Own business for the production of foam rubber. How to organize your own production of foam rubber Raw materials for the production of foam rubber detailed description

Elastic polyurethane foam, better known as foam rubber, has practically no analogues on the market in terms of price and consumer qualities. The material is distinguished by high wear resistance, good elasticity, moisture resistance, tightness, excellent level of noise and heat insulation, safety (does not cause allergies), and long service life.

Production methods

The technology for the production of flexible polyurethane foam is based on the foaming of polymers, during which air cells are formed, which make up 90% of the finished product. There are two ways - block and continuous.

With each of them, the raw material for the production of polyurethane is poured into the mixer, where it foams until the desired volume is obtained. Depending on the mixing modes, foam rubber with different physical properties is obtained.

With a continuous method, the prepared foam at a temperature of 20-21 ° C is fed to a conveyor with high sides, where in the process (5-7 m) of movement it foams up to a height of 1-1.3 m.

The next 25 m of the belt movement, the raw material gains the necessary physical properties as a result of the polymerization process, 32 m after the start of the conveyor movement, the resulting material can be cut off with a special guillotine. In this way, you can get a long block up to 64 m long.

Then the material is transported to a special workshop, where its final formation takes place at the completion of chemical processes and gradual cooling. The PPU obtained in this way is of higher quality.

Types and areas of use of the material

Depending on the operational purpose, foam rubber is produced according to various technological maps. This allows you to get the following types of foam (in terms of rigidity):

• ST - standard;
• S - soft;
• HR - highly elastic;
• EL - increased rigidity;
• HL - with high bearing capacity;
• HF - acoustic;
• SPG - special purpose (refractory, with memory function and others).

All of these types of foam are used in the production of upholstered furniture. Various types of foam rubber are used to make mattresses and mats, stuffing for sports equipment, upholstered furniture, car seats.

Foam rubber has also received the widest distribution in the automotive, medical, clothing industries, and construction. Manufacturers of overalls, soft toys, household appliances, sound recording equipment cannot do without it. Foam rubber is needed by all industries where packaging of fragile products is necessary.

Where to buy foam rubber in Moscow?

The Santeks LLC company is engaged, including to order.

Many years of experience in this field, as well as modern equipment, careful control at all stages of production allows us to guarantee high quality products.

If you are interested in purchasing foam rubber, call us or place an order online. Information on how to obtain goods and prices will be provided to you as quickly as possible. Our consultants will help you choose the type and configuration of foam rubber, we work with both large and small wholesale.

Production of foam rubber: analysis of the sales market + technology for the production of foam rubber of 3 types + purchase of equipment + search for a production facility and employees + paperwork + calculation of expenses and income of the enterprise.

Foam rubber is a softener that gives elasticity to some products, such as upholstered furniture or toys. It is also used for thermal insulation, it is durable and very light.

For the first time, the development of polyurethane foam (the scientific name of foam rubber) was taken back in the last century, in the 30s and 40s. Despite the long history of the existence of such auxiliary material, its production in Russia still does not cover all the needs of the population.

Often, material for furniture or thermal insulation is imported from abroad. This is associated with an overestimated cost of the material, and as a result, a considerable final price for sofas, armchairs, etc.

The production of foam rubber can be a great business start, especially since the competition is still at a fairly low level.

We analyze the sales market

Production costs are relatively small, they can be mastered by a novice entrepreneur. However, it is worth starting a business with the production of foam rubber in small batches until you find regular customers and can not fully sell the goods.

We want to make a reservation right away that polyurethane foam is a product far from essential. The sales market for such products is small and rather specific. Selling foam rubber to a simple consumer will not work, because he simply does not need it.

Who can sell the goods:

1. As we wrote above, the main sales channels are furniture factories that produce sofas, armchairs, upholstered chairs, mattresses, etc.
2. Often, electronic equipment is packed together with polyurethane foam to protect the goods during transportation.
3. Some construction firms use foam rubber to insulate the room heat or sound during repairs.
4. Sometimes foam rubber is used when transporting building materials that can be damaged, such as tiles.
5. Foam rubber is used in toys, in the manufacture of seats in cars, in the manufacture of washcloths for the shower and washing dishes.

The sales niche is really not very extensive, and if there are no such organizations in your region that can supply foam rubber, then it will be difficult to develop a business.

It is not worth spending money on advertising, you need to personally negotiate the supply of foam rubber to large customers. The only thing worth spending money on is buying a site and promoting it. So you can tell the whole of Russia about yourself, attract new customers.

You can buy a site for about 5-7 thousand rubles. Additionally, you will have to pay for services to promote the portal in search engines, and this is another 10,000 rubles every month.

Types of polyurethane foam and technological features of the production of foam rubber

The future entrepreneur should know that the basis of foam rubber is chemicals that are very harmful to health. For this reason, the workshop should be located only outside the city; supervisory authorities simply will not allow you to work near residential premises.

Workers should also be provided with special uniforms, goggles, rubber gloves and respirators so that they inhale harmful impurities as little as possible.

So, to create polyurethane foam, you need 3 components:

1. Water.
2. Isocyanate.
3. Polyester.

All components must be purchased, because their production on their own will entail additional costs.

Now consider the production process of foam rubber of different types:

Periodic foam	All components must be mixed with a production mixer and poured into a special form. In a few minutes, the material will begin to rise and take its shape due to the action of water on chemicals. The material should stay in the form for 15-20 minutes. Then it must be removed and transferred to a room with a low temperature (10-15 degrees) for final shaping for 24 hours. The finished foam rubber is cut into pieces and sent to the consumer.
recycled foam	Polyurethane binders and foam rubber left after the production of periodic foam rubber are the basis of secondary production. Such material is much tougher and has a high resistance. Recycled foam rubber is used in furniture factories as a top layer to protect primary foam rubber from wear.
Acoustic foam	To soundproof the room, it is necessary to use dense foam rubber, which is made from foam rubber crumbs. Acoustic foam is of 2 types - embossed (wave or pyramid) and non-relief, which also differs in thickness. The sound absorption coefficient depends on the thickness of the foam rubber.

Documents for opening an enterprise for the production of foam rubber

If you plan to produce foam rubber not for friends, but with the expectation of a wide audience, then you should contact the Tax Service to register an individual entrepreneur (individual entrepreneur).

From the documents you will need a minimum - a passport, TIN, a receipt for payment of state duty (800 rubles), an application in the form No. P21001, an application for switching to the simplified tax system.

note! In the application for opening the status of an individual entrepreneur, you must indicate the OKVED activity code 22.23 - "Production of plastic products used in construction."

Documents confirming will be ready in 5 days.

In addition to the Tax Office, you must obtain permission from the Fire Authority, which will check the safety of the building and the presence of a fire suppression system. SES will also check the premises for compliance with the norms and requirements of SanPiN.

Do not forget about Rospotrebnadzor, which must certify that the foam does not contain harmful impurities, is suitable for use in the manufacture of furniture, toys, etc.

No licenses are needed to work, but it is important to constantly monitor all documentation from raw material suppliers, the tenant, and the buyers of the goods.

Settlement in such industries is carried out by bank transfer, so take care of opening a bank account and order a print.

Legal registration of a business will require not such large expenses from the entrepreneur - about 10,000 rubles.

Equipment for the production of foam rubber

it is worth thinking about purchasing a finished line. Equipment for the production of foam rubber is difficult to assemble into a complex separately, especially for those who do not know all the intricacies of this business.

The set of equipment consists of the following elements:

• Form for pouring raw materials.
• Thermal camera.
• Mixer for foaming.
• dispenser.

The finished equipment for the production of foam rubber consists mainly of the above elements. Separately, you should think about buying a crusher in order to also produce recycled foam rubber.

If you have enough money, then buy a machine for twisting and packing. Packed foam takes up less space, so you save money on shipping.

Separately, you will have to pay for the delivery of the equipment itself and its installation in the workshop, which is about another 200,000 rubles.

№	Equipment	Quantity	Price, rub.)
TOTAL:			1,248,000 rubles
1.	Foam rubber production line (32 m3)	1	720 000
2.	Crusher	1	68 000
3.	foam cutting machine	1	340 000
4.	Packing press	1	120 000

A separate expense item is the purchase of uniforms for workers, equipping the technologist's office (desktop, computer, test tubes for testing raw materials) and locker rooms for ordinary personnel. Depending on the chosen furniture, shape and technique, you will need about 60,000 rubles for this.

Selecting premises and hiring employees

For the production of foam rubber, you need a room of 200 m2. Ceilings in the building must be at least 3 meters.

Special requirements are put forward for the workshop where the equipment will be located and the foam rubber production process itself will take place - the temperature should not fall below 18 ° C, otherwise it will be impossible to fill the foam rubber into blocks, and you will simply spoil the raw materials. In all other rooms there are no special requirements for temperature indicators.

At the plant for the production of foam rubber, there should also be workshops for cutting foam rubber and its packaging, as well as storing finished products. Take care of a room for workers and an office for a technologist.

Pay close attention to ventilation and electrical wiring at least 380 V with a grounded loop. It is necessary to make an entrance to the workshop for trucks that will bring raw materials and unload finished products.

The cost of renting a workshop for 1 month with an area of ​​200 m2 - from 150,000 rubles + payment of utility bills - from 20,000 rubles.

Of the staff, you will definitely need a specialist in the field of chemistry, who will hold the position of a technologist and control the production process. Hire simple workers at the enterprise who will stand behind the machines. You can’t do without movers, and a cleaner can work part-time.

Only the technologist should have qualifications and special skills, all other people can be taught to handle the equipment from scratch. The production manager himself can control the flow of money and look for points of sale

The workshop will work in one shift, 5-6 days a week. If demand increases, then more people can be hired and the plant can operate in two shifts.

Production of foam rubber as a business idea.

What equipment is needed to implement the idea?

Calculation of the profitability of the production of foam rubber

All costs in business are divided into and monthly expenses. Separately, we will calculate the cost of production of foam rubber and approximate revenue.

1. The foam block has a size of 1 (width) * 1.1 (height) * 2 (length) meters.
2. From 1 block we get 11 sheets of foam rubber 10 mm thick.
3. On average, equipment, depending on its capacity, can produce up to 20 blocks per shift, and 480 blocks in 24 working days.
4. For one block of foam rubber, you need to purchase 50 kilograms of the starting chemical material. The cost of 1 kilogram of such a substance is from 180 rubles.
5. The cost of 1 block is 9,000 rubles.
6. The cost of 1 sheet of foam rubber is 819 rubles, the market price is from 1,200 rubles.
7. For a month of work, we can sell 5,280 sheets and receive revenue in the amount of 6,336,000 rubles.
8. Of this amount, you need to pay 15% of taxes - 950,400 rubles, and also deduct the cost of purchasing a chemical - 4,320,000 rubles.
9. The profit will amount to 1,065,600 rubles, but from this amount we still have to cover the costs of rent, utilities, wages and other monthly expenses.
10. Net income will vary in the redistribution of 600,000 rubles.

All calculations are approximate. We did not take into account the fact that the goods may not be sold out, or the equipment may suddenly break down. There are a lot of pitfalls in every business, the production of foam rubber is no exception.

The enterprise will be able to pay off in a year of successful work, if the founder makes an effort and is able to find permanent buyers of foam rubber.

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The main chemical components of the formulation for the preparation of polyurethane foam (PUF) are polyethers and polyesters. When using polyesters, an elastic molded polyurethane foam is produced. Outperforming polyurethane polyurethane foam many times over, it is twice as expensive to manufacture and has virtually disappeared from our everyday use.

On our production of foam rubber technologists use a molded (periodic) method for preparing foam rubber.

When using this option, the production of foam rubber occurs by pouring an elastic mass into molds, where it foams. During polymerization, the foam rises above the level of the upper cut of the mold. After that, we remove the finished block of polyurethane foam from the mold and send it to a special chamber for 24 hours until maturation. After this time, we cut off the crust frozen at the edges from the block and cut it into sheets of the required size and shape.

Thus, molded foam rubber has wider stereometric possibilities, that is, depending on the requirements of the customer, we can produce a product of any shape, i.e. contour cutting is applied to certain parts.

Our production offers various grades of foam such as: ST - standard foam; EL - foam rubber of increased rigidity; HL - super hard foam, HR - high resilience foam; S - soft foam rubber; HS - super soft foam; VE - viscoelastic foam (memory foam).

The main range of products made from foam rubber in our production is sheets with a size of 1000 × 2000 mm., The thickness of the sheet varies from 0.5 mm to 200 mm. Also, at the request of the customer, we are ready to fulfill the order for non-standard sheet sizes such as: 1200 × 2000 mm; 1300×2000 mm; 1400×2000 mm; 1500×2000 mm; 1550×2000 mm; 1600×2000 mm.

Foam rubber is a synthetic material that is made from flexible polyurethane foam. This name of this material has already taken root, since in Soviet times it was supplied by the Scandinavian company Porolon.

Since foam rubber is a soft foam material with almost 90% air cavities, it has excellent elastic and breathable characteristics.

It is used as a shock-absorbing and insulating material for packaging fragile items, furniture filler, soft toys, and the like. In addition, due to its soundproofing properties, foam rubber is used for soundproofing.

Since chemically active substances are used for the production of foam rubber, such as polyol, isocyanate, then its manufacture, foam rubber is considered environmentally unsafe, since the fumes during the chemical reaction of these materials are toxic and dangerous to humans.

For the manufacture of foam rubber, foam stabilizers and special catalysts are used, thanks to the first foam rubber, under the influence of external factors such as air and moisture, decomposes into safe components and can be easily disposed of.

The main disadvantages of this material include: not long service life and a high degree of flammability. The last drawback is solved by introducing into the production process the use of specific additives, with the help of which the so-called nonflammable foam.

foam manufacturing technology

The technological process for the production of foam rubber is based on carrying out a chemical reaction to mix its components in a special device for foaming. After that, the prepared mass is poured into a special form for solidification.

The whole technological process can be divided into the following successive steps:

• delivery of the mixture components to the foam rubber production site;
• preparation of components for the manufacture of foam rubber, control of their characteristics (temperature, viscosity, quality, and so on);
• filling in the constituent components;
• mixing of raw materials in the machine for foaming, in a given mode, to achieve certain characteristics of the material;
• filling the resulting foam with a special movable (collapsible) matrix (form);
• a process of waiting for a chemical reaction to form foam in the upper part of the matrix, which can be on the order of 20 minutes;
• disassembly of the matrix (form) and extraction of a semi-finished product from it;
• cooling the material and waiting for the end of its active chemical processes;
• waiting for the final solidification of foam rubber (about one to three days);
• cutting foam rubber, according to a perky template;
• storage of the finished product.

Equipment used to make foam

One of the necessary conditions for the manufacture of foam rubber is the exact observance of a given recipe, since the chemical reaction, which is the basis for preparing the mixture, is carried out at the molecular level.

In addition, the quality and temperature that the ingredients have before mixing is equally important. The equipment that is used to produce this material must ensure not only the correct dosage, but also the temperature characteristics of the starting material.

Therefore, most devices that carry out preliminary preparation and dosage are equipped with various sensors and automated systems that are designed to provide control over the performance of the ingredients.

Depending on the degree of automation and the complexity of the equipment used for this, the price of the line for the production of foam rubber, as well as the quality of the goods that are produced with it, directly depend. The lines of equipment used for the manufacture of foam rubber are of the same type. The difference in configuration depends only on the method of production of foam rubber.

Video: foam production process

Depending on the volume and serial production, there are continuous and periodic methods of its manufacture. They differ in the method of foam extraction, in continuous production, foam extraction is carried out constantly and the foam material is fed to the mold, which is made in the form of a transport line.

Among the main devices that are used in the manufacturing process of foam rubber can be identified:

Also, some highly automated lines may include various packaging units and machines for the manufacture of tape or shredded foam rubber, for use as fillers.

Since the production of foam rubber refers to processes associated with emissions of toxic and harmful substances, a prerequisite for the construction of a production line is the presence of special devices that allow not only forced ventilation of the premises, but also monitor the degree of air pollution.

foaming machine

Foaming machine is the key in foam rubber production line.
Typically, the design of such devices provides for the presence of such main components and mechanisms:

1. Block for storage, pre-mixing and supply of mixture components.
2. High pressure block for foaming the mixture.
3. Node of automatic process control.
4. Cooling block.
5. Spray device.

Among the promising areas of business activity, the production of foam rubber has recently attracted a steady interest from novice businessmen, as well as from their more experienced colleagues. This trend is explained very simply: domestic enterprises operating in this industry are not able to satisfy the steadily growing demand for foam rubber, and buying these products abroad, firstly, is very expensive (especially after the growth of the dollar), and secondly, normal trade is hampered by political instability in relations with supplier countries.
Therefore, domestic businessmen need to take advantage of the current situation and actively organize enterprises that will produce foam rubber, and this article will be an excellent assistant in this difficult matter. The reader will be able to study not only the technical nuances of the production process, but also learn what is needed to draw up a business plan, what legal form is suitable for this activity, how to start a business, and what start-up capital is needed to open a foam rubber manufacturing company.

Production of foam rubber - advantages and disadvantages

Despite the development of modern technologies and a huge number of discoveries in the field of inorganic chemistry, foam rubber continues to be in demand, as in the 40-50s of the last century. Elastic, soft, but strong enough material is indispensable for clothing and furniture production. In addition, excellent children's toys are made from it, and it is also used as a packaging material for fragile products and in enterprises manufacturing modern computer equipment. In everyday life, foam rubber, like 50 years ago, is an indispensable thing. In short, the demand for this material in our country will be stable and high for at least the next ten years.
Let's move on to the disadvantages of this material. Its production harms the health of the company's employees and the environment. You will have to buy powerful fans, obtain the appropriate permits from regulatory authorities, and also allocate money for measures to reduce the negative impact on the environment. Get ready for constant "courtesy calls" from fire inspectors, as well as representatives of sanitary and environmental services. In addition, equipment for the production of foam rubber is not cheap, which means that a large start-up capital is needed to open an enterprise.

Legal aspects

Today, even schoolchildren know that in order to open their own business, it is necessary to register a company with the tax office and special funds. For the production of synthetic materials, LLC is best suited. Registration of a legal entity will cost more than filing documents for an individual entrepreneur, but this will help you get all the necessary permits faster, suppliers of specific raw materials often refuse to work with individual entrepreneurs, and many large buyers of foam rubber sign cooperation agreements only with legal entities.
There are exceptions when you can limit yourself to registering an IP. For example, you create your business specifically for the work of several large companies (2-3 furniture factories). In this case, even before the start of your activity, you have preliminary agreements, you know exactly how many materials you need to produce, and the buyers agree to cooperate with the individual entrepreneur.
You will receive a full package of necessary documents (permits from the fire inspectorate, environmentalists, SES, certificates for finished products, etc.) only after preparing the premises and concluding agreements with suppliers of raw materials. That is, when you have everything ready to start production, you will be able to close all issues related to the execution of permits.

Preparatory stages of production organization

Almost every foam rubber manufacturer in Russia focuses on its own circle of buyers of finished products and does not violate the boundaries of its territory. Before starting production, you must conduct thorough market research and determine how much foam rubber you can sell in a certain period of time.
Representatives of the target audience of this area of ​​activity are:

• furniture factories;
• construction shops and supermarkets;
• companies producing soft toys;
• firms that need foam rubber as a packaging material;
• manufacturers of audio equipment and footwear.

You need to conduct preliminary negotiations with all enterprises in your region on the specified list and, ideally, agree on cooperation, as well as clarify how much finished products they will buy. This parameter will allow you to draw up the most accurate business plan. Knowing it, you will be able to choose the right equipment, figure out what kind of staff is needed for the production of foam rubber, calculate the cost of production of finished products and the amount of profit.

Premises, equipment and staff

When choosing a room in which the production of foam rubber will be carried out, it is necessary to adhere to the following criteria:

• the air temperature in the workshop should be at least 18 degrees;
• The optimal area for a small factory is 200-250 sq. m;
• ceiling height not less than 3 meters;
• it is obligatory to have electrical wiring with a voltage of 380 V and grounding;
• there must be a large area for the entrance of trucks.

Entrepreneurs experienced in such matters recommend looking for premises on the outskirts of the city. It is easier to comply with environmental safety standards here, and renting production space costs much less than in areas close to the center.
For the operation of your enterprise, it is necessary to purchase a foaming machine, molds, a belt machine, dosing tanks, automatic machines for grinding raw materials and waste, a thermal chamber and a packaging machine. It is better to buy a ready-made production line, which will be set up and your specialists will be taught how to work on it. It makes sense to look for a company operating under a leasing agreement. This is especially important for businessmen who do not have enough own funds to open a plant. Some entrepreneurs buy used equipment to save money, but it all depends on your personal luck. If you decide to buy used equipment, do it only together with a highly qualified specialist, so as not to buy a lot of scrap metal for a lot of money.
To work at your enterprise, you definitely need a technologist, preferably with the appropriate education, 3-6 workers per workshop, 2-4 handymen and a fitter. With regard to administrative staff, this issue depends on individual factors.
You definitely need a chief accountant (a good specialist will save you 2-3 of his salaries), a manager, as well as a manager for working with suppliers and buyers. But if you take part in the work of the enterprise, then the list of administrative personnel may look completely different.

Production technology

Considering the production of foam rubber as a business, it is necessary to pay attention directly to the technological process. Without this, your knowledge of the production organizer will be incomplete. As mentioned at the beginning of the article, the manufacture of foam rubber is a process that is very harmful to human health, so all workers must have respirators, and fans must be installed in the workshop.
Technologists distinguish two methods for the production of this material: periodic and continuous. The latter is used in large factories, where more than 2 thousand tons of finished products are produced per year, and the former is used in small and medium-sized enterprises. But there are no fundamental differences between these methods, the only question is performance. The process itself is carried out as follows: the necessary reagents in a special mixer enter into a chemical reaction, and then poured into a collapsible form, where the interaction of the ingredients continues. As a result, a block of foam rubber is obtained, which is released from the mold and placed in a prepared room for a couple of days, where the reaction ends and the foam rubber familiar to us is obtained. The final stage is cutting the finished product on a band saw to get sheets of the desired size.

Economic indicators

To start the presented business, you need to: register an enterprise, rent a room, make repairs in it if necessary, buy equipment, obtain all necessary permits. This requires an initial capital (we take average figures, focusing on real data) of about 90 thousand dollars.
Monthly expenses necessary for the normal functioning of the company include:

• salary of employees, including deductions and taxes - 9 thousand dollars;
• raw materials, consumables - 14 thousand dollars;
• rent and utility bills - $9,000;
• taxes and other expenses - 6 thousand dollars.

The total monthly expenses are $38,000. This enterprise has a net profit of about 8 thousand dollars every month, while the calculations include the salary of the manager, which can be received by both the owner of the enterprise and the hired manager. Based on these indicators, we can calculate that in a year, maximum one and a half, all the money invested in the development of the enterprise will return to investors. Summarizing, we can conclude: in the current economic conditions, it is quite difficult to find a business such as the production and sale of foam rubber, which allows you to earn big money without fear of competitors or other unforeseen circumstances.

Polyurethane foam, or foam rubber, is a very common material that is successfully used in construction, furniture manufacturing and other areas of life. In order to choose the right equipment for the production of polyurethane foam, it is necessary to figure out what materials are needed for work, what type of product you will be producing.

Classification of the presented product

So, the presented material can be divided into 2 types:

• Elastic. This type of material is most often used in the production of sponges, washcloths, furniture upholstery or in the manufacture of shoes.
• Hard. The presented type of polyurethane foam is used in construction for insulation of buildings.

It should be noted that foam rubber can also be used when packing fragile items: dishes, electronics.

Material advantages

Before purchasing equipment for the production of polyurethane foam, it is necessary to understand the advantages of the presented product. Among them are the following:

• consistently high demand from buyers, especially since their own production facilities cannot provide the consumer 100%, so your business will quickly pay off;
• light weight of the product;
• the ability to manufacture polyurethane foam of different sizes and stiffness, which will allow you to sell it for completely different purposes;
• low cost of the product.

What equipment is needed for work?

Naturally, now you will have to choose equipment for the production of polyurethane foam. Try to buy it at certified points of sale. Of course, the equipment must be of very high quality. Therefore, give preference only to those manufacturers who have already proven themselves in the technology market on the positive side. Naturally, try to carefully examine the technical condition of the devices at the time of purchase.

Standard equipment for the production of polyurethane foam includes the following machines:

• a machine for foaming the mixture;
• a device with which the grinding and mixing of raw materials with all the necessary additives is carried out;
• dosing machine;
• molding unit;
• apparatus for the production of polyurethane foam, which provides cutting the finished product into elements;
• device for packaging and storage of material;
• a machine that provides shredding of waste in order to launch them into a new production.

The most important apparatus is the foam generator, in which all the necessary components (polyol and isocyanate) are mixed.
In addition, such equipment can be divided into low-pressure and high-pressure devices. In the first case, you will not need to spend a large amount of money. In the second, the equipment is equipped with various sensors and automatic control.

What raw materials are needed for work?

Naturally, for the manufacturing process, you will need not only equipment, but also, in fact, the material from which you will make the final product. That is, you will need to purchase such raw materials for the production of polyurethane foam:

• liquid polyurethane;
• hardeners;
• special additives for foaming raw materials;
• isocyanate component;
• various catalysts;
• watera.

In principle, such components are not too hard to find.

Product manufacturing technology

The presented material is produced continuously or periodically. The second method is most suitable for those firms that have just opened and have not yet expanded their capacity. In addition, the periodic production of the product allows you to constantly monitor the market and sell it quickly enough so that it does not stay in stock.
During the manufacture of polyurethane foam, you must be extremely careful, since an extremely dangerous substance is used for the chemical reaction - polyol, as well as some catalysts and foam formers. However, they subsequently decompose and become non-poisonous. Therefore, the final product will not cause any harm to health.
The manufacturing technology of the product itself is very simple. The plant for the production of polyurethane foam is filled with all the necessary ingredients: there the reaction takes place. It should be noted that the initial raw material has a liquid state. Naturally, it is necessary to strictly dose the number of components. After the foam is formed and stays in the mold for some time, it is sent to another block where it is cooled.
Polyurethane foam is cut after 24-72 hours using a special band saw. Then the finished product can be sent to the customer. If necessary, foam rubber can be stored and stored for a long time. That's all the features of the manufacture of polyurethane foam. Good luck!


The domestic market for the production of foam rubber cannot fully satisfy the needs of the population. Most often, this material is purchased abroad. Therefore, the production of foam rubber is a good idea to start your own business. With a vast market, convenient transportation, and the fact that this business does not require a lot of initial capital, with the right choice of equipment, you can make it a success.

The production of foam rubber is quite harmful, because the fumes that occur during the manufacture of this material can cause significant damage to the human body. They are released into the environment in large quantities. However, after that, harmful substances completely decompose into safe chemical elements that do no harm.
Therefore, it is very important that the production is equipped with a modern ventilation system and plumbing. In addition, production shop employees must have respirators and other protective equipment.
The choice of equipment for the production of foam rubber depends on the required capacity and volume of finished products, as well as on the method of manufacturing products, which can be batch or continuous.
To make foam rubber, the necessary chemicals are mixed in a foaming machine. After that, the finished mixture dries out after a while, and it is cut into sheets of the required thickness.

Necessary equipment

To set up the work of the foam rubber production workshop, you will need the following equipment:

1. Apparatus for foaming solution.
2. A machine that dispenses components for the production of foam rubber.
3. Thermal camera.
4. Equipment for cutting finished material.
5. Additional equipment, namely couplings, pumps, hoses, waste crushers, packaging machines and more.

This equipment can be purchased separately, or as a production line, which will include all the necessary elements to organize the work of the production workshop.
However, what should be guided by when purchasing equipment so that the business can generate maximum income?

The choice of equipment depending on its cost

The choice of equipment for the production of foam rubber should primarily be based on the initial capital that you are willing to invest in it, as well as on the required productivity. In addition, you should decide whether you will buy a finished production line or equipment separately. The production line is much more convenient. The fact is that in it all the elements are perfectly matched. Thus, malfunctions occur much less often.
In the event that there is no possibility of large investments, it is worth considering purchasing a machine with a capacity of about 10 cubic meters per shift. The line for the production of foam rubber will cost two to three times more, but its capacity is about 25 cubic meters per shift. If the sales of products are well established, then it makes sense to purchase even more powerful equipment, otherwise it will be impractical.

Choosing equipment for a small budget

In the event that your financial capabilities are small, you should take a closer look at non-new domestic machines. You can buy them very cheaply, but you will have to spend a little more to get them back in working condition. Thus, it will be possible to purchase more expensive raw materials for the production of foam rubber so that the quality of the finished product meets all indicators.
If you have the opportunity, it is better to purchase imported equipment. It is more durable and high quality.

Basic equipment for a small production workshop

The most necessary equipment, without which no production can do, is:

1. A machine that froths the foam rubber components. This device is the main one in production.
2. Forms into which raw materials are poured for solidification.
3. Machine for cutting foam rubber into sheets of required thickness.

Of course, for the normal operation of the production workshop, additional equipment will be required. However, it can be purchased gradually. To start production, the main thing is the presence of the three above-mentioned machines.

Equipment search

The choice of equipment for the production of foam rubber will be more successful if you first consult with the owners of existing industries. If you can do your own research on this issue, then you will definitely not make the mistakes made by others.
There are several ways to find out this information.

1. Call your future competitors by introducing yourself as the manager of a company that sells Chinese equipment parts. You will be able to find out which manufacturer's equipment is used in the workshop, and how often it fails.
2. You can call the sales department and say that you go to buy products. At the same time, ask on what equipment foam rubber is produced. You can come and see advertising samples yourself to make sure of the quality of the products.
3. Communicate on forums where owners of the foam rubber business discuss their problems with this or that equipment. In addition, in this way, you will be able to understand which production site slows down the production of the product the most. Most often this is the packaging of finished products.

When choosing the direction of the future business, it is better to give preference to the production of those products that are in high consumer demand, regardless of the season and the state of the economy in the country. Here we include the production of foam rubber. Investments in launching an enterprise will be impressive, but with a competent approach, investments will pay off very quickly. Study the issue thoroughly to take into account all the nuances.
How to open a plant for the production of foam rubber in Russia?

Our business valuation:

1. Starting investments - from 1,000,000 rubles.
2. Market saturation is low.
3. The complexity of starting a business is 6/10.

Business Advantages and Disadvantages

Foam rubber (polyurethane foam) has been used in everyday life and for industrial purposes for many decades. Despite the appearance on the market of fundamentally new materials with similar properties, foam rubber does not lose its popularity among consumers. This will be the main advantage for a businessman - you can always find wholesale customers!
Foam rubber is a soft, elastic material used in furniture and clothing production. But these areas of application are not limited - the manufacture of soft toys, the transportation of fragile goods.
The production and sale of foam rubber in Russia is not very developed, which gives future entrepreneurs good chances for a quick payback of the project. If you supply quality products to the market, you can beat any competition.
As for the shortcomings, the main one is the difficulty with the equipment of the room. The production of foam rubber is considered harmful, so powerful ventilation equipment must be installed in the workshops, which will entail financial costs. You will need to obtain permission from the regulatory authorities to operate. The enterprise must strictly observe working conditions and control the amount of harmful emissions into the atmosphere - frequent inspections of sanitary, environmental and fire services cannot be avoided.
It is better to start a mini plant in early spring. It was during this period that all furniture factories “activated” - an active purchase of raw materials began. So you will quickly find buyers for your products.

Legal registration of the enterprise

It will take at least 3 months to collect all documents and permits for registration of the enterprise. Much faster, everything can be done with the help of a lawyer.
OKVED is suitable for the enterprise to be opened: 24.70 (Production of artificial and synthetic fibers).
It is better to formalize the industrial production of foam rubber in the form of an LLC - it is easier to find buyers of finished products and suppliers of raw materials. You will receive a permit to conduct activities only after the premises are found and prepared, contracts are concluded with suppliers of raw materials, and certificates of quality of finished products are received.

Business premises

Place the production of furniture foam rubber in a free room on the outskirts of the city. Firstly, renting real estate here is cheaper, and secondly, the requirements for environmental safety will not be so high. This will greatly facilitate the process of starting an enterprise.
To organize a production workshop, warehouses and service rooms, at least 200 m 2 will be required. If a large capacity plant is planned, look for a larger building.
In addition to ensuring good ventilation in the workshop and the availability of treatment facilities, other requirements are imposed on the premises found:

• To accommodate the equipment for the production of foam rubber, the height of the ceilings must be at least 3 m.
• The temperature in the shop for pouring the foamed mass into molds is not lower than 18 ˚C.
• The presence of electrical wiring for 380 V.

If free space does not allow, the company's office can be located in another place - where it will be convenient for customers to get to. But this is an extra cost for the organization of activities.

foam production technology

Raw materials for foam rubber are polyol and diisocyanates. These substances, if the technology is not followed, can be harmful to the human body. But if good ventilation is provided in the workshop, and only high-quality “ingredients” are processed, there will be no chemical poisoning of personnel and harmful emissions into the atmosphere. The specific ratio of components will depend on the type of foam produced. There are several of them:

• Standard (ST). For production, 1 type of polyol is used. The stiffness of the resulting material is determined by its density.
• Increased rigidity (EL). In the foam manufacturing process, several types of polyol are used to give the finished product a special rigidity. Ideally, it is this material that should be used in the manufacture of furniture. But because of the high price, many furniture makers refuse it.
• Hard (HL). The manufacturing technology differs little from the previous method. But the final price of the product, due to cheaper raw materials, is much lower.
• Highly elastic (HR). The material is made on the basis of special grades of polyol. After the raw materials pass through the equipment, foam rubber blocks are obtained.
• Soft (HS). It is a soft, resilient material used to make some types of upholstered furniture and pillows. In this case, components for foam rubber are used, which give the material greater porosity.

There are also special brands of foam rubber, which later go to the manufacture of sponges for washing dishes, self-adhesive insulating strips. There is foam rubber, which has soundproofing properties. Prices for products in this case will be slightly higher.
It is better to immediately agree with suppliers on the wholesale supply of raw materials - this will ensure the uninterrupted operation of production equipment.
The production technology of foam rubber depends on the method - continuous and periodic. To choose the appropriate option, it is necessary to evaluate the planned capacity of the plant, the raw materials used. It is advisable for small enterprises to introduce a periodic method in production. The "averaged" technological scheme for the manufacture of foam rubber looks like this:

• Preparation of raw materials - acceptance, dosing.
• Mixing liquid components
• Mass foaming.
• Bookmarking the mass in special forms with folding walls.
• Form cooling.
• After 3 days, the foam rubber is cut into sheets of the desired size.

In the process of manufacturing the finished material, waste is generated. They can either be sold to consumers (the same furniture factories, for example), or you can plan the production of recycled foam rubber. The technology involves foaming foam rubber chips and scraps with a special glue, followed by pressing the mass under pressure. Finished products have excellent quality characteristics - increased strength, sound insulation, durability. It is in this way that the production of acoustic foam rubber and mats for gyms is carried out. So you will find more buyers interested in your products.

Foam production. Business idea

Secondary foam rubber is available in several grades - BB-60, BB-80, BB-100, BB-120, BB-140, BB-160. Materials differ in properties and physico-chemical parameters.

Purchase of technological equipment

The simplest line for the production of foam rubber
The foam rubber production line is the most expensive budget item. For the manufacture will require the following machines:

• raw material grinding machine,
• dosing tanks,
• frother,
• thermal Camera,
• forms,
• packing machine,
• waste shredder machine.

It is difficult to assemble a line from separate devices. It makes sense for novice entrepreneurs to buy a line that is already ready for work.
The price of equipment for the production of foam rubber will depend on the capacity of the machines. The mini-shop can be equipped with a low-productivity line that produces up to 12 cm 3 of finished products per shift. This will cost 400,000 rubles. But you can buy equipment for foam rubber of greater power (up to 50 m 3) by spending at least 2,000,000 rubles. To the cost of purchasing devices, add the seller's services for their commissioning. All manipulations to set up the line can be done on your own, but you need to know the specifics of its work well.
You can save money by buying used equipment. The price of used machines is much lower. And if you find a reliable seller, the purchased line will last a long time.

Profitability of the planned business

All costs for the foam rubber machine will begin to pay off when contracts are concluded with regular customers of finished products. Depending on what type of material is produced within the walls of the workshop, offer the goods:

• furniture factories;
• factories of toys and household products;
• enterprises producing sports equipment;
• mattress factories.

Offering consumers special types of products, such as foam rubber with an adhesive layer, can attract more customers. If this cannot be done at the beginning of the formation of the enterprise, be sure to think about developing the business. It is important to constantly improve production methods.
The payback period depends on the initial costs. If we consider the minimum, then the organization of the workshop will take 1,000,000 rubles. This will include funds to buy a foam rubber cutting machine and other equipment, prepare the premises for work, and formalize the enterprise. You will open a high-performance plant if you have at least 3,000,000 rubles.

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