Mini workshop for the production of ceramic tiles: how to open a business?

Where to buy raw materials for tiles?

State assistance in the business of this direction.

Organization of a mini business, how to open a workshop:

Line for the production of ceramic tiles.
Staff for mini-production.

Finance and Development:
Financial plan.
Profit and payback period.

Development and improvement of this business.

The production of ceramic products can be attributed to the most ancient craft. And one of the most popular ceramic products is tile. Demand for this product has not fallen at all for a very long time, not only for its attractive appearance, but also for such properties as hygiene, increased wear resistance, strength and fire resistance.

Despite the centuries-old history of this product, the basics of making tiles are almost the same for each manufacturer. The only difference between a cheaper and more expensive product is the quality of the raw material itself. To understand what kind of materials were used to make tiles, it is enough to look at the finished product.

If there are small dots on the surface, single foreign inclusions, color heterogeneity and vagueness of the pattern occur, then materials of lower quality were used for the manufacture of this tile sample.

The main raw materials for the manufacture of ceramic tiles are the following elements:

1. Kaolin and clay are the main raw materials for making tiles;

2. Quartz sands - are added to the main raw material to obtain the effect of shrinkage;

3. Slags, nephelines, feldspars are fluxes that are used to obtain the effect of lowering the sintering temperature;

4. Surfactants, thinners, mechanically activating agents are special additives necessary for the manufacture of tiles.

The entire list of raw materials described above can be divided into the following groups:

1. Raw materials from carbonate - gives the fired product a vitreous structure;

2. Components of quartz - contribute to the formation of the "skeleton" of the tile;

3. Components made of clay - give the mass a special plasticity, which makes it possible to obtain shaped products in the future.

Depending on the type of clay components used, the body of the manufactured tile may differ. It can be white, red, or completely colorless. Ceramic tiles that have a red or brownish body are made from a special grade of red clay. White tiles are obtained by using kaolin. If several types of clay are used simultaneously for the manufacture of tiles, then a body with a gray tint can be obtained.

It is important to note the fact that the color of the raw material does not affect the quality of the final product at all. Of course, the cost of a white body tile may differ from that of a red body product, but only for commercial reasons. Namely, from the place of production of the product itself and the cost of its delivery. The only difference between the white case and the red case is that the former is made with more precise geometric dimensions.

If we talk about glazed tiles, then the color is completely invisible under the glaze layer. But with the unglazed product, things are a little different. Such a tile is one-color throughout its thickness. Therefore, the aesthetic properties of the final product directly depend on the quality of the selected raw materials. Therefore, special dyes are used to obtain the color of the tiles.

Where to buy raw materials for tiles?

You can buy raw materials for the manufacture of tiles both in our country and abroad. For example, kaolin is mined mainly in the UK, France and Germany. The quality of such material, of course, is excellent, but this will directly affect the final product and it will be more difficult to find a consumer. Clay deposits also exist within our state. Which make it possible to supply all production facilities with high-quality raw materials, which are practically not inferior to their foreign counterparts. And its cost is much cheaper for both the manufacturer and the end user.

The quality of clay is monitored by laboratories that use modern equipment in the course of their work. That is why you should not look far, all the necessary components for the manufacture of ceramic tiles can be found within our state. To purchase the necessary raw materials for the manufacture of ceramic tiles, it is necessary to allocate about $6,000.

The production process of ceramic tiles is quite simple. For the manufacture of tiles, clay of various grades is taken, with the addition of additional components, depending on its type and purpose. When using industrial equipment, all components are pressed at elevated pressure with further firing in a special furnace at a certain temperature.

Modern production involves several ways of manufacturing ceramic tiles, depending on the type of product required.

The main types are:

1. Bicottura - used for interior wall cladding;

2. Monocottura - for wall cladding inside the building, for the floor;

3. Monoporosis for facade cladding;

4. Clinker tiles for swimming pools, bathrooms, plov;

5. Cotto - for facade cladding;

6. Kiremic granite - for the floor.

Under the name Bikkotura understand enameled ceramic tiles. It is classified as a product of low strength, therefore, most often it is used for interior wall decoration in a room. The manufacturing technology of this type of tile involves pressing and double firing.

During the first stage - this is pressing and primary firing, only the body of the tile is made. After that, specialists carry out linear measurements to correct the parameters of the product. Samples that have incorrect parameters are sent as a reject for the production of second-class tiles.

Tiles of standard sizes go through a secondary firing stage, which helps to fix the enamel on the base of the tile. Such a layer not only gives the product aesthetic beauty, but also prevents destruction under the influence of moisture. The last stage of production is to check the product for defects and further packaging the goods.

Monocottura can be somewhat compared to the type of tile described above, but in its manufacture there is no re-firing step. But this type refers to a more wear-resistant and impact-resistant product. For its manufacture, a mixture of several varieties of clay with various necessary additives is used. The raw material is mixed in drums to obtain a homogeneous mass and moistened. Then there is a stage of drying and further grinding of raw materials in professional vertical silos. The resulting mixture is transferred through the dispenser to the conveyor belt and sent to the mold. There, the distribution of all raw materials is carried out over the entire area and shape of the stamping product.

The last step is to dry the tiles in a special chamber and apply a layer of enamel. Then the product is baked in an oven at a temperature of 1200 0C and the finished product is gradually cooled down. After this stage, the tile acquires the necessary hardness and the enamel layer is fixed on the body of the product. All processes take place under the close supervision of modern equipment. After baking, the tile is subjected to flaw detection and visual inspection. After that, the tile is labeled and packaged.

Monoporosa is also a type of tile using a single firing step. A distinctive feature is the use of slightly different components in the manufacture of the product. This allows you to change the thickness of the tile and its physical properties. This manufacturing technology makes it possible to produce ceramic tiles of large size and almost perfect shape and proportions.

This tile is additionally subjected to the technological process of ratification - this is the stage of additional processing of the edges of the product. It takes place on special machines, where the edges of the product are cut. This stage allows you to make a product that has an ideal shape, which greatly facilitates the process of laying the product.

A type such as clinker tiles is made from heterogeneous varieties of clay with the addition of special oxidizers and dyes, as well as flux and fireclay. The product is formed by extrusion. This stage is carried out by forcing the finished semi-finished product through special extruders. The finished product has a low porosity, due to which it acquires such properties as wear resistance and resistance to mechanical stress. The scope of this type of tile is floors, stairs, the bottom of pools and more.

Cotto tiles are also obtained by extrusion. Its components are based on several varieties of natural clay. The main positive aspect of this type of tile is its aesthetic qualities. Therefore, it is widely used for the reconstruction of buildings and premises, in the construction of structures in the old style.

This type of tile, like ceramic granite, is made on the basis of a mixture of varieties of white clay, quartz, feldspars and kaolin. This type of tile is classified as a product that has increased mechanical resistance. The only point is that the finished products do not differ at all in the texture and appearance of the pattern. Most often, ceramic granite does not lend itself to the glaze coating stage. It is used for cladding the facades of premises, as well as areas that may be subject to heavy wear during operation (floors, stairs).

Depending on the type of ceramic tiles that the company is going to produce, the planned financial capital directly depends.

Video, ceramic tile production technology:

To date, polyurethane molds for the manufacture of ceramic tiles have found wide application. The growing tile industry is focused exclusively on high quality products. That is why, today, a form for polyurethane tiles is made. Such forms imitate natural materials as much as possible (with the help of which tiles were made earlier).

It often happens that manufacturers can produce various forms of tiles in limited quantities or produce by order of the consumer. These can be both standard tile shapes (square, rectangle, square with rounded or beveled edges), as well as completely non-standard tile shapes made to order.

The requirements for the forms are:

1. Resistance to abrasives and alkalis;

2. High elasticity;

3. Resistance to breaks, deformation and tearing;

4. The possibility of carrying out a large number of technological cycles (most often more than 1000).

All of the above requirements are met by polyurethane molds for the manufacture of ceramic tiles for both internal and external work. That is why tile manufacturers choose such modern and durable products.

State assistance in the business of this direction.

To date, many start-up entrepreneurs can use state support to organize a business in this area. And for this, the country has provided a number of opportunities. These are special programs to help young entrepreneurs, which include several areas of support:

1. Subsidy;

2. Credit;

3. Property;

4. Training;

5. Export support.

Although there are many more people who want it than the state suggests. Yet many have a chance to get the desired support. You can look at support options in more detail.

First of all, it is financial assistance (a subsidy or a loan for small businesses). It can be used by a businessman who is already in the register of entrepreneurs (no more than two years ago). In this case, you can relate to a young businessman and are entitled to support from the state. The amount of financial assistance for Moscow residents can be up to $7,000. For residents of the regions, this amount is about $4,000. All funds can be allocated to the entrepreneur only on condition of co-financing. This means the need to simultaneously invest in the project and their hard-earned money. Such funds give the right to use such as renting premises, equipping workplaces, purchasing equipment, and more.

In addition, the state offers to help with property. Most often, this is the provision of production areas on a preferential basis, which are listed on the city's balance sheet. For this, the selected premises are offered to entrepreneurs on competitive terms. And rental rates in this case are much lower compared to the market ones. The winner of such an auction receives the premises for use on special, preferential terms. It is important that having received the premises in which it is necessary to carry out repair work, you can have every right to co-financing.

The state also offers its assistance in education. To understand the basics of the tile business, professional training is needed. And the government is ready to help. Such training may take the form of lectures, seminars, and legal consultations. It is important that such training is completely free and can help young businessmen learn the basics of entrepreneurial activity.

Additionally, government assistance can be provided to support exports. In this case, such state assistance can be useful already at the stages of production of finished products and the possibility of its further marketing. Most often, the state offers preferential terms for the export of manufactured products.

The following are real examples of government assistance:

1. Compensation of expenses for participation in exhibition events;

2. Subsidy for compensation of all costs associated with the payment of interest on the loan and the development of leasing of production equipment;

3. Subsidy to compensate for the costs associated with the purchase or modernization of equipment;

4. Grants for young entrepreneurs for reimbursement of costs associated with the sale of goods or the provision of various services;

5. Subsidy for connection to the electrical network and much more.

All of the above opportunities for obtaining state assistance are on preferential terms.

To organize a business for the manufacture of tiles, you need to rent a room of about 100-120 m2. This area will be enough to arrange the necessary equipment, properly organize workplaces for staff, allocate space for storing raw materials and finished ceramic tiles, as well as allocate a corner for office space. There are no special requirements for the choice of this room. It is important that the ventilation system works well there, and the room is dry in order to create comfortable conditions for storing raw materials and raw materials.

Ceiling height can be from 3.5 to 4 meters. Higher wall height needed. There is still a need for all communications: water, heating in winter, sewerage. It is important that the power line withstand a voltage of 380 watts for the normal operation of the equipment.

There are also several mandatory requirements for the production facility where ceramic tiles will be manufactured:

1. The presence of opening sashes or vents in window openings for ventilation in the room;

2. The presence of several exits for the possibility of evacuating personnel in case of danger to life or health;

3. The roofs of the building itself must necessarily have perimeter fencing with a height of at least 60 cm;

4. Roofs must be equipped with a special device for the removal of atmospheric precipitation;

5. The floors in the production and storage facilities must be even, several and necessarily of increased strength;

6. Workplaces of personnel must be equipped with heat-protective mats;

7. The covering of walls and floors should allow for the possibility of regular wet cleaning of the premises;

8. Industrial premises must be equipped with fire safety equipment.

The rental price of such premises is about $220 per month. It is better to choose a room far outside the city or in an industrial area.

Line for the production of ceramic tiles.

To start a mini-factory for the production of ceramic tiles, it is important to purchase the following equipment without fail:

1. Concrete mixers.
This equipment allows you to evenly mix the source material for the manufacture of tiles using special blades. This equipment comes in different sizes. For a mini-factory for the production of tiles, it is enough to purchase 2-3 concrete mixers costing about $ 560 each.

2. Vibrating machine.
The main purpose of this type of machine is the formation of future tiles from a semi-finished product. The technological process of manufacturing tiles involves the movement of the main raw material into special forms, where, under the influence of vibration, the product is formed. The cost of the vibrating machine is $5.5 thousand;

3. Furnaces for drying and firing products.
The semi-finished product of the finished tile is placed in a special oven for drying and subsequent disposal of excess moisture. When purchasing this equipment, it is better to opt for an oven that uses hot air for drying. This stage adds strength to the finished product. Kilns for firing have a design in the form of a tunnel. When the finished tile enters the conveyor, it is fired at more than 900 ° C. The cost of the oven for drying and firing is about $ 1.7 thousand;

4. Chamber for glazing tiles and applying patterns.
Today, manufacturers of modern equipment offer a wide range of special machines that are able to apply a layer of glaze using a variety of methods: bucket, cone, embossed or spun. The choice of this equipment fully depends on the allocated finances. The cost of such equipment starts from $1.2 thousand.

The above set of equipment can be attributed to the minimum for opening a mini tile factory. But its cost is quite high - $10.1 thousand. If you want to offer consumers more unique products and make a profit not on production volumes, then you will need to purchase two more types of equipment for making tiles:

1. Modernized sputtering chamber;

2. An additional set of stencils for applying a unique pattern.

In this case, another $6,000 should be added to the total cost of the equipment.

It is important to note that it is best to choose the most automated equipment. But the cost of this will be higher. Alternatively, at the dawn of business development, one can give preference to partially mechanized labor. And only sweats, at the moment of making a profit and developing a business, you can purchase more modern devices.

Video of how the full cycle equipment looks like for the production of ceramic tiles:

Staff for mini-production.

Regarding the staff, 3-4 people are needed to organize the production process. They will be able to fully control production processes: mixing mortar, pouring into special molds, control of such technological processes as vibrocompression, drying and firing. Line operators will also check the received products for defects, reject non-standard products and pack the finished ceramic tiles.

There are no special requirements for operators. It is enough experience in this area and a minimum amount of knowledge. There is a need to invite a quality controller for manufactured products to work. An employee of this specification must have experience and knowledge in this area. There is also a need for a minimum number of auxiliary workers (1-2 people) to perform unloading and loading operations. To carry out organizational issues, you will need an accountant, manager, secretary. The salary of the staff is about $3,000.

The target audience of the business in this area are all kinds of construction outlets and individuals. Therefore, to organize the marketing activities of a business in this area, you can use all the advertising tools. First of all, this is the creation of your own web resource. An important point to beat the competition is the constant promotion of the site.

Consumers can also be influenced by commercials on radio and television. Additionally, you can place advertising articles and publications in popular newspapers and magazines. Additionally, it is worth taking part in exhibitions and seminars. At such events, you can not only advertise the manufactured ceramic tiles, but also learn something new and interesting for your business. It will not be superfluous to visit such foreign events, where you can learn about new tile manufacturing technologies and modern materials. The implementation of marketing activities should be approached with a special approach, it is even possible to entrust such work to a specialist in this industry. In order to promote your production as quickly as possible and get the maximum profit. You need to allocate at least $300 for marketing.

Sales of ceramic tiles.

There are several main consumers of ceramic tiles:

1. Individuals;

2. Companies offering construction or renovation services;

3. Construction markets;

4. Hardware stores and supermarkets.

This is the main target audience for the sale of ceramic tiles. As you know, it is most profitable to sell manufactured products to a wholesale buyer. And the higher the party, the greater the profit for the company.

Financial plan.

To organize a mini-factory for the manufacture of tiles, it is necessary to invest the following amount of funds:

1. Rent of production and office premises - $220 per month;

2. Expenses for the purchase of equipment - $10.1 thousand;

3. Working capital with monthly payments - $3.5 thousand;

4. Permits for business development - $400;

5. Marketing activity - $300;

6. The salary of workers - 3 thousand $;

7. Raw materials and supplies - $6 thousand;

8. Taxes - $170;

9. Other expenses - $200.

The principal amount for investment is $24,000.

Profit and payback period.

The profitability of this production is about 45%. A small business can produce $27,000 worth of tiles every month. From this amount, you can subtract the monthly operating costs - $ 3.2 thousand. You also need to subtract $12,000 for variable costs. The balance sheet profit from all sales is $13,000. Based on the above data, the maximum profit of the enterprise can sell 27.5 thousand dollars. But, minus all expenses, about $8,000 remains for the company's share.

Based on practice, experts have proven that a mini-plant for the production of ceramic tiles can fully recoup its initial investment within 12 months after the start of production. But this payback can only be obtained in cases of an ideal combination of circumstances. This is when all distribution channels are fully operational and are established from the first day of operation of the equipment. But, most often, young entrepreneurs in developing a business in this area may encounter a number of obstacles. It could be seasonal. After all, everyone knows that repair and construction work is most often carried out in the warm season. Therefore, it may happen that the production line may be stagnant during autumn and winter. Therefore, to prevent this from happening to your production, it is important to start the production of ceramic tiles in the spring and put the maximum amount of effort into the development of marketing activities.

Business development.

To develop a business in this area, you can implement a project for the production of ceramic photo tiles to order. In total, in order to open the direction of manufacturing photographic tiles, it is necessary to invest an additional amount of $ 4.8 thousand. This amount will include the purchase of the necessary equipment, raw materials and the implementation of promotional activities. Any pattern can be applied to this type of tile, and instead of a regular tile, you can get a bright and colorful panel. Photo tiles have a number of advantages over standard tiles:

1. Possibility of applying any pattern;

2. High quality finished product;

3. The resistance of the pattern to abrasion;

4. Resistance to moisture and product durability.

The manufacturing technology of such tiles is quite simple. Modern trends allow you to apply a pattern by direct printing on ceramic tiles using a special printer. For the future panel, light-colored tiles are used. Its surface is cleaned and degreased. Using a spray gun, a layer of precoat varnish is applied.

Then the tiles are dried in an oven at a temperature of 150°C. Next, the tile is taken to the table of a special printer. After drawing the pattern, the product is subjected to repeated drying. The process itself takes no more than an hour.

For the manufacture of tiles, you must purchase the following equipment:

1. Airbrush - $30;

2. Printer for printing on ceramics - $ 3.7 thousand;

3. Oven for drying - $ 600;

4. Computer and special software - $450.

The company's services for the manufacture of ceramic photo tiles require additional advertising. First of all, you can use radio advertising and the creation of an Internet site for this.