Paving slabs manufacturing costs. Calculation of the costs of opening a tile manufacturing enterprise. How to implement? The most common ways

As the well-being of people grows, more and more attention is paid to the improvement of the territory, the arrangement of beautiful walking paths in gardens or courtyards, as well as in areas immediately adjacent to the building.

While the asphalt traditionally used for these purposes is losing its relevance, the improvement of paths and areas with the help of paving slabs.

That is why the production of paving slabs as a business is attracting more and more entrepreneurs today.

Of course, large municipal customers choose factories with large production volumes. However, private customers or entrepreneurs prefer ordering paving slabs from a small business, due to the possibility of obtaining an individual approach and flexible conditions. When small investments to start a business, such a production can quickly pay off and start making a profit.

You will find a business plan for the production of paving slabs with calculations below.

What does it take to start a successful business?

The basis for the success of any successful business is careful and quality planning.

Drawing up a business plan for the production of paving slabs will help to calculate the necessary investments, think over the production cycle and develop the necessary stages for building your enterprise.

Such a business plan must necessarily include answers to the following questions:

• The choice of technology that will be used for the production of paving slabs, as well as planning the estimated production volumes.
• List definition necessary equipment, selection of optimal suppliers, calculation of the total amount of investments that will be required for its purchase, delivery and installation.
• Based on the selected technology and the equipment planned for the purchase, determine the amount of raw materials required for the production of one batch of tiles. Analyze the proposals of possible suppliers, their prices, terms of delivery, calculations.
• Solve the packaging issue finished products and provide the necessary storage space.
• Based on the planned production volumes, the selected equipment and the space required for storing the finished tile, calculate the required area of \u200b\u200bthe future production facility.
• Think over the issue of the future sale of finished tiles, determine the sales market: operating private hotels, cafes, shops, as well as repair and construction teams. Calculate the planned profitability.

Each of these issues requires careful consideration when drawing up a business plan, since the success of the created enterprise will depend on it.

What are the types of paving slabs?

Depending on the production technology and the raw materials used, today there are several main types of paving slabs, each of which has its own advantages and disadvantages.

The types of tiles and their characteristics are shown in the following table:

The choice of the type of tile planned for production must be made based on the planned sales market and competition in a particular region.

Production technology

For the production of paving slabs, two main technologies are used:

1. Vibrocompression. The tiles created using this technology are characterized by high geometric accuracy, excellent resistance to low temperatures, reduced water absorption and stable performance. The main disadvantage of this production technology is the high cost of the required equipment.
2. Vibration casting. The tiles produced in this way have a glossy, smooth surface and excellent performance. Due to the low cost of the required equipment, this technology is the best choice for small businesses.

Equipment for the production of paving slabs by vibrocompression

Whichever technology is chosen, the production cycle will consist of the same stages:

• Work on the preparation of forms. Before starting production, the molds are lubricated with a special compound. The main requirement for such a lubricant is the absence of petroleum products in its composition. Instead of being lubricated, molds can be treated with an antistatic agent.
• Preparation of the mixture for pouring into molds. According to the preparation technology, a prepared mixture of crushed stone with sand, cement, filler and water is fed into the concrete mixer. In the case of the manufacture of colored paving slabs, the addition of a dye is required to the original mixture.
• The forms are filled with the resulting mixture on a vibrating table or compacted using a vibrating press.
• Drying of finished products. For drying using hot steam, the molds are placed in prepared containers and covered with foil. Under natural conditions, drying takes place on special racks or simply on the floor.
• Obtaining finished paving slabs from molds on a vibrating table. For this, baths are prepared, which contain water heated to 50 degrees. After placing the mold in such a bath, it expands and the finished tile is easily removed.
• Preparation of the tiles for transportation is carried out by placing them on pallets and tying them with packing tape and film.
• Sending finished paving slabs for subsequent storage or sale.

Getting a quality product depends on careful adherence to production technology at each stage.

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Equipment required for production

To start a business, you will need to purchase the necessary equipment:

• Gravitational concrete mixer. If you plan to produce two-layer tiles, you will need to purchase an additional unit.
• Vibrating table for shaping paving slabs and an additional table for shaping.
• Equipment for packing.
• Hydraulic rocker for transporting finished tiles.
• Pouring forms.
• Reinforced PVC film for drying tiles.
• Drying racks.
• Pallets for transportation.

The amount of initial investment depends on the planned production volumes, as well as on the type of equipment selected.

Raw materials used

The following raw materials are used in the production of tiles:

• Cement. To create a mixture, brands M400 and M500 D-o are suitable.
• Granite crushed stone, fraction size not exceeding 10 mm.
• Sand, the modulus of which does not exceed 2 mm.
• Dry mineral additives such as dispersant, plasticizer and colorant.

Accurate adherence to the mixing proportions, as well as the use of high-quality raw materials, affects the characteristics of the resulting tile.

Business profitability: essential ingredients

It is difficult to give an unambiguous answer about the profitability of the production of paving slabs. This indicator may fluctuate depending on the specific region in which the production is created, on the selected type of tile, as well as production volumes.

To correctly calculate the future profitability, it is necessary to estimate the volume of the initial investment in creating a business, calculate the cost per square meter of tiles and determine the planned selling price. The results of the calculations are consolidated into financial section business plan.

Starting a Business: Initial Costs

An important decision that will affect the amount of the required initial investment is the choice of premises: will it be your own premises that you plan to buy, or the workshop will be rented.

Vibrating table for the production of paving slabs

To start production, you need to purchase equipment in the minimum configuration:

• vibrating table - from 4 thousand US dollars;
• forms - from 1 to 8 US dollars per piece;
• concrete mixer - from $ 600.

You can minimize the cost of purchasing equipment for the production of paving slabs by purchasing used devices (second-hand).

As the business develops, you can buy optional equipment... However, this should be planned at the stage of selecting a production facility.

Cost of finished tiles

The cost price includes:

• premises rental costs;
• utility costs (water supply and electricity);
• wage fund for workers;
• cost of raw materials for production.

On average, the cost of 1 sq.m. produced tiles are about 210 rubles (excluding rental costs).

The financial component of the business plan

Thus, having all the necessary data, you can calculate the profitability of your business. With a production cost of about 210 rubles and a selling price of about 350-370 rubles per square meter, the profitability reaches 150%.

Due to its high profitability and low initial cost, the production of paving slabs becomes a good solution for small businesses.

Paving slabs are a product that is in ever-growing demand and does not lose its relevance. It is used to cover squares, sidewalks, steps, roads, driveways for cars.

Paving slabs market share large manufacturers is 95%, small - 5%. Consumers are municipal bodies, commercial enterprises, individuals.

Paving slabs are gradually being replaced by asphalt pavement. According to experts, the business for its production is different high profitability (100%) and is beneficial.

• clarify the volume of production and selling prices from future competitors;
• identify potential customers (stores, outdoor cafes, hotels, construction companies);
• find potential suppliers of raw materials.

After the analysis, in case of insufficient market saturation, it is possible to calculate the profitability of production with a higher productivity. An entrepreneur who has no experience in running such a business should not immediately purchase an expensive set of equipment. You can buy it additionally after receiving large orders.

Industrial production of paving slabs as a business: where to start?

When starting a business, consider:

1. tile manufacturing technology;
2. choose equipment and calculate the costs of its purchase, delivery, installation;
3. calculate the amount of raw materials and their costs;
4. solve the issue of packaging of finished products;
5. foresee advertising costs;
6. think over ways to implement tiles.

Room selection

There are no requirements and restrictions for the premises for the production of paving slabs.

The area should be sufficient to accommodate the equipment; a room of 70 m2 or more is suitable.

According to the technology, a certain temperature regime must be observed in the production of tiles, therefore, in winter, the premises must be heated.

Additionally, a drying chamber is required (with a constant temperature of about 45 degrees), the floor in it must be warm, there must be no ventilation. A warehouse is needed for finished products. Requires a water connection, 360 V power supply.

The technology for the production of tiles using the vibrocasting method requires a constant supply of water in large quantities, therefore communications must be reliable.

Documents for registration of activities

To open a business you need

Paving slabs are not subject to mandatory certification in the GOST system, however, you can voluntarily obtain an EZ (expert opinion).

After checking the tiles (for strength, frost resistance, water absorption, abrasion and other properties), the certification center issues a document confirming the quality. This increases the competitiveness of the product. A consumer who is serious about choosing a tile will certainly pay attention to all the characteristics.

Equipment for the production of paving slabs

The production of paving slabs requires:

• concrete mixer;
• shaping table;
• stripping table;
• plastic forms.

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Production personnel

Deal with technological process (preparation of concrete, pouring it into molds, pressing and sending it to the drying chamber) can be 3 people, provided that the daily production of paving slabs is 50 m2.

They do not need special education. If demand increases during the high season, it is possible to employ several additional people.

An approximate business plan for the production of paving slabs

Initial investment in production:

• melting and heating unit 540 thousand rubles;
• press D2430 470 thousand rubles;
• mold PP TP 210 thousand rubles;
• concrete mixer SBR-500 69 thousand rubles;
• commissioning works 110 thousand rubles;
• bath for washing forms 5 thousand rubles;
• scales MK-15.2 4.2 thousand rubles.

Total: 1408.2 thousand rubles.

Necessary materials:

• cement;
• sand;
• plasticizer;
• pigment.

Necessary costs:

1. The cost of raw materials is 3.794 rubles / ton (136.58 rubles per 1 m2 of tiles).
2. 60 thousand rubles (provided that you work in 1 shift). Expenses for wages will amount to 28.58 rubles. for 1 m2 of tiles.
3. Tax deductions 8.7 rubles. for 1 m2 of tiles.
4. Rent of premises 10 thousand rubles. (2.38 rubles per 1 m2 of tiles).
5. Electricity consumption per shift is 135 kW (7.8 rubles per 1 m2 of tiles).

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Cost of 1 m2 of paving slabs:

The price of paving slabs is 480 - 500 rubles / m2. With a monthly production of 50 x 22 \u003d 1100 m2 of tiles, the amount from its sale will be 528 thousand rubles.

Industrial production of paving slabs as a business: profitability and payback

The calculation was made taking into account the daily production of 50 m2 of tiles and its selling price of 400 rubles / m2. When organizing 2-shift work, income will double, and the payback period will be reduced.

Making paving slabs as a vibrocasting business requires more manual labor, and therefore increases the cost of wages for workers. The type of raw material also affects the cost price: for the production of high-quality tiles, washed sand is needed, the cost of which is several times higher than the usual one.

, technology, business plan and other issues were covered in detail in our article at the link.

It is not recommended to save on raw materials: due to its low quality, the tiles will become unusable in 3 years, this ruin the entrepreneur's reputation... To reduce the cost, the production process should be optimized.

Video on the manufacture of paving slabs

Paving slab production as a business - in this video you can watch the tile manufacturing technology:

• Step-by-step paving slab business plan: where to start
• How much money is needed to start a business
• Production of paving slabs: what documents are needed
  • • • Related business ideas:

Initial investment in opening a paving slab business is no more than 200 thousand rubles. The business profitability reaches 50%, and the payback of the equipment is only 3 months.

Characteristics of paving slabs

The attractiveness of tile production lies in the fact that the state and individuals are beginning to use it more and more for laying sidewalks and private plots. And this is logical, because the pavement surface is more reliable, easier to repair and looks much more attractive than concrete or asphalt. And the laying process itself is understandable to many homeowners, in contrast to the same asphalt, the laying technology of which is known from the strength of 5% of the country's population.

For the production of paving slabs with a volume of 1000m2 per month, you will need to rent a room with an area of \u200b\u200bat least 100m2 with warehouse and places for installing a drying chamber. The rental price for such premises ranges from 20 to 30 thousand rubles per month, depending on the region.

To organize a mini-production of paving slabs, it is enough to attract no more than 3 people. Initially, you will need one molder, de-molder and accountant.

What equipment to choose for the manufacture of paving slabs

The total cost of purchasing such a set of equipment will amount to about 130 thousand rubles, taking into account the purchase of plastic forms.

When choosing equipment for the production of paving slabs, it is recommended to pay attention to the equipment of domestic production. It may partially lose in manufacturability and level of automation to imported counterparts, but our equipment is cheaper, easier to repair, easier to find spare parts and because of its simplicity does not require hiring highly qualified workers.

The initial raw materials for the production of paving slabs are crushed stone screening, sand, Portland cement, chemical additives (plasticizers, concrete modifiers, etc.), dry pigments and water.

Paving slab production technology

The technological process for the production of paving slabs is not complicated, and includes such stages as preparing a concrete mixture, preparing forms, forming on a vibrating table, holding products in forms, stripping products and packing finished tiles.

Forms are a key element in tile production. Molds can be plastic, rubber and polyurethane. The most practical are rubber molds, as they can withstand up to 500 cycles of use. Plastic molds are slightly inferior to them in strength, they are enough for 200-250 cycles, and polyurethane ones for only 100 cycles.

Before pouring the concrete, the molds are lubricated with chemical additives based on the S-3 plasticizer, which improves the mobility of concrete during spreading, increases the strength and frost resistance of products.

For the preparation of concrete, it is recommended to use cement of the M500 and M400 grades. Crushed stone with fractions of 0.5-0.10 cm is used as a coarse aggregate, and building sands with a particle size of at least 2 are used as fine aggregate. Crushed stone and sand are mixed in proportions 1: 1.

After preparing the concrete mixture, it is placed in molds and compacted on a vibrating table. Then the vibrated products are stacked on a pallet and sent to an oven, where they are kept in molds for 24 hours.

The tiles are de-molded on the de-molding table using attachments. Unshaping one tile takes about 5 seconds.

Upon completion of the stripping, the finished tiles are placed on pallets. Products are packed using packing scissors, tape and metal staples. The final strength of the tile is gaining within 21 days.

The cost of production of 1m2 of paving slabs averages 250 rubles. In this case, the main costs consist of material costs and salaries of hired personnel. The wholesale selling price of tiles reaches 450 rubles / m2.

How much can you earn by starting a production of paving slabs

Net profit after all taxes is 120 rubles / m2. In the production of paving slabs with a volume of 1000 m2 per month, the profit of an entrepreneur is about 120 thousand rubles.

The payback of the equipment, subject to 100% sales of the produced tiles, can be only 3 months.

The most popular coating on the city streets is paving slabs. The emergence of which saved the paving workers from the need to select the size and shape of the natural stones used earlier.

An important factor is its cost, which is much lower than the old paving stones.

The production cost of paving slabs depends on two main factors:

• materials for manufacturing (cement, fillers);
• the complexity of the technological process.

In addition to two main factors, when determining the cost of manufacturing paving slabs, it is taken into account: price policy a specific enterprise. It is determined not only by the cost of the finished product, but also by economic costs and the level of cost of tiles in the foreign and domestic markets.

The seasonal price per piece of paving slabs is formed at the beginning of spring. In May, it adjusts depending on the level of supply and demand - and remains at this level until the end of the season. An exception is the increase in the cost of consumables.

The difference in the cost of tiles from different manufacturers ranges from 5 to 8 percent.

Cost calculation

To calculate the cost of manufacturing paving slabs, you must have the following information:

• Consumables cost: cost of cement and sand with delivery.
• Financial costs for energy resources (in particular, electricity).
• The costs of operating the main type of equipment performing vibropressing operations.
• Costs associated with renting and operating premises for production.
• Operating costs auxiliary equipment (forklift).
• Additional (indirect) costs: clothing for workers, tools.
• Service personnel salaries.

Types and advantages of paving slabs

The modern building materials market offers different kinds paving slabs and prices.

There are two main types of paving slabs: vibropressed and vibrocast. One has an attractive appearancewhile the other can withstand enormous loads.

The vibrocast type of tile is intended for the arrangement of private summer cottages, where high loads are not expected.

The production process is quite simple and profitable (when manufacturing large batches). The advantage of such a tile is the base - white cement, which can be painted in different shades. This allows you to make a variety of compositions that will decorate any track or area.

Vibro-pressed tiles are indispensable for cities and busy streets. It can withstand enormous loads of transport and significantly surpasses vibrocasting in terms of strength, frost resistance and durability of operation.

The sizes and prices of paving slabs directly depend on the brand, method of manufacture and purpose of the tile.

Prices for paving slabs

Each manufacturer sets its own price for products. You can find out how much paving slabs cost in Moscow in the following tables.

In contact with

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Indeed, today this industry is not yet oversaturated, on the contrary, there is an active development due to the emergence of new technologies.

And as profitable business we will consider the most affordable investment. So, let's consider the manufacture of tiles by vibration casting.

Both methods of manufacturing street coverings have the same requirements for the room. This area is not less than 80 sq.m. and the availability of all communications. Renting will cost no more than 30 thousand rubles, and in some regions the price may be even less.

Here you should immediately give an approximate amount utilities: 3 thousand rubles for electricity and the same amount for cleaning the territory, maintaining the housing stock, water and so on.

Equipment

Naturally, this is the most expensive item in our plan. So, we need:

• Vibrating table (take the VS-1500 model): 34.5 thousand rubles
• Concrete mixers: 20 thousand rubles for 2 pieces
• Forms for tiles: from 70 rubles for 1 piece
• Capacity for demoulding forms: 10 thousand rubles

With the expansion of production, it is possible to take a more productive model of the vibrating table, as well as replace the concrete mixers with a forced action mixer. In addition to the above, you will need:

• Mold washing bath
• Racks for spreading and storing tiles
• Wardrobe, table and chairs for workers

Material

To prepare the mixture you will need:

• Cement: 4.5 thousand rubles per 1 ton
• Sand: 650 rubles per 1 ton
• Plasticizer: from 220 rubles per 1 liter

To save on materials, it is worth paying attention to the delivery conditions when ordering, as well as discounts to wholesalers. But one should not forget about quality either; it is better to give preference to suppliers with a positive reputation.

Profit and return on investment of paving slab production

This point is important not only for your sidewalk tile business plan, but for any other activity as well. Therefore, we are carefully evaluating the data that will be presented now.

So, at the above prices, the cost per square meter of finished tiles is approximately 210 rubles (including electricity and labor of workers). At the same time, the average market price is equal to 350 rubles per square meter. Total from 1 sq.m. the profit will be 140 rubles. If you release 30 square meters per work shift. m tiles, the costs will pay off in a month.

Naturally, the payback is calculated taking into account the timely sale of finished products.

By the way, the costs can additionally include packaging material and packaging equipment. At the beginning of business development, reinforced film is suitable. Its price is about 45 rubles per 1 sq. M.

Workers

In general, this point in a similar plan should go even before calculating the profit, but we did it differently. Why? It's simple. In order to provide your employees with a normal salary, as well as not stay in the red, it is worth offering piece-rate pay. In these earlier calculations, it was 45 rubles per square meter.

If a team of 2 people produces 30 square meters per shift, then its earnings are: 30 * 45 \u003d 1350 rubles. Accordingly, each worker receives 675 rubles per shift. For a month, each of the employees has average salary in the industry. Also, to save the first time, you can independently perform production operations by simply hiring a partner.

As for the accounting department, you can use the services of the respective firms without recruiting your own staff. It will cost significantly cheaper.

What else?

The last thing in the business plan is certification. It is completely optional for our products. But buyers believe that what more product passed the checks, the more reliable it is. Therefore, you can use the services of specialists. On average, this last item of expenditure ranges from 3 to 10 thousand rubles.