Decor 

Profitable business: production of paints and varnishes. Packaging for hair dye Business plan for organizing the production of water-based paint

In this article:

Once forgotten, boring walls and ceilings painted with ordinary paint give way to modern wallpaper, stretch ceilings and drywall trim. However, despite the current trend, the volume of produced water-based paint (which is often called water-dispersion) continues to grow steadily. Moreover, such production is considered to be cost-effective and cost-effective, since there is simply no fierce competition in this segment of paint and varnish products.

We draw up documents

Water-based paints is a suspension that consists of water, a binder base and pigments. All raw materials are practically harmless to the human body, since there are no harmful fumes. That is why it is not necessary to obtain a certificate of conformity for paint, since water-based paint is not on the list of paint and varnish products that are subject to mandatory certification. A voluntary certificate of conformity (photo certificate) should be issued for water-based paint.

It is issued for any type of paint and varnish products, and it can be obtained from an accredited certification body. Before starting production activities, a novice entrepreneur needs to study the regulatory documents governing quality finished products, namely:

  • GOST 19214-80 Water-based paints for interior work. Specifications
  • GOST 20833-75 Water-based paints for outdoor work. Specifications

We should not forget about the official registration of the business, namely the registration of a legal (or natural) person. To do this, you should decide on the most preferable option, focusing on the minimum tax deductions. For example, it can be an LLC (with a simplified form of taxation) or an individual entrepreneur.

Necessary equipment for the production of water-based paint

The production line will consist of the following equipment:

  • dissolver;
  • bead mill;
  • automatic bottling and packaging line for finished products.

Dissolver- This is a special unit designed for mechanical mixing of all initial components. Thanks to the rapid rotation of the dispersing disc with teeth, a high efficiency of grinding particles is ensured: they collide, mix, crush and dissolve. The dissolver is equipped with a high-speed milling type agitator, and the rotation speed can be adjusted. Thanks to this, it is possible to organize the production process in the most optimal way.

If necessary, for convenience, this equipment can be equipped with a lift (hydraulic or pneumatic).

When using a dissolver, the service life bead mill increases significantly. The main function of the bead mill is the homogenization of all components for the manufacture of future paint. It is characterized by high performance, because several discs provide high-quality processing of raw materials. The bead mill body and sieve are made of durable metal that will not rust or wear out. Grain size can be easily adjusted by changing the size of the shot.

The automatic packaging line consists of the following key mechanisms:

  • conveyor belt with cylindrical containers;
  • container supply system;
  • capping caps;
  • warehousing.

Components of water-based paint

The composition of water-based paint often includes about 10-15 components, which in percentage terms is:

  • latex dispersion (about 40%);
  • pigments and fillers (37%);
  • plasticizer (3%);
  • functional additives: cellulose ethers, titanium dioxide, etc. (nine%);
  • fine chalk (11%).

Technology for the production of water-based paint

The technological process for the production of water-dispersion paint is the following algorithm of actions:

  • pouring water into the dissolver;
  • turning on the unit at minimum speed;
  • loading the remaining components in a certain sequence (fillers and pigments);
  • addition of dry components (titanium dioxide and chalk);
  • dispersion of the solution for a certain period of time;
  • filtration of the finished product;
  • packaging of paint in consumer containers.

During the dispersion process, liquid and solid bodies are finely ground. To increase productivity, bead mills are used, the agitator of which brings the paint composition to standard characteristics.

At the final stage, the finished paint is passed through mesh filters and poured into containers. It should be noted that the entire cycle of work on the manufacture of water-based paint should take place at a temperature environment not lower than +5 °C.

Business plan for organizing the production of water-based paint

Production infrastructure requirements:

  • The area of ​​the production workshop is about 80 m 2 .
  • Temperature regime– not lower than +5 °C.
  • Availability of necessary engineering and technical communications.

Process line cost:

  • dissolver - 200,000 rubles;
  • bead mill - 250,000 rubles;
  • electronic scales - 6,000 rubles;
  • hydraulic trolley - 7,000 rubles;

Total: 463,000 rubles.

We will conduct a detailed raw material analysis to establish the production process.

For the production of 10 tons of finished products, the following components are needed:

  • latex dispersion (65,000 rubles);
  • defoamer (7,000 rubles);
  • calcium carbonate (5,000 rubles);
  • other Additional materials(coalescent, thickener, titanium dioxide, etc. - 28,000 rubles);
  • chalk (12,000 rubles);
  • labels (6,000 rubles).

Total: 123,000 rubles.

Per year this enterprise with the declared production capacity is capable of producing up to 120,000 kg. water-based paint. The annual cost of purchasing raw materials will be 1,476,000 rubles.

The production department staff will consist of the following employees:

  • head of production 15,000 rubles;
  • worker 8,000 rubles.

Total: 23,000 rubles.

Annual payroll - 276,000 rubles.

Calculate the cost of 1 kg. water-based paint: 123,000 rubles / 10,000 kg = 12.3 rubles.

The production capacity of the equipment is 10,000 kg per month.

Production monthly costs are:

  • rent production premises: 10,000 rubles;
  • depreciation of the main equipment: 3,000 rubles;
  • wage fund for employees: 23,000 rubles;
  • payment utilities: 5,000 rubles.

Thus, production costs per month (22 working days) are equal to 41,000 rubles, for a year, respectively - 492,000 rubles.

We evaluate the economic efficiency of the project.

Annual cost\u003d raw material cost + production costs \u003d 1,476,000 rubles. + 492,000 rubles = 1,968,000 rubles / year.

wholesale paint price is 30 rubles / kg., and the monthly income, subject to full implementation, will be 300,000 rubles, the annual income will be 3,600,000 rubles.

Annual profit: RUB 3,600,000 - 1,968,000 rubles. = 1,632,000 rubles.

Net profit(minus the cost of equipment and payroll) = 1,632,000 rubles. - 463,000 rubles. - 276,000 rubles = 893,000 rubles.

Of course, in the first year of operation of your enterprises, the amount of net profit will be significantly underestimated due to a one-time purchase production line. In the future, it will be possible to gradually increase production volumes, if there is a corresponding demand.

We establish sales channels

The main indicator of product recognition should be its quality and affordable price (at first). Thus, you can establish yourself as a conscientious manufacturer of high-quality water-dispersion paint, which is in no way inferior to expensive imported analogues. The use of imported raw materials will achieve a similar result. Exceptions may be those fillers that are in no way inferior to foreign ones, but are much cheaper.

An indisputable advantage in work can be the prompt execution of large volume orders - about 2 days. Therefore, soon the profit will cover all costs and production will become economically profitable.

The main sales channels are the establishment of cooperation with hardware stores, supermarkets. It is also possible to conclude contracts with construction organizations that provide services for the repair of apartments, offices and private houses, carry out restoration work, etc. In the market, it will not be superfluous to open a retail outlet for the sale of paint, or even a company store with products. The cumulative system of discounts, various bonuses and promotional offers will help increase sales.

Packing of powder paint into consumer containers (a box made of multilayer corrugated cardboard with an inner polyethylene bag-liner) is carried out on a special installation according to the following technological chain. The finished product after passing the sieve through the dispenser enters the packaging unit - a roller conveyor with electronic scales mounted in the middle part. Powder paint enters the box located on the scales, when the specified mass is reached, the dispenser automatically turns off. The filled box is conveyed from the scale to the packaging table, and the empty box is moved to the scale for filling. In the absence of a box on the scales, the supply of the finished product is automatically turned off. The regulation of the parameters of the packaging process is carried out from the control panel of the packaging unit. All the necessary information about the performance of the powder paint production line is displayed on the control panel in real time.
On the packaging table, after sampling and a positive conclusion about the quality of the finished product, the tying of a polyethylene bag-liner, packaging of containers and its marking are performed.
Product packaging according to GOST 9980.3-86 can be made in different kinds consumer or transport packaging. For powder paint, taking into account the special requirements for transportation and storage conditions, the so-called combined packaging is currently the most widely used. It consists of a box (box) fixed size(for packing PCs of 20 kg), made of 5-layer corrugated cardboard, and a polyethylene bag-liner. Each of the parts of the container is designed for specific purposes and performs its function: the box is lightweight, easy to carry, protects against mechanical and atmospheric influences, including exposure to direct sunlight; liner - mechanically strong storage of paint, hermetically protects from adverse weather conditions. The combination of multilayer corrugated cardboard and polyethylene creates a kind of air barrier against extreme (especially elevated > 25ºС) temperatures. The packaging operation is completed by tying a plastic bag - liner with a plastic clamp and tying the top of the box with adhesive tape.
Then proceed to the labeling of the packaging. According to GOST 9980.4-2004 "marking: information applied by the manufacturer directly to containers, labels or labels."
A label with the following information is firmly attached to each packaged unit of production without distortions and wrinkles:
- name of the manufacturer and its legal address;
- product name and color;
- net and gross weight;
- name of the technical document for the product;
- basic consumer properties or product characteristics;
- expiration date or warranty period of the product;
- purpose and method of application;
- lot number and bar code symbol.
On the cardboard box additionally, in accordance with GOST 19433, hazard signs and transport markings are applied in accordance with GOST 14192 - handling signs: “Protect from moisture”, “Top”, “Protect from sunlight”.
When marking is applied directly to the package, the color of the marking must be contrasting with the color of the package.
Packaged and labeled products are formed into a transport package: the boxes are placed on a pallet (pallet) with the label on the outside and tied with a packaging film. Transport packages of finished products are transferred to the warehouse for storage and shipment to the user.
Storage and transportation of products is carried out in accordance with GOST 9980.5-86 in compliance with the manufacturer's specifications. As well as general rules transportation and storage of powder paint has a number of features that you should pay attention to.
During transport, due to vibration and shaking, some compaction of the paint in the package may occur. But the sign of caking is not yet a paint defect. It can be eliminated fairly quickly and simply by sifting, shaking or fluidization.
It is much more important to know if chemical curing processes have taken place. This phenomenon can occur when the material has been exposed to a temperature above the allowable limit specified in the manufacturer's specifications and on the PC packaging label. Chemical transformations of the material make it unusable. Chemical reactions under the influence of elevated temperatures are especially susceptible to powder paints of fast or low-temperature curing. As a result of chemical aging, not only a decrease in fluidity at the melting stage is observed, but also solidification in particles without complete sintering of the powder. Therefore, it is necessary to observe certain conditions during the transportation and storage of paints. For the transportation of some types of highly reactive powder materials, it is sometimes necessary to use vehicles with refrigeration equipment. Most of the paints, however, do not require special conditions for transportation and storage.
Material that is known to be storage sensitive should be tested prior to industrial use. It should be applied to an appropriate substrate and cured to test film coating performance. Acceptable results from such testing will give confidence that such a material is fit for the job and will form coatings with good performance.
Therefore, it is important to store the material so that it retains these consumer properties. Some of the reasons that cause changes in the properties of paints during storage:
- moisture absorption from the air (for example, due to an open box);
- various pollution (dirt and dust in the painting area);
- excessive exposure to heat (storage close to heat sources).
Powder material left in a feed hopper or open box overnight can absorb moisture and cause application problems. If the moisture absorption problem occurs frequently, steps must be taken to get rid of excess moisture. This can be done, for example, by fluidizing the powder in an apparatus or feeder with dry air.
The problem is the contamination of paints after opening the package. If the powder is not completely used, the remaining boxes must be resealed. Wrap (tie) plastic bags and tape the corrugated cardboard boxes to make sure that dust, foreign powders and other contaminants do not get into the container and spoil the powder. Do not reuse powder containers to store new products. This may lead to contamination. Do not store powder paints near the coating line or near ovens. Exposure to excessively high temperatures can lead to sintering or chemical aging of paints.
If the conditions of the place of storage of the paint are different from the conditions of the place where the coating is received from it, it must be subjected to acclimatization within the area of ​​application of the coating. This is especially necessary when the temperature in the warehouses where the powder is stored is much lower than in the area where the paint is applied. Such heating can prevent moisture from condensing on the powder.
Lumps that may form in the powder from time to time can be easily removed by sifting through a sieve. The practice of sifting all the powder before using it is a good guarantee for the success of the coating equipment.
Loading and unloading of powder must always be done with mechanical storage equipment and personal protective equipment. When poured, the powder easily forms into airborne dust, which can be hazardous if inhaled.
Storage of powder paints in air-powder mixture generators (spraying machines) with plugs installed is allowed for one month at an air temperature of 15-30 degrees and a relative air humidity of not more than 80%.
After warranty period storage of the PC every two months is subject to verification for compliance with the requirements of the specifications. The use of paint is allowed only with positive test results.

According to the GATCHINA PLANT OF POWDER PAINTS

The production of paint and varnish products is in great demand, especially in connection with the growth of the market for construction and finishing materials. This article will fully reveal the technology of production of paints and varnishes. For the production of paints and varnishes, a heated room is needed, tap water, standard ventilation, food 380/50, 220/50.

You will also need warehouses for containers, raw materials and finished products.
For dosing paint components during its creation, production and packaging, the following systems are used:

  • The unit for filling paint and dosing liquid raw materials is the simplest and most economical system using a rotary manual dispenser
  • The pneumatic pump system is the most convenient system to use because it uses a special gun with a non-drip shut-off device and an air pump.
  • Pneumatic semi automatic system– the most rational equipment according to the quality-price system. It has no wearing parts, it has the ability to rebuild for different viscosity of paintwork materials
  • The pneumatic automatic two-channel system is very convenient to use because it has two independent channels and automatic dose cut-off. One channel is used for dispensing paint components, and the other for packaging finished products.

Node for filling paint and supplying liquid raw materials

It is used to automate the operations of filling water-based paints into bucket containers with manual cut-off of the dose, and pumping liquid raw materials for the manufacture of paints and varnishes from a container with raw materials into a bucket container for paint production.

The principle of operation of the system is to supply paint components into containers from a barrel for the manufacture of paint and for packaging finished products thanks to a rotary dispenser.

This system includes:

  • rotary dispenser
  • trolley - tipper for barrels
  • bucket container

Pneumatic pump system

It is used to automate the operations of filling water-based paints into bucket containers with semi-automatic cut-off of the dose, and for pumping liquid raw materials for the manufacture of paints and varnishes from a container with raw materials into a container for paint production.

The principle of operation of the system is to supply paint components into containers from a barrel for the manufacture of paint and for packaging finished products using a pump device.

This system includes:

  • packing unit
  • pedestal
  • bucket container
  • pump device
  • drip-free ink cut-off device
  • tare scales

Pneumatic semi-automatic system for supplying liquid raw materials and packaging paint

It is used to automate the operations of filling water-based paints from a working tank into a bucket container with semi-automatic dose cut-off, and for vacuum pumping of liquid raw materials for the manufacture of paints and varnishes from a container with raw materials through a working tank into a container for creating paint.

The principle of operation of the device: for the manufacture of paint, liquid raw materials are sent under vacuum to the working tank. After that, the liquid raw material, of a measured dose, passes into a container for making paint under the influence of high pressure. This operation is repeated once more until all the liquid products flow into the containers for making paint. In order to pour the finished product into containers, the created paint is sent to the working tank. And already from the working tank, it enters the container under the influence of high pressure, which is created by the pressure regulator.

This system includes:

  • Remote Control;
  • cabinet;
  • working tank;
  • scales;
  • semi-automatic packing unit.

Pneumatic automatic system for filling paint and other liquids, equipped with an electronic control unit with dose cut-off

The principle of operation of the system is in the supply of paint components from a barrel to a container for the manufacture of paint and for packaging finished products thanks to a pump device.

This system includes:

  • cabinet;
  • Remote Control;
  • working tank;
  • automatic packaging unit.

Pneumatic automatic two-channel system

It serves to automate the operations of filling water-based paints from a working tank into a bucket container with automatic dose cut-off, and for vacuum transfer of liquid raw materials for the production of paints and varnishes from a container with raw materials into a container for paint production.

This system includes:

  • measuring container
  • automatic packing unit
  • weighing platform for measuring container
  • Desktop
  • working tank
  • Remote Control
  • compressor

The production of paint and varnish products is not only a set of modern equipment, but also high-quality raw materials and starting materials. This should be given special attention in the production of products of this kind.

Paintwork material (LKM) - a product that has the ability to form a protective or decorative film (coating) on ​​the surface when applied in a thin layer to the product.

. Assortment of paints and varnishes (LKM):

  • Lucky (solutions of film-forming substances in organic solvents or in water, forming after curing (drying) a solid, homogeneous and transparent film).
  • enamels (suspensions of pigments or their mixtures with fillers in varnish, forming after drying an opaque solid film with different gloss and surface texture) - according to the degree of gloss, enamels are divided into glossy, semi-gloss, matte, semi-matte.
  • Paints for interior and exterior works, facade, texture coatings of wood (suspensions of pigments with fillers in drying oil, emulsion, latex or other film-forming substance, which forms an opaque, uniform film after drying). Paints are divided into oil (based on drying oil) and water-based (based on aqueous dispersions of synthetic polymers).
  • Primers , primers (a suspension of pigments with fillers in a film-forming substance, which after drying forms an opaque film with good adhesion to the substrate and protection of metals from corrosion).
  • Putties (viscous paste-like masses consisting of a mixture of pigments, fillers and a film-forming substance and designed to fill the irregularities and depressions of the painted surface).
  • Drying oils (film-forming liquid obtained by processing vegetable oils with the introduction of desiccants to speed up drying).
  • PVA dispersion (polyvinyl acetate dispersion - a viscous liquid of white or slightly yellowish color - a universal material with high adhesive power. It is used in the production of water-dispersion paints, putties, primers, PVA adhesives and other building materials).

The dispersion of the pigment is characterized by the size of its particles, which should not exceed the thickness of the paint film, otherwise the surface will be uneven, rough. The size of the pigment particles depends on the purpose of the paintwork material. The best hiding power is achieved when using pigment particles of 0.2-10 microns.

. Water-dispersion paints

High-quality water-based paints not only are not inferior to the best oil and perchlorovinyl paints, but also surpass them in a number of indicators (weather resistance and durability of the coating, resistance to dirt, drying speed) and compare favorably with the absence of volatile organic components.

Water-dispersion paints allow you to get a number of technological advantages (the ability to paint wet surfaces; the use various ways application (brush, roller, spray gun, electrophoretic deposition); harmlessness and less laborious cleaning of equipment in contact with the paint; transportation and storage of dry paints and "breeding" them immediately before applying to the surface).

The quality and manufacturability of coatings, including water-dispersion (WDM), is largely determined by the degree and nature of dispersion of the solid phase - pigments and fillers.
The degree of dispersion and the shape of the solid particles directly affects:

  • hiding power
  • protective properties
  • paint stability during storage (resistance to delamination).

Water-dispersion paints are conditionally divided into three groups:

  • paints for general construction purposes (including facade paints) - particle size 30-70 microns
  • paints (enamels) for high-class coatings - particle size is not more than 15-25 microns
  • special materials (for example, pigment pastes) - particle size 2-5 microns.

Hair dye packaging requires the use of opaque film bags with internal metallization and a minimum number of seams. The best option packaging for hair dye - flow-pack, sachet, doypack. Materials for the manufacture of bags are matte and glossy barrier films. The paint in the bags is not exposed to third-party factors, does not lose its chemical properties. Packaging design options - euroslot, fitting, tear-off notch. Storage of paint in such packaging is possible in a horizontal form. Demonstration in showcases is carried out in a vertical position, with the help of special suspensions. Hair dye packaging has special requirements regarding design decoration. The flexo printing technique allows applying images with the most accurate reproduction of color shades, which is the main factor when choosing this product by customers. Professional development of the design of bags is carried out by our specialists at the request of the customer. As additional elements design, you can use partial or complete varnishing of the surface, rounding the corners of the bag, applying holograms. Packing into a package for hair dye occurs both automatically and manually, depending on the type of package and dosage.

To buy a package for hair dye in Moscow and find out about the price of bags and films with a print for hair dye, please fill out the form feedback by clicking on the "ASK A QUESTION" button in the upper or lower right corners of the site, or call the number +7 495 664 51 31 .

10000 pcs
minimum print run

15 days
printing time, taking into account the finished flexo form

82%
all shipments are printed ahead of schedule

8 colors
maximum number of colors per pack

1260 mm
maximum shaft width

Types of hair dye bags

doy pack
(doy pack)

Opportunities:
Zip-lock installation, die-cutting handle installation, euroslot installation, degassing valve installation, corner rounding, notch, demonstration window, partial or full varnishing

Packing type:
vertical

Three-seam
(flow pack)

Composition of the material of hair dye bags:
, Kraft/BOPPmet, Kraft/OPPmet, Kraft/CPPmet

Opportunities:

Packing type:
vertical

With side seams
(side fold)

Composition of the material of hair dye bags:
PET/BOPPmet/PE, PET/BOPPmet, PET/OPPmet, PET/AL/PE, APET/AL/PE, PET/PETmet/PE, PET/PETmet/PVD,PET/CPPmet, OPP/BOPPmet, BOPP/CPPmet, OPP/OPPmet, Kraft/BOPPmet, Kraft/OPPmet, Kraft/CPPmet

Opportunities:
Installation of a degassing valve, demonstration window, partial or full varnishing

Packing type:
vertical

Sachet
(sachet)

Composition of the material of hair dye bags:
PET/BOPPmet/PE, PET/BOPPmet, PET/OPPmet, PET/AL/PE, APET/AL/PE, PET/PETmet/PE, PET/PETmet/PVD, PET/CPPmet, OPP/BOPPmet, BOPP/CPPmet, OPP/OPPmet

Opportunities:
Zip-lock installation, die-cutting handle installation, euroslot installation, degassing valve installation, notching, corner rounding, demonstration window, partial or full varnishing

Packing type:
vertical

stick
(stick)

Composition of the material of hair dye bags:
PET/BOPPmet/PE, PET/BOPPmet, PET/OPPmet, PET/AL/PE, APET/AL/PE, PET/PETmet/PE, PET/PETmet/PVD, PET/CPPmet, OPP/BOPPmet, BOPP/CPPmet, OPP/OPPmet

Opportunities:
Zip-lock installation, die-cutting handle installation, euroslot installation, degassing valve installation, notch, demonstration window, partial or full varnishing

Packing type:
vertical

Vacuum

Composition of the material of hair dye bags:
PET/AL/PE, PET/BOPPmet/PE, PET/OPPmet/PE, PET/CPPmet/PE

Opportunities:
Zip-lock installation, die-cutting handle installation, euroslot installation, degassing valve installation, notch, demonstration window, partial or full varnishing

Packing type:
vertical

Do you have any questions?

1. How is the packaging production process?

The production process begins with the choice of material for future packaging. Next, the material is printed according to the layout. The main type of printing on film or kraft paper is flexo printing (a type of printing using flexo forms and special quick-drying inks). The package is formed after complete drying of the paints and lamination.

2. What is a flexo plate?

Flexo form - a plate that is put on the shaft of flexographic equipment for further transfer of ink to the printed surface, thereby creating an impression.

3. What kinds of package are there and which one is better to choose?

There are several types of packages: doypack, with side folds, three-seam, sachet, stick, vacuum, packing, craft. To select future packaging, several factors should be taken into account: the type of packaged product and its properties, consistency, ways of placing on the counter.

4. Is it possible to do everything on a turnkey basis and what is the production time?

The company's capacities allow us to implement any package on a turnkey basis, from the development unique design layout, ending with packaging and placement of packaging in special show boxes. Material production time - 30 calendar days, shaping and packaging - 10 calendar days.