- registration, obtaining permits – from 15 thousand rubles;
- rent – from 50 thousand rubles;
- taxes – from 20 thousand rubles;
- utilities - from 30 thousand rubles;
- equipment – 2-4.5 million rubles;
- raw materials - from 200 thousand rubles;
- Payroll – from 250 thousand rubles;
- advertising – from 55 thousand rubles.
Profit will depend on the type and characteristics of the plastic products produced and pricing policy. In general, it is quite possible to count on 300-400 thousand net profit per month. Profitability reaches 18%, and costs will pay off within 2-3 years.
With the right approach to planning activities, market analysis, purchasing high-quality raw materials and equipment, the production of plastic pipes will become a profitable business area.
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PVC pipes are pioneers among polymer pipes, which began their journey more than half a century ago in America and Europe. In the domestic market, PVC pipes gained popularity extremely slowly. This is explained both by the conservatism of the consumer and the lack of a full-fledged regulatory framework that allows the widespread use of PVC pipes in housing and communal services.
Slowly but surely, pipes made from polymers of this group are constantly expanding their sector in the pipe products market due to the improvement of the quality characteristics of pipelines. This is achieved thanks to the emergence of not only innovative technologies for the production of PVC pipes, but also new methods of installing pipeline networks.
The raw material for the production of PVC pipes is granulated PVC polymer.
To create a full range of required properties, a number of additives are used in the manufacture of these products:
- catalysts that accelerate the polymerization reaction;
- inhibitors used to slow down unwanted processes;
- stabilizers that impart stability to the resulting polymer;
- plasticizers that provide the polymer with the necessary plasticity parameters;
- antistatic additives help eliminate static electricity charges;
- Pigments make it possible to obtain the required color of the manufactured pipe.
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Other components can be added to the standard composition to impart certain properties to the product. Supplements, as a rule, are manufactured abroad.
Equipment for the production of PVC pipes
An extrusion line for the production of PVC pipes provides a continuous cycle consisting of the stages of extrusion (pushing material through a molding hole), calibration and cooling in baths, drawing, cutting the pipe to a given length and laying the finished product.
The extrusion line includes:
- an extruder consisting of an extrusion head and a granular raw material supply system;
- baths designed for calibrating and cooling pipes;
- pulling device;
- a mechanism for cutting the resulting pipe into measured lengths - disk cutters or guillotine shears;
- stacker or automatic winder of small diameter pipes.
The extrusion head can have a design solution in the form of a single block with a flange for fixation to the material cylinder. Consists of the following elements: body, matrix, divider, mandrel holder.
The matrix is centered relative to the position of the mandrel using adjusting bolts. The uniformity of the diameter of the pipe wall thickness depends on the accuracy of alignment.
The German company Krauss Maffei specializes in the production of high-performance extrusion lines for the production of pressure and non-pressure PVC pipes. The largest plant for the production of PVC pipes in Russia, JSC Hemkor, uses several such lines. The quality of the plant's products has increased thanks to the introduction of a gravimetric dosing system for raw polymer.
Extrusion technology for the production of PVC pipes
The process of producing pipes from polymers is relatively simple, environmentally friendly, requires little labor and electrical energy. The area required to install and operate a complete line for the production of polymer pipes is only about 100m2.
The production of PVC pipes begins with pouring granular polymer into a hopper 
extruder. In the extruder, a screw made of high-quality nitrided steel rotating inside a material cylinder mixes the incoming granules. During rotation, the material is heated to a predetermined temperature.
The molten polymer is fed into the extrusion head, where the forming elements of the cylindrical surfaces are:
- mandrel - it is responsible for the formation of the internal diameter,
- a matrix involved in the formation of the outer diameter.
At the exit from the extrusion head, a plasticized blank in the form of a pipe is obtained. To give the pipe blank the required outer and inner diameters, ensuring uniform wall thickness along the diameter, it is calibrated in a vacuum calibrator (bath).
The calibrator is a stainless steel container three meters long, at the ends of which rubber cuffs are installed to ensure tightness.
The outer diameter calibration device is located at the front of the bath and is a stainless steel cylinder with a central hole whose diameter is equal to the diameter of the pipe. Through the diaphragm of the calibrating device, the pipe enters the cooling bath, in which a vacuum is also maintained.
To stretch the pipe evenly, track-type or belt-type pulling devices are used. Pipe cutting is carried out circular saws or guillotine shears. At the end of the line there are devices for laying products on a special rack or for winding small-diameter pipes. These devices can operate in both manual and automatic modes.
The production of PVC sewer pipes, which belong to the non-pressure category, can be focused on the production of pipes with a single-layer wall (monolithic pipes) or with a three-layer wall. The outer layers of a three-layer pipe are made of virgin uPVC. The intermediate layer has a porous structure, and is made from either our own recycled uPVC or a third-party recycled polymer.
The production of corrugated PVC pipes is most often carried out by twin-screw extrusion of two-layer pipes. Inner surface– smooth cylindrical, outer – corrugated wavy. Both walls are produced simultaneously using the hot method and form a single monolithic structure. The cavities formed between the outer and inner walls facilitate the construction of the pipe. The outer wavy wall helps achieve the required annular rigidity.
Process Innovation
One of the innovations in the production of PVC pipes is the production of biaxially oriented pipes. These products have high levels of impact strength and other mechanical characteristics with a simultaneous reduction in wall thickness, pipe weight, and, consequently, its cost.
Currently, two methods of biaxial orientation of PVC pipes are used:
- The two-stage batch method consists of extruding the product and its subsequent biaxial orientation in two different installations. This production is quite energy-intensive and labor-intensive, but makes it possible to obtain products of very high quality.
- In the second method, extrusion with orientation in both directions is carried out on the same line. This production requires high qualifications; it is unprofitable in small-scale production.
Since the production of PVC pipes is not a very complicated and labor-intensive process, and the demand for such products is constantly increasing, this direction is promising for those who want to organize their own business. The payback time for the investment depends on the level of equipment utilization. At 50% utilization of the extrusion line, the costs are recouped in about a year.
1.GENERAL DESCRIPTION
Purpose and scope polypropylene pipes:
Universal sewer polypropylene pipes with a nominal outer diameter from 110 to 160 mm, designed for laying:
in internal domestic sewage systems of buildings with a maximum temperature of permanent wastewater of 80°C and short-term (within 1 minute) wastewater with a temperature of up to 95°C, with a maximum flow rate of 30 l/min;
in external sewerage systems with a laying depth corresponding to the stiffness class;
in drainage systems and storm sewer.
When using polypropylene sewer pipes in external sewerage systems, their advantages are fully realized in comparison with pipes made from both traditional materials (steel, cast iron, etc.) and modern plastics.
Based on the totality of their properties, polypropylene pipes and fittings are the most optimal solution for external and storm sewer systems of small diameters.
Advantages and characteristics:
high temperature resistance waste water, up to 95°C;
high chemical resistance to most aggressive environments, under the influence of which traditional materials corrode and age;
there is no cracking under the influence of surfactants (detergents), which is especially important when used in domestic sewage systems;
pipes made of polymer materials do not conduct current, which distinguishes them favorably from steel and cast iron pipes, which, in the vicinity of cable routes (in cities and industrial zones), are subject to accelerated aging under the influence of electrochemical corrosion;
high resistance to water-abrasive wear, which makes it advisable to use PP pipes for transporting liquids containing solid particles;
low roughness coefficient makes it possible to use minimal slopes, there is practically no overgrowth of pipes;
resistance to impact at low temperatures is an important advantage during installation and repair work.
Polypropylene pipes, unlike PVC pipes, have significantly higher resistance to impact at low temperatures. The ring stiffness of polypropylene pipes must be at least 4 kN/m2, i.e. The pipes have a hardness class of SN 4.
The stiffness class of the pipe is the main parameter that determines the maximum depth of the pipeline. The maximum depths for laying a gravity pipeline made of polypropylene are determined according to the methodology given in SP 40-102-2000 Design and installation of pipelines for water supply and sewerage systems made of polymer materials .
The approximate maximum depth for laying polypropylene pipelines under an average transport load is 5 - 6 m, depending on the density of the backfill.
Service life - at least 50 years.
2. SERVICES
Within the framework of this project, the production of polypropylene pipes is proposed.
Replacement of sewer and storm drains metal pipes on polypropylene allows you to permanently get rid of the shortcomings that cast iron or steel are susceptible to. Plastic is not subject to corrosion, does not collapse under the influence of low temperatures, is lightweight and relatively cheap.
The problem of replenishing the market of sewer polypropylene pipes of various lengths and wall thicknesses for external and internal use in the Southern Federal District is being solved.
3.1 Market analysis
Products made in Germany:
Gebr Ostendorf Kunststoffe GmbH&Co.KG (Ostendorf) is Germany's largest manufacturer of high-quality polypropylene pipes for sewerage systems. The company's products are recognized all over the world, and their products are also appreciated by Russian consumers. The enterprise is certified according to the DIN EN ISO 9001 standard.
It's traditional quality products without any major complaints. The price is high. Those who do not save money choose a German manufacturer of polypropylene pipes.
In second place are Czech pipes:
Ekoplastik provides polypropylene pipes and fittings throughout the Czech Republic. The company is known all over the world; its products are widely used in Europe and Russia. Of course, there are developers and individuals who fundamentally use only Ekoplastik polypropylene pipes as a guarantee of quality, proven by time.
Türkiye is in third place:
Turkish pipes are known from the manufacturers TEBO, Pilsa, Valtek, Vesbo, FIRAT, etc.
The Turkish manufacturer Pilsa produces products that are characterized by wear resistance, strength and elasticity, due to which they are used in water supply systems. If the manufacturer's recommendations are followed during installation, the lines on these pipes will serve without any complaints. These pipes cannot be used in closed systems and at temperatures above 95 degrees Celsius.
Turkish pipes Valtek and Vesbo, at a low price of products, are of high quality, but the disadvantage is considered to be a modest selection of shaped elements - those small things, without which it is impossible to make the wiring.
The Chinese manufacturer of polypropylene products Blue Ocean is a branch of the British company and produces a variety of good quality products. There is only one drawback of pipes from this manufacturer - their outer pipe diameter varies, but this does not affect the results.
Another well-known Chinese manufacturer of plastic pipes is Dizayn. DIZAYN polypropylene pipes confidently occupy their niche in the market, and the quality indicators of their products are comparable to leading European manufacturers, but at a lower price.
Lots of small businesses with unpredictable product quality but low prices.
Russian manufacturers:
the Russian market is dominated mainly by Russian-European joint ventures: Sinicon; Santrade; Polytek
Russia was not the first to join the race for pipe prestige and there was a period of dominance by competitors, but by maneuvering pricing policy and improving technology, it is possible to slowly win over its customers. According to some indicators, Russian pipes show significantly best characteristics than its closest competitor - the Chinese manufacturer, and in some cases they have displaced both Turkish and Czech analogues, but at lower prices.
The products of Russian PP pipe manufacturers have all the advantages characteristic of this type of product at the lowest price and the most affordable delivery.
Problems in the PP pipe production market:
Regulatory documentation does not clearly and clearly clarify some issues. If we talk about the introduction of new technologies - plastic pipes, then in some regions, in the old fashioned way, materials are used, the use of which is not economically feasible in these weather conditions. There, plastic would be more economically profitable, much cheaper and could pay for itself in a short time.
Disruptions in polymer materials in summer period, since many oil refineries stop for a month for maintenance, and the remaining ones simply cannot cope with the volumes. The shortage of polymers in the summer months, which are raw materials for production, leads to a shortage of them on the market and, ultimately, to a decrease in production volumes.
There are few professional installers on the market who can distinguish between high-quality and low-quality products. Manufacturers are forced to intentionally and unintentionally save on everything, and primarily on raw materials and equipment, so they slide into the low-quality sector.
The system of passing tenders, and if we talk about housing prices - budget construction. This tender policy leads to the winning of the manufacturer who gave the cheapest prices. It is impossible to make a cheap pipe from high-quality raw materials.
3.2 Market segmentation
Pricing policy
Since today in the Russian market of pp pipes there are many buyers and many sellers, and the latter set different prices within a certain price range, there is quite serious competition in such a market, and the marketing strategies of its participants have less influence on one another. The emergence of a price range is due to the presence of differentiation of offers. Differentiation of the offer is carried out both due to the product itself (its quantity, quality, properties) and the service accompanying its sale (delivery, merchandising, technical training of specialists). Buyers perceive differences in products offered by competitors and make purchasing decisions based on this. When setting prices, other external factors. The pricing policy should take into account the state of the economy, the level of inflation, the size interest rate, since these factors influence both the amount of production costs and the consumer’s perception of the price and consumer value of the product. In addition, the possible impact of its prices on other market participants was assessed. It is necessary to set a price that is attractive to resellers, providing them with an acceptable profit and, thus, stimulating them to promote the product.
Thus, a range of competitive prices has been formed, taking into account services for displaying goods and initial training of personnel for resellers and delivery to the consumer:
No.NameUnit. unit Maximum Price, rub. Minimum Price, rub. 1PP pipe 110x3.2 (external) 3 pieces 3342902 PP pipe 110 x 3.2 (external) 2 pieces 2241953 PP pipe 110x3.2 (external) 1 piece 1271104 PP pipe 110x3.2 (external) 0 , 5 m pcs 81705 PP pipe 110x2.7 (internal) 3 m pcs 2472156 PP pipe 110 x 2.7 (internal) 2 m pcs 1611407 PP pipe 110 x 2.7 (internal) 1.5 m pcs 1441258 PP pipe 110 x 2.7 (internal) 1 m pcs 86759PP pipe 110x2.7 (internal) 0, 75msht817010PP pipe 110x2.7 (internal) 0.5msht585011PP pipe 110x2.7 (internal) 0.315msht403512PP pipe 110x2.7 (internal) 0.25msht353013PP pipe 110x2.2 (internal r.)3msht21919014PP pipe 110x2.2 (internal) 0 ,5msht524519PP pipe 110x2.2 (internal) ) 0.315msht353020PP pipe 110x2.2 (internal)0.25msht322821PP pipe 110x1.8 (internal)3msht18416022PP pipe 110x1.8 (internal)2msht12110523PP pipe 110x1.8 (internal r.)1msht635524PP pipe 110x1.8 (internal)0 ,5msht292525PP pipe 110x1.8 (internal)0.25msht2320
Target Audience
Our target audience is legal entities: various construction organizations, wholesale and retail stores of building materials and plumbing, as well as individuals.
Promotion tools
The main distribution channel at the first stage is direct sales to end consumers legal entities, therefore the main promotion tool is commercial offers potential clients directly.
In addition, our products can be purchased through the online store, and flyers, online advertising, and participation in specialized exhibitions will be used as additional promotion tools.
In the future, it is planned to promote the product through sales agents.
4. ORGANIZATIONAL MANAGEMENT STRUCTURE
Organizational management chart
Draft staffing table for the enterprise:
Structural unit Position Number of staff units Tariff (salary) Allowance Total Administration Director 130000.0030000.0060000.00 Accounting Ch. accountant130000,0010000,0040000,00Accountant Accountant120000,005000,0025000,00Supply and Sales DepartmentSales Manager120000,0020000,0040000,00Supply and SalesDepartmentSupply Manager120000 ,0020000.0040000.00Logistics DepartmentHead. warehouse125000,0010000,0035000,00Logistics departmentStorekeeper220000,0010000,0060000,00Logistics departmentDriver220000,0010000,0060000,00Production departmentHead of department130000,0010000,00 40000.00Production workshopTechnologist125000.0010000.0035000.00Production workshopLine operator220000.005000.0050000.00Production workshopAssistant line operator215000.005000, 0040000.00Auxiliary departmentCleaner210000.0020000.00Auxiliary departmentElectrician115000.005000.0020000.00Total19625000.00
The total wage fund will be 812,500.00 rubles, including wages - 625,000.00, insurance contributions to the funds - 187,500.00 per month.
5. PRODUCTION PLAN
The study “Construction Industry of the South of Russia 2014”, conducted by “Expert YUG” together with the Krasnodar consulting company MACON Realty Group, showed that in general in the South last year there was a reduction in commissioning volumes across all real estate segments. The main sources of decline in indicators last year were two factors. On the one hand, the Olympic facilities had mostly already been completed, and on the other, a particularly noticeable drop was observed in housing construction. The active growth that characterized the market in the past decade has finally been exhausted, and today in southern construction, at best, moderate development can be observed, and often a downward trend.
The main difference between the new period and the previous one is that high dynamics will be observed only in certain segments of the construction market, and with reference to individual regions. The most important growth points are as follows. Firstly, this is mass housing in those regions that were not fully affected by the recent construction boom or showed insufficient dynamics (this is primarily the Volgograd and Rostov regions). Secondly, everything related to sports, tourism, hotels and resorts - here the main incentives will be the upcoming World Cup (Rostov and Volgograd) and the state's plans to build new resorts in the North Caucasus. Thirdly, social infrastructure - in this segment the North Caucasian Federal District will also be under special attention a state planning multibillion-dollar investments in social and cultural facilities in the Caucasian republics. Fourthly, transport infrastructure - in the South, new ports, airports, and roads are currently being built, and this process will last at least until the end of the decade. Finally, the construction materials market has good growth prospects.
Based on this study, the following monthly sales volumes are predicted:
No.NameUnit. unit Price, rub. Quantity, pcs Amount, rub1 PP pipe 110x3.2 (ext.) 3 pieces 29010002900002 PP pipe 110 x 3.2 (ext.) 2 pieces 19510001950003 PP pipe 110x3.2 (ext.) 1 piece 1101000110000 4PP pipe 110x3.2 (external) 0.5msht70100070000 5Pipe PP 110x2.7 (internal) 3 m pcs. 21515003225006 PP pipe 110x2.7 (internal.) 2 pcs. (internal) 1msht7515001125009PP pipe 110x2.7 (internal) 0.75msht70150010500010Pipe PP 110x2.7 (internal) 0.5msht5015007500011PP pipe 110x2.7 (internal) 0.315msht3515005250012PP pipe 110x2.7 (internal) 0.25msht30150045000 13PP pipe 11 0x2.2 (internal) 3msht190150028500014PP pipe 110x2.2 (internal) 2 pieces115150017250015PP pipe 110x2.2 (internal)1.5 pieces110150016500016PP pipe 110x2.2 (internal)1 piece6515009750017PP pipe 110x2.2 (internal)0.75 pieces60150 09000018PP pipe 110x2.2 (internal)0.5msht4515006750019PP pipe 110x2.2 (internal) ) 0.315msht3015004500020PP pipe 110x2.2 (internal)0.25msht28150042000 21PP pipe 110x1.8 (internal)3msht160100016000022PP pipe 110x1.8 (internal)2msht10 5100010500023 PP pipe 110x1.8 (internal) 1 piece 5510005500024 PP pipe 110x1.8 (internal) 0.5msht2510002500025PP pipe 110x1.8 (internal)0.25msht20100020000Total3004500 The total production plan will be 41,195 m of pipe per month.
6. FINANCIAL PLAN
Product cost calculation:
Raw materials Quantity, kgPrice, rublesAmount, rublesPolypropylene granules6051.003060.00 Dye concentrate0.8273.00218.40Chalk4.530.00135.00Total65.33413.40
Thus, the cost of 1 kg of pipe is 52.27 rubles
1 m of pipe - 41.82 rubles
Other production costs
Name Amount of expenses per month Utilities 10,000.00 Electricity 60,000.00 Rent of premises 65,000.00 Other 10,000.00 Total 145,000.00
Fixed assets:
The complete plastic pipe production line includes an extruder, a pipe cutting machine, a raw material supply system, a calibration and cooling bath, a mixer, a pulling device, a conveying belt, a vacuum molder and a pipe stacking accumulator.
Productivity depends on the pipe size: 110 - 130 kg/h. The line can produce about 1000 meters of pipes per day. The lines have different parameters, so you can order machines for your business, or you can save money and buy used equipment. The lowest cost of such a set is about 400 thousand rubles.
Calculation of profit and profitability
1Revenue, thousand rubles 360541.1 Sales of polypropylene pipes, thousand rubles 360542 Expenses, thousand rubles 332662.1 Cost of production, thousand rubles 206,762.2 Rent, thousand rubles 7802.3 Utilities, electricity, thousand rubles 8402.4 Salaries and insurance contributions, thousand rubles 9 7502. 5Taxes, thousand rubles 7002.6 Purchase of fixed assets, thousand rubles 4002.7 Other expenses, thousand rubles 1203 Profit, thousand rubles 27884 Return on sales, % 7.7 polypropylene business plan CONCLUSIONS The Russian market for the production of pipes from various plastics has expanded significantly over recent years. This is due to simple production technology, as well as high demand for this product. Plastic pipes have a wide range of applications. They are used in sewer and heating systems ah, in water and gas supply systems, as well as for the installation of “warm floors”. Such a wide range of applications is explained quality characteristics plastic pipes: they are durable, do not rust, do not rot; can withstand temperatures up to 160 -170°C; there are no lime deposits on them; shelf life is about 50 years; five to seven times lighter than metal pipes. Pipe manufacturers are improving technology and expanding their range, because competition in this type of production is quite high. For a successful business selling pipes, you need to produce high-quality products at an affordable price. To open production, you will need to obtain permits from the gas service, fire inspection, sanitary and epidemiological station, local branch of the State Supervision Service, local executive authorities, etc. The initial investment required to open the production of plastic pipes, when purchasing used equipment and 100 tons of raw materials, will be about 3139 thousand rubles. The business pays for itself in about 1 year. Profitability will be 7.7%
Over the past few years, the production of plastic pipes has significantly improved and expanded in scale. More and more companies are opening their own workshops for the production of these products.
The popularity of plastic pipe production is due to their widespread use. After all, these products are used for the construction of sewerage, heating systems, gas and water supply. This is not a complete list of all possible areas of application of plastic pipes.
Due to such popularity of products on the Russian market, there is considerable competition among manufacturers. Therefore, manufacturing technology is constantly being improved. And in order to beat competitors, it is necessary to produce high-quality products at an attractive price for customers.
Manufacturing technology
The manufacturing technology of plastic pipes is simple and does not require careful study. But, before considering it, let's discuss the advantages of this product. Firstly, plastic pipes have a durable composition that will never rust or rot. The maximum withstand temperature reaches +170 degrees C. Unlike metal, there are no lime deposits on plastic.
Shelf life with proper use is approximately 50 years. As you can see, there are many advantages. But let's get back to manufacturing. The production of plastic pipes is based on so-called extrusion. That is, the product itself is created by extrusion from molten raw materials. Production begins with the raw material being poured into the extruder receiver hopper, where the material is melted using high temperature.
After which the resulting mass enters the forming sector. There, the future parameters of the pipe are determined. Next, the product is cooled in a special bath. The calibrating mold completes the design formation stage. At the very last moment, the finished pipes are cut and laid.
Required Equipment
The necessary equipment for the production of plastic pipes depends on the type of production required. One of the main devices is an extruder. It comes in several types, namely: screwless, screw and combined. The operating process of an extruder can be compared to a juicer. When the raw material enters it, it is completely crushed (melted).
The screwless device is equipped with a disk, where the main part of the work takes place. This type of extruder can process mixed materials. But, as statistics show, in production such an opportunity is useless. Therefore, screw extruders are most often used.
The full production cycle additionally requires the use of certain devices, such as a transport belt, a raw material supply system, a mixer, a pulling apparatus, a vacuum molder and storage tank, baths for calibrating and cooling the laying pipe, and a pipe cutting machine.
Each of these devices has its own personal performance indicators, which determine the speed of operation. The cost of a complete set of devices varies greatly depending on the exact characteristics of the individual devices. According to the latest data, all equipment for the production of plastic pipes costs 400 thousand rubles (this is the lowest price).
Raw materials
The production of plastic pipes can be done using various types raw materials. The most commonly used polymers (both high and low pressure), polybutene, polypropylene, polyvinyl chloride, etc. The choice of raw materials depends on the chosen type of production. When selecting materials, it is important to pay attention to quality and shelf life.
This is especially true for polymers. Polypropylene, as well as polyethylene, have a long shelf life (which is what attracts most manufacturers). The cost of raw materials depends on the quality and type. For example, polypropylene costs 50-70 rubles per kg. Polyethylene is a cheaper raw material - 32 rubles per kg. As a rule, at the stage of purchasing equipment, the main type of materials used should already be selected.
Selecting a room
There are no special requirements for choosing a room. The main thing is that the machine for the production of plastic pipes and other things fit necessary equipment. Of course, do not forget about a special room for working personnel. The building must also have a bathroom and storage area. It is prohibited to build such factories in the city. It is necessary to organize convenient entry for trucks. Depending on the amount of equipment, the building area should be from 40 to 200 square meters.
Staff
A plastic pipe production line must be operated by at least three workers. The list of personnel includes a technologist, an operator and an assistant. If workers have never encountered such equipment, they need to be given precise instructions on all machines. At first, you may need to control everything yourself.
As a rule, a technologist receives 50 thousand rubles, an operator – 25-30 thousand rubles. But depending on the load and location, the numbers will change. Also, do not forget that you will need to hire several work groups who will work in shifts. Each of them must appoint its own leader. This will make it easier for you to manage your staff.
Documents
The production of plastic pipes requires permission from a number of government agencies. If you have additional funds, you can use the services of specialized companies that help in collecting the necessary documents. Permission must be obtained from Gosnadzorohrantruda, fire inspection, gas service, sanitary and epidemiological station, local executive authorities.
In addition to the documents, there are a number of rules for transporting and storing plastic products. The conditions are established in accordance with GOST 18599-2001. Transporting finished products is permitted only in closed transport. The pipes themselves must be completely placed in protective packaging and equipped with plugs. During transportation, it is not allowed to transport pipes longer than 5.5 meters and weighing more than 1.25 tons (including packaging).