Business plan for the production of paving slabs: technology, equipment, calculations. Business idea: how to open a paving slab business

• Where to begin
• Room search
• paving slabs
• Luminous paving slabs
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• What equipment to choose

Production technology

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This article will focus on the organization of a small production workshop for the production of paving slabs and related materials or mini production. Why "mini"? Because the lion's share of those interested in this business want to start with small capacities, due to the lack of proper capital. And then, as volumes grow, move to another level. Those who have a lot of money, as a rule, such articles are not interesting.

Where to begin

Before setting up production, you can do one tricky thing - try to resell paving slabs. Believe me, this is the most difficult thing not only in a particular case, but also in any other manufacturing business. It is not so difficult to lower your hard-earned investments in equipment and technology, it will be much more difficult to sell the entire volume produced. To completely reduce any risks, you can work for a while at a similar firm. The best position is a sales manager. Such an employee, in view of his job responsibilities, as a rule, knows the whole "kitchen" of any production. And for you, as a future business organizer, you can’t imagine a better option. This is an invaluable experience that will save you more than one million in the future. Not a single article on the Internet can find everything that you will find in practice.

Room search

What you can definitely save on in the beginning is on the premises. The quality of the produced tiles does not depend at all on where you are - in a perfectly renovated room or in the courtyard of your house. At first, any large rental costs can be detrimental to your business, so if you decide to rent something, go for the cheapest options. For example, in the industrial area of ​​the city. Of course, you should not take the entire “departure” of the workshop. The main thing is the availability of convenient access roads and uninterrupted electricity. The rest of the "frills" at first can be neglected.

Assortment of goods - what to produce in a mini-production

What you should not save on at the beginning is the development of the assortment and technology for manufacturing tiles. As noted above, the buyer does not care where the tiles were made. He cares about quality and price. If you can make a product that is competitive in terms of price and with proper quality, success is guaranteed to you. If you study the reviews of existing businessmen, then you will understand that many manufacturers took years to develop the technology for manufacturing paving slabs. For the most part, this is due to the fact that the organizers did not really invest in this direction, but did everything themselves, by trial and error. I don't think you're interested in this scenario.

It will be interesting:

• Feasibility study for the production of paving slabs
• Production of paving slabs - profitability from 50%

Hiring an experienced technologist who is familiar with this production can help in developing the technology. As an option, you can contact a company that has been manufacturing tiles for a long time and which, in parallel, sells technology. There are such companies, you just need to look for them. As a result, you can agree and generally become an official representative office in your region. It is good for you that you get a full consultation on starting a business, from the choice of equipment and the development of technology, to advertising and sales. What exactly can be produced in a mini-production environment? Read on.

paving slabs

A popular material for covering paths, approaches to buildings and sidewalks of streets. Very easy to install and resistant to temperature extremes. Does not melt in the sun and does not emit harmful substances when exposed to direct sunlight. It can be made from several types of raw materials, but concrete (a mixture of cement, sand, plasticizers and water) is considered the most popular and affordable. Portland cement grade 500 should be used optimally. The most common product shapes are rectangular tiles, hexagon, coil, fat, square, rhombus and wave. In the production of paving slabs, two well-known technologies are used - vibrocompression and vibrocasting. We will talk in more detail about the choice of production method a little later.

Luminous paving slabs

A slightly more expensive, but increasingly popular coating is luminous paving slabs. In its production, concrete is used as the top layer with the addition of a luminous component - a phosphor, which does not lose its properties for 200 years. Phosphor is a chemical composition that has a light-accumulative memory. The light energy collected during the day is then released at night. Imagine how unusual the night path looks from luminous paving slabs. If you correctly convey to the buyer all the advantages of this product, you can earn very good money. Of course, you should not focus on the production of these products, but as an extension of the range, luminous tiles can be a good help. Because from time to time you may come across customers who are ready to overpay for a twist in the design of their local area or recreation center.

borders

Often, in parallel with paving slabs, a road curb is also made. This is a popular material used in the construction of yard driveways and sidewalk paths. The manufacturing technology of the curb is similar to the manufacturing technology of paving slabs. The main difference lies only in the fact that concrete of heavier grades (B 30) is used for the curb. The most frequent customers of the road curb are government agencies that take large orders through a tender (auction). Most of the purchased lines for the production of paving slabs also have the ability to produce wall and partition blocks. Such material is used for the construction of curtain walls in low-rise and high-rise construction. High-quality concrete is used as a raw material for wall blocks, obtained from cement, purified water, inert filler and plasticizers. They are all produced by the same vibrocompression method.

Vibropressing or vibrocasting

All manufacturers, from small to large, agree that the best way to produce paving slabs today is the vibrocompression method. It has a number of advantages over the vibrocasting method. To understand the difference, we first briefly describe each technology.

Production technology by vibrocasting

During vibratory casting, the concrete mixture is compacted in special polypropylene molds placed on a vibrating table. Vibration is carried out by means of an electric motor. After 18 - 24 hours, the product is removed from the mold and sent to the warehouse. At the exit, the tile is almost perfectly flat. In fact, this is the only advantage of this method, apart from the low cost of the equipment and technology itself. Video - production of paving slabs by vibrocasting

Several obvious shortcomings are immediately evident. The first is the speed of production. Due to the fact that each product must be kept in shape for a long time, productivity will be extremely low. Or you need a lot of forms (and places where to store them), which will require appropriate costs at the start. Moreover, each forum needs to be poured, then formwork must be done, and this all takes time and manual labor. Another common problem that occurs when using vibrocasting is that the tiles are of different thicknesses. As a result, this affects the quality indicators of the entire batch. When laying such tiles, protrusions and depressions are possible. The vibrocasting method is most often chosen by small manufacturers with extremely limited capital, who are ready to reduce the productivity and quality of manufactured products, just to save money at the initial stage. But will it do any good? Controversial question.

The vibrocompression method requires several large investments at the start, because it is necessary to purchase the appropriate installations - vibropresses. The price of even the most low-power press is at least 300,000 rubles. During vibrocompression, the concrete mixture is placed on a mold standing on a bed. The machine is constantly vibrating. At the same time, the mixture is subjected to a pressure of 35 atmospheres using a punch. The punch also vibrates continuously. The whole process takes no more than 6 seconds, after which the punch rises, and the finished product remains on the pallet. As a result, even the most budgetary presses are able to issue 45 sq. m. of paving slabs (in monetary terms, this is about 16,000 rubles of revenue). The tile turns out to be more dense, frost-resistant, many times less manual labor is spent and raw materials are significantly saved. Moreover, a decrease in the water-cement ratio allows the use of budgetary cement of the M-400 brand. Ultimately, all this affects the lower cost of manufactured products, in contrast to tiles produced using vibrocasting technology. This results in a higher net income from 1 square. m.

Selection of equipment (vibropresses)

The choice of equipment depends entirely on the amount of capital that the entrepreneur is willing to spend. The more expensive the equipment, the higher its automation, as a rule. That is, the more you invest on the stratum, the more you can potentially earn. For example, you can simply purchase a machine that will press tiles. And the rest of the operations will have to be done manually. At the same time, you can buy additional equipment, which will, for example, stack tiles on a pallet. There are even separate lines that automatically stack products on racks and send them to the curing chamber. Savings on manual labor are enormous, but the difference in price can be hundreds of thousands of dollars. e. Also, when planning the budget, it is worth considering the cost of acquiring press forms. Because each individual type of tile (triangle, square, etc.) requires its own unique shape. That is, the higher the range of products, the more various forms are required. The price of a new form can reach up to $10,000. It often happens that buying a set of molds is several times more expensive than buying the brick making machine itself.

In the production of large volumes of paving slabs and other products, the question may arise with the purchase of BSU. BSU is an installation that prepares large volumes of concrete mix (1-2 tons each) in just 2-3 minutes. Such devices are prohibitively expensive. For small volumes, at first, a conventional concrete mixer will do. As for the choice of manufacturer, Finnish and German presses (for example, Hess) have proven themselves well. European equipment is distinguished not only by reliability, but also by extremely high productivity and quality of production. True, and the price of such equipment is appropriate. Plus, with the latest growth in the exchange rate, the acquisition of foreign presses is becoming less and less justified.

What equipment to choose

The best option can be considered the purchase of Russian-made equipment. For example, a lot of good reviews can be found about the Rifey and Condor installations manufactured by Stroytekhnika Plant LLC, which is based in Chelyabinsk. The advantages of their equipment - in the versatility of production. For example, the Condor-2 plant is capable of producing wall blocks (70 pieces/hour), partition blocks (100 pieces/hour), paving slabs (6 m2/hour) and lego bricks (30 pieces/hour). The price of such an apparatus is 310 thousand rubles. True, for each type of product, you will need to purchase several types of punch matrices, each of which costs from 29 thousand rubles. Therefore, the approximate amount of investment in equipment of this kind will be 700 - 900 thousand rubles.

A brief calculation of the cost and profitability of the production of paving slabs by vibrocompression

Calculation of the cost of 1 square. m. paving slabs 100x200 mm:

• Cement - 150.8 rubles.
• Sand - 55.0 r.
• Pigment - 36.0 r.
• Water - 0.34 p.
• Electricity - 5.53 rubles.
• Operation of the main equipment - 0.78 rubles.
• Operation of the production premises - 5.11 rubles.
• Operation of auxiliary equipment - 8.0 rubles.
• Indirect costs - 7.73 rubles.
• Salary - 40.99 rubles.
• Deductions to the PFR and the FSS (25% of the salary) - 10.25 rubles.

Total - 320.52 rubles. Retail price per sq. m. of paving slabs in the regions averages 510 rubles. Profit before tax is: 510 - 320.52 \u003d 189.48 rubles. Including taxes (STS, 15% of profit), net profit from the sale of one square. m. is 161.06 p. With the implementation of only 1500 sq. m. of paving slabs per month, the company's net profit will be 241,590 rubles.

How to start a business

If you decide to start your own paving slab business, you need to start such a business with the following steps:

• the choice of the premises in which the manufacture of paving slabs will take place (the ideal place would be an industrial zone, close to the raw material bases);
• selection of equipment that will be used to create paving slabs (to increase productivity, preference should be given to automated equipment);
• choose the technology that will be used in the process of manufacturing tiles;
• carrying out certification at will, which will allow potential buyers to purchase goods from you more confidently.

How much money do you need to start a business

To open a business for the creation of paving slabs, the initial capital can be about 170 thousand rubles. The list of costs includes:

• 10 thousand rubles - purchase of tables for work;
• 70 thousand rubles - purchase of a vibrating sieve and vibrating tables;
• about 6 thousand rubles. - purchase of a drill;
• 14 thousand rubles - necessary inventory;
• 20 thousand rubles - purchase of concrete mixers;
• about 20 thousand rubles. - rental of premises, if necessary;
• 15 thousand rubles necessary for the design of racks on which finished products will be sold;
• 1 thousand rubles - implementation of registration in the tax office;
• 14-20 thousand rubles. will be required for other costs associated with the purchase of necessary materials.

Which OKVED to indicate when registering a business

Manufacture of various concrete products used in the construction process - OKVED code 26.61. You can also specify OKVED code 26.30 - production of plates and ceramic tiles and OKVED code 26.66 - production of other products from gypsum, concrete and cement.

What documents are needed to open

To open your own paving slab business, you need to prepare the following documents:

• a document confirming the opening of an individual entrepreneur or LLC;
• photocopies of the birth certificate, passport details and identification code;
• statement;
• receipt confirming the payment of state duty.

All documents are submitted to the tax office at the place of residence of the future entrepreneur.

Which taxation system to choose for business registration

When choosing a taxation system for the production of paving slabs, one should give preference to a simplified or unified taxation system.

Production technology

Starting the production of paving slabs, the following materials should be prepared.

Paving slabs continue to maintain their leading positions in the building goods market. For exterior decoration, the owners of private houses and organizations traditionally choose this material. This means that the production of paving slabs as an entrepreneurial activity can be a profitable and promising undertaking.

Nevertheless, any entrepreneur who decides to open his own business in this direction needs to prepare for the fact that he is in for a lot of competition. However, since this business is currently one of the most profitable, in demand and promising, to achieve success, you only need to develop a competent business plan for the production of paving slabs.

Basic project properties

The purpose of this project is to determine the economic efficiency of creating an enterprise for the production of paving slabs. A ready-made business plan can be used as a commercial offer during negotiations with potential investors or creditors.

The relevance of the business for the manufacture of paving slabs lies in the high performance of this material and its popularity in the market. Paving slabs are environmentally friendly, durable, convenient to use, and also economical. And thanks to new technologies, the term and quality of its service is significantly increasing.

The project of creating a production enterprise for the production of paving slabs is designed for 2 years - during this period, according to the plan, all initial investments will pay off. The business plan takes into account all the risks and possible force majeure situations that can reduce the company's profits and even contribute to its unprofitability.

There are three main goals for creating a workshop for the production of paving slabs:

– creation of an enterprise with a high level of profitability;

— meeting the demand in the relevant market segment;

- obtaining high profits in the period indicated in the plan.

To achieve these goals, it is planned to open an enterprise that will produce paving slabs intended for arranging sidewalks in settlements of any nature and purpose.

The general funding figures are as follows:

- the cost of the project as a whole, including all types of costs - within 5.5 million rubles. It is envisaged that a commercial loan in the amount of 5.5 million rubles will be received for opening and developing a business. The interest rate in this case will be 16%;

- the investor's income, or the total amount of interest paid on the loan will be 270.9 thousand rubles;

— the total economic effect from the implementation of the project for the production of paving slabs for the established period is 34 million 413 thousand rubles or more under favorable economic circumstances.

The preliminary payback period will be 1 year. But in case of force majeure or additional expenses, this period can be extended up to 2 years.

Technical features of the manufacture of paving slabs - in the video:

Stages of opening a business

The main list of stages for opening a workshop for the production of paving slabs from scratch includes:

- development of a plan and preliminary financial calculations;

– registration of the enterprise with the Federal Tax Service;

– lease of a site and production premises (if you have your own material and technical base – its preparation for the start of the production process);

— purchase of equipment and raw materials;

- recruitment;

- the beginning of the production process.

Based on a two-year period for the development of the enterprise, it is possible to draw up such a detailed step-by-step plan:

Stages	Execution conditions	Deadlines
Project start		1 - 2 year
	1 month project	First 30 banking days
Getting a loan	The presence of a mandatory package of documents	1 month
Entering into the state register, registration with administrative and tax authorities	Concluded investment agreement	From 1 to 30 calendar days
Location selection, paperwork	Preliminary work	1 month
Conclusion of a lease or purchase agreement for a land plot	Investment agreement	1 month
Purchase of equipment	Conclusion of an investment agreement	Up to 30 calendar days
Equipment installation	Receipt of investment funds	Up to 30 calendar days
Hiring	Production activity	Up to 30 calendar days
Training	End of the stage of organization of the production process	Up to 30 days
Carrying out a marketing campaign	30 calendar days	Up to 360 calendar days
End of the project		12 – 24 months

Business registration

To get started, it will be enough to register as an individual entrepreneur. The law does not require registration of a legal entity for such activities, and at first the IP format will indeed be more successful.

The process of registering an IP requires the submission of a minimum of documents of the founder: copies of the passport, identification number, as well as a receipt for payment of state duty in the amount of 800 rubles. These documents are submitted by filling out an application for registration of an individual entrepreneur in advance in a standard form. In it, in addition to the personal data of the entrepreneur, the code according to the OKVED classifier is indicated. It must be selected using the current classifier (). In the absence of additional activities, code 23.31 (Manufacture of ceramic plates and tiles) is suitable. The prepared package of documents must be submitted to the territorial office of the Federal Tax Service, and after 3-5 days the applicant is issued a ready-made certificate.

If there are several founders, the IP will not be suitable for registering a company - you will have to choose one of the existing legal entity formats. The best option is a limited liability company. In this case, the list of documents to be submitted will be more extensive, and a special entry fee is paid additionally - the authorized capital in the amount of at least 10 thousand rubles. The procedure for registration and functioning of an LLC is regulated by a special federal law 14-FZ (http://www.consultant.ru/document/cons_doc_LAW_17819/).

Paving slabs do not require careful certification. This feature greatly facilitates the process of legalizing a business. But if you wish, you can get a certificate of product quality. This document will be a good help in the competition and will help a newcomer to the market to acquire regular customers and partners. You can get such a document in a special certification service. Previously, products must be tested for strength, resistance to frost, moisture and other qualities. If the verification is successful, the manufacturer will receive the required certificate without any problems.

Useful regulatory documents for doing business:

Equipment

Paving slabs are made by two different methods:

• vibrocompression,
• vibrocasting.

Depending on which method is chosen, the purchase of various production equipment will be required.

For the manufacture of tiles using vibropressing technology, you will need:

• Vibropress (its cost is about 20 thousand dollars)
• Concrete mixer (approximately $6,000)
• Punch (about 3 thousand dollars)

Equipment for manufacturing by vibrocasting is much less expensive. The list will include the following items:

• Vibrating table (about 4 thousand dollars)
• Molds (about $1-18 each)
• Concrete mixer (about $600)

Other types of equipment that will be needed for the production process:

• – hyperpress (makes it possible to obtain large volumes of products under high pressure;
• – conveyors for moving materials;
• - dispensers;
• – cement silos for cement storage;
• – control panel for automation of dosing, weighing and solution supply;
• — cleavers for splitting concrete products;
• - shelving. It is better to choose steel racks that have high strength.

You can purchase a ready-made production line. It will cost more than buying individual pieces of equipment, but will greatly simplify the manufacturing process.

Technology business plan for the production of paving slabs

When developing a business plan for the production of tiles, you need to take into account the technological features of this process. First of all, you need to familiarize yourself with the scheme of the vibrocompression method. This technology is also used in the manufacture of borders, wall and partition stones.

Production steps include:

1. Concrete preparation. First of all, you need a concrete mixer. In this case, the number of layers should be taken into account (if there are two of them, two concrete mixers are needed). The finished molding sand is placed in the vibropress matrix (mould).
2. molding. Then the punch and vibrators are started, as a result, the reaction of vibration impulses occurs, and the material is gradually compacted. Next, the product is sent to dry in a pallet.
3. Drying. To bring the tile to its finished form, heat-moist drying is used, for which water vapor is used. If you want to reduce production costs, you can dry the product directly in the room, without using the heat-moist method of drying.

The production of paving slabs using the vibrocasting method is as follows:

1. Prepare the mixture.
2. Concrete is placed in molds on a vibrating table.
3. The finished forms are laid out on a pallet.
4. The resulting mixture is left for 48 hours.
5. The hardened form is subjected to heating, then the product is knocked out.

Making tiles requires a sufficient number of molds. They can be rubber, plastic or polyurethane. Since the production technology can vary significantly depending on the choice of material, it is worth familiarizing yourself with the significant features and differences of each in advance.

Pproduction and organizational features of the manufacture of tiles - below:

Selection and preparation of production premises

There are no special requirements and restrictions on the location of the workshop. The main thing is the size of the area, which should allow you to place all the equipment, as well as compliance with all technical conditions. Geographically, the workshop can be located on the outskirts of the city, in the industrial zone or outside the settlement. It is desirable that a highway or a major road adjoin it, which will facilitate the delivery process.

For the equipment of the workshop, it is best to rent a former production facility - there are usually all the necessary conditions there initially, including electricity of sufficient power, provision of water and other necessary communications.

The most suitable size is from 70 sq. meters or more. To operate the equipment, you will need an uninterrupted electrical voltage of 360 V or more. The drying chamber requires special conditions - it needs to maintain the desired temperature within 45 degrees.

When renting a workshop, you should pay attention to the presence of a large and dry warehouse, a heated office for communication with customers and partners, as well as the work of management and administrative staff. For these purposes, it is necessary to have a telephone connection and the Internet. In a timely manner, you should take care of the equipment of utility rooms and a bathroom for official use.

Staff

If the production volume does not exceed 50 sq. meters of finished tiles per day, there is no need for a large number of personnel. In such cases, a team of three people will be sufficient, who will deal with the process of direct concrete preparation, pressing and sending the batch to dry. To service large-scale production, a larger staff will be needed.

At first, while the workshop will produce a small amount of products, the manager himself can perform the role of sales manager and accountant. With the expansion of production, there will be an increase in the customer base, which will require a separate employee with experience in sales to work with. Accounting will become more complex as the enterprise develops. Therefore, within the first year, you will need a full-time specialist in the field of accounting and tax reporting. In the first months of the company's operation, these services can be provided by outsourcing specialists.

The staff will also need support staff - loaders, a security guard, a cleaning lady.

Sales of finished products

An important step will be the sale of products. To acquire a wide and stable customer base, you should provide them with the entire range of tiles produced. The correct action will be to establish production in such a way that the assortment includes a variety of products that satisfy the needs of all groups of potential buyers. At first, you should not take on large orders, it is better to firmly consolidate your position among small firms or individuals.

With the development of production, it makes sense to conclude long-term contracts with large enterprises that purchase large volumes of paving slabs for construction, repair work or further sale. The specifics of the marketing campaign and the choice of advertising methods depend on what the potential buyer will be like.

Marketing plan and advertising

The overall structure of the global and national markets suffered negative changes during the crisis years of 2013-2014. At this time, there was a decrease in sales, and hence the production of all types of building and finishing materials. At the same time, the crisis also had some stimulating effect on the industry: the struggle for a client between market representatives intensified, as a result, the quality of products of surviving enterprises improved.

In order to freely enter the market, in which there is no shortage of tile manufacturing enterprises, it is necessary not only to offer the buyer a quality product at an attractive price, but also to attract attention. To do this, you need to immediately prioritize and decide on your target audience. So, you can focus on the sale of finished products to retail customers or focus on wholesale sales. In the first case, the cost of implementation will be higher, but you will have to spend more time and money on advertising and attracting customers. Having chosen wholesale sales as a priority, at the first stage it is enough to conclude long-term contracts with several large buyers.

One of the features of paving slab sales is the presence of a concentrated consumer market. This means that it is usually easier and more profitable to sell products within your region. Consequently, the advertising campaign will be aimed at a limited circle of the target audience.

Taking into account the already known features of the market, it is possible to determine the most accurate circle of the target audience. Main categories of buyers:

• - construction organizations fulfilling the order of municipal authorities;
• – private construction companies;
• - individuals or organizations purchasing tiles for personal use.

One of the trends in this industry is a slight but steady increase in demand from private buyers by 10-15% annually. But in order to keep and increase this indicator, you need to resort to the main working methods of advertising:

– dissemination of information via the Internet: a website with detailed information and feedback is required. In addition, you need to advertise your products on thematic sites and forums, online bulletin boards;

Timely placement of advertising will play a very important role. Since the peak of construction and repair work falls on spring and autumn, the main emphasis on advertising should be done just before this time.

The participation of the enterprise in thematic events - specialized exhibitions and fairs will be effective. There you can present samples of your products, exchange contacts with potential buyers and partners, and study the structure and dynamics of the market.

Financial plan

There are several main cost items necessary for opening and further development of the company:

• Initial investment:

1. Start-up and adjustment works - 110,000.00 rubles.
2. APN - 540,000.00 rubles.
3. Press D2430 - 470,000.00 rubles.
4. Concrete mixer SBR-500 - RUB 69,000.00
5. Mold PP TR - RUB 210,000.00
6. Scales MK-15.2 - 4,200.00 rubles.

Total: RUB 1,403,200.00

2) Wages. Calculation for a minimum staff of 3 people:

• manager (salary from 25 thousand rubles),
• APN operator (salary from 25 thousand rubles)
• auxiliary worker (salary 20 thousand rubles)

Thus, the wage fund should be at least 70 thousand rubles (for one shift per month; 140 thousand rubles for two shifts). With the development of the enterprise, wages should increase, which will allow retaining skilled workers.

When paying the unified social tax (UST) - 26% of the total income.

• Production area

It is desirable to allocate about 100 sq.m. area in order to place the necessary equipment and create an area for storing materials and the products themselves. The warehouse can be located outdoors, but also requires at least 100 sq.m. Heating in the production room is not a mandatory requirement for working conditions. If the rent for 1 sq. m. is 100 rubles, then the total cost of renting the entire premises should not exceed 10,000 rubles. The cost of rent per 1 sq. m. products. It will amount to 2.38 rubles.

4) The cost of materials and energy carriers. The total cost of raw materials, which includes polymer, sand and pigment, for 1 ton will be 3794 rubles. This means that the cost of raw materials per 1 sq.m. finished tiles is equal to 136.58 rubles.

The cost of 1 square. m. paving slabs:

The profitability of this type of business with the right organization exceeds 100 percent. This is facilitated by the fact that even defective products can be used (for example, in construction), so the unprofitability will be minimal.

A detailed cost plan for opening an enterprise for the production of paving slabs will include the following items:

Item of expenses	Monthly expenses	Yearly expenses	One-time costs	Total expenses for the year
Buying a concrete mixer			127400	127400
Vibrating tables (pouring, stripping)			90000	90000
Forms			33600	33600
Transformer			61600	61600
Pallet truck			20160	20160
Loader / overhead crane			3800000	3800000
Baths (for washing forms, for stripping forms)			22400	22400
Wheelbarrows, trowels, shovels and other equipment			28000	28000
Production technology, technology training			61600	61600
The cost of raw materials (per 2 thousand km. Tiles)	100000	1200000		1200000
Salary	250250	3003000		3003000
Website development, promotion	55000	660000	110000	110000
Wiring			214200	214200
Unexpected expenses			456800	456800
Total	405250	4863000	5025086	5073626

Regardless of the chosen business format, the financial year for any enterprise begins in January. From this month, the necessary tax payments are calculated. The list and tax rates of the main contributions to the Federal Tax Service are standard and include the following:

In order to calculate the amount of income of the enterprise, in addition to the cost price, it is necessary to analyze the current market prices for finished products. The price list will be based on the average prices of the relevant market segment and the amount of production costs.

The average cost of paving slabs, in rubles per sq. meter:

Traditionally, the cheapest will be gray tiles, the most valuable and expensive - white, produced without the use of dye. The better the materials used in production, the more expensive will be the cost, and hence the price of the finished product.

The company's sales forecast will be determined based on the following criteria:

— the results of the analysis of consumer demand for paving slabs;

— market analysis data for tile manufacturing enterprises;

— general conclusions regarding the state of the market for the sale of paving slabs.

The calculations take into account the lowest threshold of profitability. The plan necessarily considers all existing risks in the industry. These primarily include a high level of competition and a significant barrier to entry into the market. So, in order to open production, significant initial investments are needed for the purchase of equipment and raw materials. At the same time, without a quality marketing policy, it is impossible to fully enter the market and take a strong and advantageous position in it.

Taking into account the main stages of the creation and development of the enterprise, a plan for the provision of services is drawn up:

Period	Type of service	The volume of the provided service per month	price, rub.	Sales proceeds, thousand rubles
1 – 6 months of investment		2000 sq.m	500 - 540 per sq.m	1000 - 1100 thousand rubles
1 – 6 months of investment		2000 sq.m	From 560 per sq.m	From 1120 thousand rubles.
	Production of paving slabs	2000 sq.m	540 sq.m	1000 - 1100 thousand rubles
7 – 12 month of operation	Tiling and related work	2000 sq.m	From 580 per sq.m	From 1150 thousand rubles.

At the moment, the market growth rate is at the level of 10-15 percent. If this level continues, over the next 1-2 years, the growth in sales volumes will reach 26.7 million per year and more. The main condition that will help overcome the entry barrier is to provide the enterprise with modern and high-quality equipment. The second important advantage of the tile production workshop will be the selection of qualified personnel. An active marketing campaign and a well-designed advertising plan will speed up the process of business promotion.

The paving slab manufacturing business plan includes average cost calculations and a rough profit forecast for the production shop. Specific financial indicators may differ under the influence of objective and subjective factors, risks and changes in the market. Taking into account the high level of demand for paving slabs among individuals and enterprises, the following conclusion can be drawn: with a good preparation of the material base and a thorough study of the sales market, a tile manufacturing workshop will be a profitable and promising undertaking.

Features of the business for the production of scarves from scratch - in the video:

The advantages of this building material include:

• durability (the average service life of an asphalt pavement is 7 years, for paving slabs - about 30);
• ease of installation (no heavy construction equipment required);
• frost resistance;
• environmental friendliness (paving stones, unlike asphalt, do not emit harmful volatile products in the heat - when replacing 1 million m2, 665 tons less toxic substances will enter the atmosphere during the year);
• puddles do not form on the tiles.

You do not have to obtain special permits or licenses to start production. Certification is also not required. Although, if desired, the certification procedure is worth going through, since the availability of documents confirming the high quality of products will stimulate consumer demand. The procedure is inexpensive - about 20 thousand rubles.

A business plan should take into account a number of key points related to the legal form of the enterprise, the choice of premises, the purchase of equipment and the hiring of employees. The successful implementation of the project will ultimately depend on how responsibly you approach the preparation of a business plan and competently make all the calculations.

Organizational moments

Our business plan provides that for the organization of production it is enough to become an individual entrepreneur. The procedure is simple. You will need:

• make a photocopy of the passport;
• certify it with a notary;
• write an application to the tax authorities;
• pay the stamp duty.

After 2-5 days, the Tax Inspectorate will give you a TIN and PSRN (certificate of registration as an individual entrepreneur).

An example of registration cost calculations is provided in our sample business plan.

room

This business plan implies the presence of industrial premises with an area of ​​at least 150-160 m2. The building must be equipped with:

• mains (380 V);
• water supply (the presence of cold water is mandatory, hot water is desirable);
• heating;
• convenient access for transport.

The building should be divided approximately equally. One half will house the production itself. The second half is intended for drying and storage of finished products. An indispensable condition is the year-round maintenance of a temperature in it of plus 40-45 ° Celsius.

Our business plan provides that the monthly cost of renting the premises will amount to 60-70 thousand rubles.

Equipment

Production includes work on:

• production of concrete mix;
• pressing;
• transfer of finished products to storage racks;
• packaging.

When calculating the payback period of the project, it should be taken into account that the finished paving stone must be aged in the warehouse for about a month to acquire the final consumer properties.

Paving slabs can be made in two ways, each of which will require the purchase of a different set of equipment. The first technology - vibrocompression - requires large financial costs, but has such advantages as:

• great performance;
• high quality products;
• minimal use of manual labor.

The second technology is vibrocasting. The advantages of this method include the relative cheapness of the equipment and the possibility of manufacturing paving stones of various configurations and shapes. Among the main disadvantages are the lower quality of products and the high cost associated with less economical consumption of concrete.

The cost of purchasing equipment, depending on the chosen production technology, can range from 600 thousand to 4 million rubles. Our plan for the implementation of the project for the organization of production is based on the option of using vibrocompression technology, which will require the purchase of an automated line worth 1,950,000 rubles. The calculations can be found in our business plan.

Staff

The production of paving slabs does not involve a large number of workers. For the full operation of the workshop will require 5 people. The foreman directly manages production and keeps records of products sold to consumers. Four workers are engaged in maintenance of an automated production line - they load raw materials and store finished goods.

Monthly expenses for staff salaries - 110 thousand rubles. Examples of calculations can be found in the sample of our business plan.

Profitability calculation

The cost of manufacturing 1 m2 of paving slabs is about 220 rubles. The average market price is 450-500 rubles / m2 (depending on the shape, color and consumer properties, the cost of one meter can reach up to 1200 rubles / m2.

When manufacturing products in two shifts, the workshop will be able to produce approximately 300 m2 of paving stones daily.

Let's make the necessary calculations:

500 - 220 \u003d 280 x 300 \u003d 8,400 rubles. - daily net profit.

8400 x 22 = 180,000 rubles. - net profit for 1 month of operation of the shop.

Accordingly, the initial investment will pay off within one year.

For detailed calculations, see our sample business plan.

In this article:

Starting the production of paving slabs (paving stones) is much easier than, for example, setting up the production of food products or clothing. Why? Yes, because you do not need any special licenses to open such a business. You just open a private enterprise - and go ahead.

In fact, you don’t even need to be too meticulous about paving slab production technology. You can open such a business without having any skills in construction or related fields.

Paving slab production: business plan

Step 1: Certification

Finished products of such production do not need mandatory certification. However, certification is worth it. Buyers will be more willing to purchase a product that meets high quality standards and has a certificate confirming this. Fortunately, the necessary expertise will not cost too much: 100-300 dollars.

Step 2: Room

Any room is suitable for a workshop, for example, a warehouse or production areas. It is best if your production is located in an industrial area and has convenient access routes. The main condition is that the premises are located near cheap raw material bases (this way you will save on the delivery of raw materials, such as concrete).

Other characteristics of the premises:

• The area of ​​the premises for a small production of paving slabs (up to 100 m 2 tiles per shift) should be at least 70-80 m 2. The larger the output, the larger the area should be;
• An electrical network with a voltage of 380 W must be connected;
• Cold water is provided (it is also desirable to have hot water);
• It is desirable that the workshop be heated.

You will also need a separate heated room with underfloor heating, which will maintain a temperature of 40-45 ° all year round. Its dimensions should not be less than the room under the workshop. This room should be taken under the drying chamber, as well as a warehouse.

Total monthly rent for all premises: $500-1000 per month.

Step 3: Hardware

The description of the technology is quite capacious, therefore it is placed in a separate chapter.

Equipment

Cheap non-automated equipment will cost many times less. However, when buying such inventory, you will have to put up with a number of restrictions:

• Mostly manual labor;
• Low quality products;
• Small volumes of production;
• Low energy efficiency of the equipment.

More expensive counterparts (both domestic and foreign) are almost always automated and guarantee the release of high quality products. They also allow you to increase productivity, provide low energy consumption and a number of other advantages.

There are 2 most common technologies for the production of paving slabs, paving stones:

• vibrocompression;
• Vibrocasting.

The use of each of these technologies will require the purchase of a different set of equipment. Moreover, each method is characterized by several levels of mechanization - from fully automated production to the involvement of workers to perform most manipulations. Let's consider each method in more detail.

Vibrocompression

With this method, a vibropress is used for the production of paving slabs. It happens like this:

• With the help of a mixer, a concrete mixture is prepared;
• The finished mixture is fed from the mixer to the vibropress using a conveyor;
• The vibropress compresses the mixture, forming finished products - tile blocks;
• Further, finished products are moved to special pallets or storage racks, where they are kept for 12 hours;
• Finished products are packed and prepared for shipment to the buyer.

Often, all these procedures are performed by a single unit. It is a fully automated conveyor type line. At the same time, workers should only fill in the correct proportions of the ingredients necessary for mixing the mixture.

There are also less automated lines, where some stages of production are performed by people. They typically cost less than their fully automated counterparts, but product quality can suffer from these savings. Benefits of vibrocompression:

• This method implies high labor productivity;
• Products obtained by this method are more durable and frost-resistant;
• They are designed in strict geometry;
• Such products are more durable.

vibrocasting

In fact, with this method, the only type of equipment is a vibrating table for the production of paving slabs. It can be an automated line with a conveyor and automatic knockout of finished products, or it can be very simple and inexpensive. According to this method, tiles are made as follows:

• The finished mixture is poured into molds for the production of paving slabs;
• Next, the forms are placed on the vibrating table;
• The vibrating table is a special machine for the production of paving slabs. It has a vibrating surface, and forms are kept on it for a certain time;
• Forms are removed from the vibrating table and stand in a warm room for 12 hours;
• Finished products are knocked out of the casting molds. This is done in such a way that the products do not turn out with chips.

This technology can also be highly automated, but there are also options when all procedures, except for vibration treatment, are performed by workers. In this case, you, in fact, are producing paving slabs with your own hands.

Equipment for vibrocasting is cheaper than for vibropressing. Products obtained by this method can be of various configurations and sizes - everything depends only on the molds. It has a smoother surface and attractive appearance.

In other respects, the products obtained by this method lose in quality to pressed analogs (see "Advantages of vibrocompression"). For the price, the production of paving slabs by vibrocasting is slightly more expensive than by vibrocompression. This is due to the fact that concrete is consumed less economically.

The approximate cost of the equipment will be 3.000-10.000 dollars. In both vibrocasting and vibrocompression, you only need 3-5 workers to start production. They do not need any special skills or education. Monthly salary fund: 1.000-2.000 dollars.

Total starting capital: 5.000-14.000 dollars.

Alternative option

What is the fastest way to start the production of paving slabs? It is known that it takes several months to start such a business from scratch. In addition, it is often possible at first to break firewood due to inexperience. That is why you can buy the production of paving slabs. It is worth noting that the purchase is justified only if the enterprise being bought has a large production.

Consider the advantages and disadvantages of such a purchase. Let's start with pluses:

• You can immediately start working. Production (and often marketing) of products is already well established. You can immediately begin to implement all your fresh and bright ideas to improve your business;
• You do not need to look for premises and equipment, everything is already done for you;
• Experienced staff. When you buy a business, you buy the services of all its employees. You will almost certainly have to part with some of them, but there are those who will help you quickly get used to and understand the whole point of this business.

Minuses:

• High price. Buying a business is much more expensive than starting the production and sale of paving slabs from scratch. In fact, you overpay for the so-called "goodwill". This English word denotes everything that cannot be measured in meters, kilograms or pieces. However, it includes everything that is critical for business - an established team, well-established relationships with suppliers and customers, a recognizable brand, etc. "Goodwill" cannot be measured, but it has its own price, which can often be higher than the price of all assets of the purchased production;
• Underwater rocks. Have you thought about why the current owner decided to sell his successful business? It happens that the reason lies in the problems of production, which may not be obvious to a person from the outside. It turns out that you buy a company only to find that even more serious investments are required to correct the situation;
• You can buy a paving slab factory and realize that everything is not arranged there in the way that it should be organized in a good way. Low labor productivity, poor product quality, too high costs - all this most often depends on wrong management decisions. Correcting the situation can be very costly. In the worst case, you just have to close the old plant and start from scratch.

These are just a few obvious disadvantages that lie on the surface. If you do not understand anything in the production of paving slabs and do not have experience in this area, you should be very careful about the possibility of buying a company.

Here, perhaps, is all you need to know about the production of paving slabs. As you can see, there is nothing complicated in this, and your own small production will not require huge investments. If things go well, it might be wise to expand production. At the initial stage, you just have to trust your instincts and try your hand at business.

Making paving slabs as a business at home is an excellent solution for doing business. The demand for building material in combination with a competently organized production process will allow the head of the business not only to receive a stable income, but also to flourish. The acquisition of high-quality raw materials and compliance with technological standards are a guarantee of success, which will quickly change the status of a small business to a large one. Additional income can be obtained by expanding the scope of activities in the field of tile laying services. This solution will attract customers who want to receive a comprehensive service.

Organization of paving slab production business

About the product

With the growth of people's well-being, the question of practical and aesthetic changes in the environment in the place of residence, recreation and business becomes relevant. Happy owners of private houses are given the opportunity to express themselves through the arrangement of the courtyard, paths and individual areas adjacent to the buildings. Finishing is made by paving slabs. Today, this building material is considered one of the most popular, because it can not only create a beautiful view in the yard, on the streets, near the entrance to the company's office, in parks, but also provide traffic in these places.

Paving slabs can level any road, providing the possibility of a comfortable access to the required place, as well as minimizing the impact of mud in rainy weather on human shoes.

Business Advantages and Disadvantages

The production of paving slabs as a business has a number of advantages and disadvantages, expressed in the nuances of production, sale and installation of products. The positive aspects of entrepreneurial activity in this area are the growth in demand for the product and related services. The main clients are representatives of middle class citizens and successful businesses. For such consumers of services, the quality of the building material and the services provided for its installation are important. Cost criteria for them are usually not relevant. This makes it possible to make good money by setting high prices, which should not be raised more than those of competitors engaged in similar activities.

Varieties of used forms for the manufacture of paving slabs

Registration of a business is limited to the registration of a business entity. It does not require permits to operate. Also, you do not need special skills in the construction industry. The nuances of production technology can be mastered in practice by trial and error, which will be excluded from the technology after the first batch of products. Production can be organized in any room in which the inhabitants of neighboring objects will not be disturbed by noise and vibration. These factors are practically eliminated when using high-quality imported equipment.

The technological process is provided by several workers, and the area required for production should slightly exceed the size of the equipment. The business in the production of paving slabs is characterized by profitability and quick payback, provided that it is properly organized. Along with the many advantages of doing business, there are also negative aspects. They are expressed in fierce competition, since many want quick and easy money, which is easy to earn in this area.

The activity is classified as seasonal. Purchases are typical only for the warm time period. This causes the lack of activity or its maintenance in small volumes in winter. Low wages due to part-time employment during this period may provoke a desire among employees to look for a new job. In this case, the head of the company will have to look for a replacement for them. It is worth noting that the production of tiles is a boring and monotonous work, therefore, even with high wages, the business organizer will have to put up with staff turnover.

Pouring the prepared mixture into molds

Types of materials used in production

The production technology of paving slabs implies the production of several types of products: vibrocasting, vibropressed and hydropressed. vibrocasting tiles suitable for paths that are not planned to be affected by the gravity of objects moved along it. Vibropressed and hydropressed tiles fit in places where heavy load is planned. Paving slabs can be made of concrete, clay or expensive natural stones, which give the product strength.

Read also: Polymer paints for crushed stone

room

When compiling a business plan for the production of paving slabs from scratch, a section should be included in the document about the characteristics of the premises used for production.

Its parameters must correspond to the chosen method of production, the type of equipment used and the number of workers employed in the production of products. You should not consider the option of buying or renting a room with an area of ​​less than 70 square meters, since these dimensions are comfortable for small equipment and a minimum number of employees involved in production. With an increase in productivity, you will have to worry about expanding production areas. When choosing the location of the premises for the implementation of a business idea with the production of paving slabs, one should pay attention to industrial zones that have convenient access and a place for storing raw materials and finished products. By choosing an object located near the place of purchase of raw materials, you can save on its delivery.

Tile with the addition of dyes

The main criterion for choosing a room is its technical characteristics. It must be supplied with electricity, with a minimum voltage of 360 V. Sewerage is recommended, as well as a supply of tap water, hot and cold. The best option would be the presence of insulated floors, as well as the possibility of heating the production premises and warehouse, since the drying of finished products after processing in the drying chamber is carried out in a dry and warm room.

Equipment

An obligatory element of the technological operation is vibrocompression. To ensure this process, special complex equipment for the production of paving slabs is required, which includes:

• vibropress;
• concrete mixer;
• punch.

The cost of such a line exceeds $30,000. When buying each component of the equipment separately, its complex can be much cheaper. This is due to the choice of machine tools manufacturers offering their products cheaper. You can save money by making equipment to order or on your own.

vibrocasting tiles

For example, a vibrating table for the production of paving slabs with your own hands can be made even without experience in working with metal. To do this, you must have a welding machine, grinder and drill. The main expense in the manufacture of equipment will be the purchase of metal sheets. A well-designed scheme of the machine, as well as following the instructions for its manufacture, will save the money of the business organizer, since the price of the finished table is calculated in thousands of dollars.

Raw materials used

Filling the form with a pre-prepared mixture

For the manufacture of paving slabs, a concrete mixture is used, consisting of cement, crushed stone and building sand. Special additives-plasticizers are used to improve product characteristics. The use of coloring pigments is used to give a variety of shades to tiles used to create unique architectural forms. When choosing raw materials, one should take into account the requirements for its parameters. Crushed stone fractions should not exceed 10 millimeters, and sand grain size should not exceed 5 millimeters.