How paint is poured in the chemical industry. Equipment for the production (LKM) of paints and varnishes. We establish sales channels

Protective and decorative coatings, obtained by applying acrylic paints, are durable, chemically resistant and have low toxicity. Enterprises for their production are distinguished by a short payback period and low complexity of the equipment used.

What is needed to organize the process

The list of requirements for running a production line is very small, compared to the preparation of non-aqueous paints. The central device in which the process of dispersing the acrylic binder, fillers and additives in water is the dissolver.

TO auxiliary equipment relate:

• wooden and metal pallets;
• containers for collection and temporary storage of paint;
• containers for bottling the finished product;
• electronic and commodity scales;
• forklift and hydraulic trolley (for large volumes of production).

The dissolver can be purchased as a working device or assembled in a workshop yourself. An important milestone is the acquisition of technology for the production of the finished product. Technological regulations can be developed independently if you have the appropriate skills and time.

Raw material

In the production of acrylic-based paints, the following components are used:

• saturated acrylic dispersion;
• dispersant - to increase the resulting emulsion;
• calcium carbonate is a standard filler and pigment in cheap paints;
• thickener - gives the mixture the necessary fluidity;
• defoamer - prevents foaming of the product during mixing and dispersion;
• coalescent - promotes film formation;
• inorganic pigment. The most popular among paints white color received titanium dioxide.

Requirements for the premises

For release acrylic paint fit non-residential premises area over 40 m 2 (no more than 80 m 2 at the initial stage). Workplace should have natural and artificial lighting, have natural ventilation, water supply and sewerage.

A significant advantage of the production of water-acrylic emulsions is the absence of the need for special exhaust system. The low volatility of most components requires only standard protective clothing.

Staff

To take into account the peculiarities of production, a technologist with relevant experience or education is needed. The organization of a production line without a specialist will not be carried out so efficiently.

Control and operation of the equipment can be carried out by two workers at the same time. With continuous production, three work shifts per day should be provided.

Acrylic paint production

The technology for preparing a mixture for acrylic paints is as follows:

1. an acrylic mixture and a solid pigment are loaded into a water-filled dissolver;
2. mixing of the mass is started to a homogeneous state. Pigment pieces are additionally ground to a predetermined size;
3. during mixing, other additives are introduced to ensure that the paint achieves the desired qualities (according to specifications or regulation)
4. after mixing, the mixtures are packaged and stored at a low temperature (2º). It is impossible to allow the paint to freeze, since the emulsion stratifies irrevocably.

The preparation time of the product is 1.5-2 hours. During operation, the temperature is maintained at 16-18º, which requires the workshop to be equipped with air conditioning and heating systems.

For construction

The largest and most competitive enterprises are engaged in the production of construction paints(for example, for painting, etc.). Their equipment is represented by large dissolvers with a long working cycle. Particular attention is paid to the place of storage and packaging of goods, since the demand for building acrylic paints fluctuates throughout the year.

The process of making facade acrylic paint for construction is shown in the following video:

For nails

A feature of the manufacture of decorative ones is the use of small dissolvers with a high degree of dispersion of solid additives. Since the profitability of the production of paints is one colors is low, several parallel mixing streams should be provided.

For fabric

different from their counterparts for construction works less aggressive fluid.

Ensuring a dense and uniform impregnation of a woven fabric is possible with the use of high-quality dispersant additives that promote the penetration of the dye and binder between the fibers.

For drawing

They constitute a narrow segment of production in which there is practically no competition. The preparation of high-quality and popular coloring compositions requires a large assortment of pigments and high-quality thickeners. Compliance with the technological process plays a special role in the production of acrylic paints for drawing.

Those undertakings are profitable, the results of which are in demand. We will talk about one of them today. In particular, we will consider the features of the implementation of the idea, which is based on the production water-based paints.

The composition of water-based paints:

• water;
• connecting elements;
• pigments.

These components do not provide negative impact on human health and ecosystems. This is one of the obvious advantages of the business - there is no need for a certificate of conformity for paint. At the same time, one cannot do without a voluntary certificate, for which one will have to visit an accredited body specializing in certification.

Legalization of the future undertaking

There are 2 OPFs available:

• entity;
• individual.

In the process of choosing a form of business registration, you need to be guided by the amount of tax. The system of taxation at LLC is “simplified”. You can go the other way - to file a business as an individual entrepreneur.

Equipment

The set of units is small. It includes:

• dissolver;
• eurocube;
• bead mill;
• automatic line that pours and packs the paint.

The dissolver mixes the original components of the paint. The fast rotation of the disc guarantees high efficiency crushing ingredients. The dissolver is equipped with a high-speed milling mixer, the speed of which is adjustable. That is, you can set the optimal volume of production.

Among other things, the dissolver prolongs the "life" of the mill, which is necessary for the homogenization of the ingredients. Modern mills used in the production of water-based paints are highly productive and allow you to get quality products. Therefore, saving on this unit is not worth it. The material for the mill body, the sieve is durable metal which is not afraid of corrosive processes.

The packaging line is represented by:

• conveyor belt;
• container supply system;
• a mechanism that seals the lids;
• storage unit.

A few words about the composition of the paint

The minimum number of ingredients is 10, the ceiling is 15. In their structure, latex accounts for 40%, pigments and other fillers - 37%, plasticizers - 3%, titanium dioxide (plus esters) - 9%, dispersed chalk - 11%.

Features of the production process

First, water is introduced into the dissolver. Then the minimum speed of the installation is turned on, other ingredients are loaded - fillers, pigments. After that, dry components are added (titanium dioxide, chalk. At the next stage, the solution is dispersed. The finished product is filtered.

1. High productivity is ensured by the bead mill.
2. Production facility, cost of units (thousand rubles)
3. Sufficient area of ​​the shop will be 80 squares. The temperature is at least 5 degrees.
4. The price of a dissolver is 200, a mill is 250, an electronic scale is 6, a hydraulic trolley is 7.

As a result, we get 463 thousand rubles. Agree, in comparison with many undertakings, the cost of the units is symbolic.

Proof of a promising business idea

The volume of production is 10 tons. In this case, the cost of the latex dispersion will be 65 thousand rubles, the defoamer - 7 thousand rubles, Ca carbonate - 5 thousand rubles, other additional materials - 28 thousand rubles, chalk - 12 thousand rubles. r., labels - 6 thousand rubles. We get 123 thousand rubles. At the end of the year, the volume of production will be 120 tons of paint, and deductions for raw materials - 1.476 million rubles.

Working staff

You will need to hire:

• chief who will be responsible for manufacturing process, - 15 thousand rubles;
• worker - 8 thousand rubles.

Every year, 276 thousand rubles will be spent on wages.

Calculation of the cost of a kilogram of the product:

123 rubles / 10 tons \u003d 12.3 rubles. per kilo. The monthly productivity of the facility is 10 tons.

Monthly costs (thousand rubles) will be associated with:

• payment of rent - 10;
• depreciation of the main units - 3;
• FOT - 23;
• communal - 5.

At the end of each year, 492 thousand rubles will be spent.

Economic efficiency

The size of the annual cost is 1.968 million rubles, the wholesale price is 30 rubles. per kilo, monthly income - 300 thousand rubles, annual - 3.6 million rubles, net profit - 893 thousand rubles.

Sales

It will be easier to implement if you define optimal combination costs/price/revenue. The image is important. Poor quality products will cause a meager customer base, unprofitability. Therefore, it is important to establish the production and marketing of only a quality product.

The experience of successful domestic paint manufacturers suggests that it is necessary to use imported raw materials, which are a guarantee of obtaining competitive paints that are not inferior in quality to foreign manufacturers' products.

It is necessary to bet on wholesale sales, large volume. At the same time, it is important to work quickly, otherwise it will take more time to return the investment.

Sales points:

• building stores;
• supermarkets.

There is a high probability that they will agree to work with you construction firms specializing in the repair of residential and other real estate. If you have the opportunity to acquire your own commercial objects, do not miss it. You can increase sales, increase your customer base through a cumulative system of discounts, various bonuses, promotions ...

Good luck in your endeavors!

This is a semi-automatic line for the production of water-dispersion paints and finishing materials a new generation (80 types in total) with automatic loading of liquid components and an automated packaging system for finished paint.

Our dissolvers PLT-L, PLT-0.75, PLT-1.5, PLT-1.5M, PLT-2.2 and PLT-2.2 EURO are universal mixers for the production of all 80 types of coatings (paints, varnishes, primers, fillers, decorative mixtures, etc.).

Unlike other offerings on the market, our dissolvers:

• Cheap - the cost of our dissolvers is several times cheaper than standard ones.
• Versatile - on them, with the help of interchangeable screws and cutters, you can prepare both light compositions (soils, texture coatings, primers, etc.) and heavy mixtures (putty, paste coat, etc.)
• Compact - mounted on a small area (from 1 sq.m to 3 sq.m), can be used directly at the construction site.
• Adapted for the work of one operator with several units at the same time (thanks to the remote control panel, connection to a computer, timer, etc.)

Dissolvers

Dissolver “PLT-L”

(0.7 kW 220/50) - for small experimental volumes and tinting of finished compositions from 1 to 5 kg. Drive mechanism Bosch. Smooth adjustment of cutter rotation (2 gears: 200-850 and 600-2500 rpm). It consists of a holder stand, an engine, a device for smoothly changing engine speed, two types of cutters. Additionally, it can be equipped with a cabinet.

Dissolver “PLT – 0.75”

(0.75 kW 220/50) - universal installation for the production paintwork materials. The electronic control unit (Japan) provides a smooth start and shutdown of the engine, simple and reliable control of the engine speed, automatically increases the torque, protects the engine from overloads, one cutter

Dissolver “PLT – 1.5”

(1.5 kW 220/50) - a fairly powerful unit with increased productivity. In addition to the listed functions of the dissolver PLT 0.75, it is equipped with a weighing platform with an electronic display panel, a ramp, one cutter.

Dissolver “PLT – 1,5M”

(1.5 kW 220/50) - in addition to the options of the PLT-1.5 dissolver, it is equipped with an electronic display of technical regulations, one cutter.

Dissolver “PLT – 2.2”

(2.2 kW 220/50) - this is the most powerful unit we produce with maximum performance, the most rational device in terms of price - quality. It is completed with a weighing platform with an electronic display board, a ramp, an electronic display board for technical regulations, one cutter.

Dissolver “PLT – 2,2 EURO”

(2.2 kW 3800/50) is a high-tech dissolver. In addition to the options of the dissolver, “PLT-2.2” has a hydraulic drive, wheels for moving around the workshop, a control unit with remote control, PC connection, timers, clock, one cutter.

From April 2018, all our dissolvers can also be ordered in the “NEXT” version.

Main features of NEXT series dissolvers:

• protective cover
• monolithic control panel
• LCD screen with touch screen control
• clock, timer
• the ability to display and calculate recipes and technological support on the screen

Specifications.

Systems for filling paint and dosing liquid raw materials manufactured by PLT SYSTEM LLC

For dosing paint components during its preparation and packaging of the finished product in containers, our mini-factories use the following systems:
1. The unit for filling paint and supplying liquid raw materials is the most economical and simple system using a manual rotary dispenser.
2. The pneumatic pump system is more convenient to use, as it uses a pneumatic pump and a special gun with a non-drip cut-off device.
3. Semi-automatic pneumatic system is the most rational device according to the price-quality system. It does not have wear parts, it is rebuilt for different viscosities of coatings.
4. The automatic two-channel pneumatic system is the most convenient in operation, as it has automatic dose cut-off and two independent channels - one for dosing paint components, the other for packaging the finished product.

The unit for filling paint and dosing liquid raw materials is designed to automate the filling of water-based paints into bucket containers (from a plastic bowl) with manual cut-off of the dose, as well as pumping liquid raw materials for the production of paintwork materials from a container with raw materials into a plastic bowl for paint preparation.

The principle of operation of the system is to supply the components of the paint from the barrel to the bowl for the preparation of paint and packaging of the finished product under the action of a rotary dispenser.

The system includes:
- plastic bowl;
- rotary dispenser;
- scales;
- trolley - tipper for barrels.

Specifications:

Plastic bowl 200 l;
Work with metal barrels up to 215 liters when dosing liquid components of paintwork materials;
Dosing range, l……………………………………………..…………….……….1 – 50;
Practically realized dosing accuracy, g……………………………………… 10;
Outlet diameter ……………………………………………………………………….……….1/2;
Productivity - 5 liters per 20 revolutions;
The rotary dispenser is made of plastic;
Antistatic body.

2. Pump pneumatic system

The pneumatic pump system is designed to automate the filling of water-based paints into bucket containers (from a plastic bowl) with semi-automatic cut-off of the dose, as well as to pump liquid raw materials for the production of paintwork materials from a container with raw materials into a bowl for paint preparation.

The system includes:
- pumping device;
- packing unit;
– device for non-drip cut-off of paint;
- cabinet;
– tare scales;
- plastic bowl.

Specifications:

Working environment - water-based paints and components of low and medium viscosity paintwork materials;

3. Semi-automatic pneumatic system

The semi-automatic pneumatic system for dosing liquid raw materials and filling the paint is designed to automate the filling of water-based paints into bucket containers (from the working tank) with semi-automatic cut-off of the dose, as well as for vacuum pumping of liquid raw materials for the production of paintwork materials from the container with raw materials through the working tank into the bowl for making paint.

The principle of operation of the equipment is as follows. For the preparation of paint, liquid raw materials are fed into the working tank under vacuum. Then the measured dose of liquid raw materials flows into the container for the preparation of paint under the action of overpressure. The operation is repeated until all liquid products will not end up in the paint preparation container. To fill the finished product into containers, the prepared paint is fed into the working tank. From the working tank, the product enters the container under the action of excess pressure (the value of which depends on the viscosity of the paint) created by the pressure regulator.

The system includes:

- Remote Control;
– packing unit (semi-automatic);
- cabinet;
- scales.

Specifications:

Working environment - water-based paints and components of low and medium viscosity paintwork materials;
Compressor outlet pressure (set by the pressure reducer on the compressor and controlled by the pressure gauge on the compressor), MPa (bar) …………………………………………………………………………. .0.6 (6);

The pressure in the PP is adjusted by a filter-pressure regulator and is controlled by the pressure gauge of the regulator. The pressure value in the PP is selected experimentally and, depending on the viscosity of the packaged product and the volume of the container, varies from 0.2 to 1.0 kgf/cm2.

Practically realized dosing accuracy, g……………………………………. five.

Structural parameters:

filling lines……………….……..………………………………………………………………19;
PP replenishment lines and drain lines………………………………………………………….26;
- internal diameter of a replaceable drain tip, mm:….…….…..……….6, 12, 15;
(selected experimentally and varies depending on the viscosity of the liquid and the volume of the container).

Automatic pneumatic system for filling paint and other types of liquids with an electronic control unit with dose cut-off by time.

The principle of operation of the system is to supply paint components from a barrel to a bowl for preparing paint and packaging the finished product using a pump device.

The system includes:
– working tank (vacuum bowl made of of stainless steel 200l);
- Remote Control;
- packing unit (automatic machine);
- cabinet;

Specifications:

Working environment - water-based paints and components of low and medium viscosity paintwork materials;
Pressure at the compressor outlet (adjusted by the pressure reducer on the compressor and controlled by the pressure gauge on the compressor), MPa (bar) …………………………………………………………………………… ..0.6-0.8(6-8);
Maximum air consumption, m3/h……………………………………………………………6;
Dosing range, l……………………………………………..…………….…….0.1 – 50;
Practically implemented dosing accuracy, g……………………………..…… …….5;
Outlet diameter ………………………………………………………………………..……..1/2;
Productivity of the pump device…………………………………………….48l/min.

The automatic two-channel pneumatic system is designed to automate the operations of filling water-based paints into bucket containers (via the first channel from the working tank) with automatic dose cut-off, as well as for vacuum pumping of liquid raw materials for the production of paintwork materials from a container with raw materials into a bowl for paint preparation (according to the second channel - using a measuring container).

The principle of operation of the equipment is as follows. For the preparation of paint, liquid raw materials are fed into a measuring container under vacuum. Then a measured dose of liquid raw materials flows into the paint preparation tank under the action of excess pressure. The operation is repeated until all liquid products are in the paint preparation tank. To fill the finished product into containers, the prepared paint is fed into the working tank. From the working tank, the product enters the container under the action of excess pressure (the value of which depends on the viscosity of the paint) created by the pressure regulator.

The dose is cut off automatically.

The system includes:
– working tank (vacuum bowl made of stainless steel 200l);
– measured capacity (30l);
– control panel;
- packing unit (automatic machine);
- Desktop;
– weighing platform for measuring capacity;
- compressor;
- tare scales.

System Specifications

Working environment - water-based paints and components of low and medium viscosity paintwork materials;
Compressor outlet pressure (adjusted by the pressure reducer on the compressor and controlled by the pressure gauge on the compressor), MPa (bar) …………………………………………………………………………… …………………….0.6 (6);
Maximum air consumption, m3/h…………………………………………….…………………….6;
UU supply pressure (adjusted by the filter-pressure regulator according to the pressure gauge on the regulator), MPa……………………………………….……………………………………………0, 14 10%
The pressure p1 in the PP is adjusted by the adjuster Zd1 (Fig. 1) and is controlled by the pressure gauge M.
The value of pressure p1 is selected experimentally and, depending on the viscosity of the paint and the volume of the container, varies from 0.2 to 0.8 kgf/cm2.
Dosing range, l……………………………………………..…………….…….1 – 50;
Dosing accuracy, g……………………………………………………………………… 5;

Structural parameters:
- inner diameter of hydraulic lines, mm:
lines for pouring paint into containers……..……………………………………………………..……….19;
PP loading lines……………………………………………………………………….…….26;
- inner diameter of replaceable drain tip CH, mm:….…….…..….6, 12, 15;
(selected experimentally and varies depending on the viscosity of the paint and the volume of the container);
– automatic dose cutoff;
- the first channel - packaging of paint using a working tank (vacuum bowl 200l);
- the second channel - dosing of raw materials using a measuring container (30l).

Mini plants are completed with packages technological maps, which include a description of the properties of these types of paintwork materials, chemical composition and technological solution for cooking. The technological map is compiled in such a way that even an unprepared worker can produce a quality product the first time, carefully following the cooking instructions contained in the technological map. In total, 80 technological cards for 80 types of paintwork materials are provided (see the list of paintwork materials).

pump action automatic system filling and dosing of liquids (APSF) is an innovative development, the main advantage of which is the absence of an intermediate tank - dosing occurs directly from the working capacity of the dissolver. Ultra-precise dosing and high pumping speed.

The system includes:
– diaphragm pump(special modernization);
– damping capacitance;
- packing unit (automatic machine);
– pneumatic control device;
- Desktop;
- small weights.

Semi-automatic packaging system for viscous products (SFVP) such as putty and decorative plasters(basic equipment). Mobile high-performance plant (up to 1 ton per hour).

The system includes:
– Plastic bowl;
– Installation of SFVP.

Additionally:
- working cabinet;
- scales;
- fastening to the bowl;
– dispenser holder with adjustable height of product supply (depending on container).

Semi-automatic packaging system for highly viscous products (SFOVP) such as adhesives, plasters, mastics, etc. (basic equipment).

The system includes:
- installation of SFOVP.

Additionally:
- Desktop;
- frequency converter;
– electric drive lifting the dispenser or fastening to the bowl;
- scales;
– dispenser holder with adjustable product feed height (depending on container)

Bulk Component Supply System (SPSK)

Automatic system for unpacking and supplying bulk components (chalk, microcalcite, etc.)

• hopper volume from 50 to 250l (standard 200l -300kg)

The production of acrylic paint is not difficult, success depends on the observance of the technological process and the quality of the components. The main item of expenditure is the purchase of equipment. Under favorable circumstances, the investment will pay off after a few months of work.

Acrylic is a polymer or polymer material made from acrylic acid. Acrylic is clear and almost transparent with the following properties:

• Mechanically stable.
• Not afraid of heat treatment.
• Small specific weight.
• UV resistant.

On the basis of acrylic, varnishes and paints with water-soluble plastic dispersions are produced, which, when dried, form a strong protective and decorative film.

Acrylic paint contains three main components:

• Pigment.
• Water.
• Binder.

The binder is a synthetic material called an acrylic polymer emulsion. Acrylic paints have been produced for over 50 years, and their popularity is still growing. They are versatile and easy to handle, have a bright stable color, fit perfectly on the surface and are very durable to mechanical stress.

Acrylic dries quickly enough due to the evaporation of water, after which the paint forms a strong film of binder and pigment.

There are many uses for acrylic paints. There are acrylic paints:

• For fabrics.
• For building facades.
• For a tree.
• For glass
• Automotive.
• Aerosol.
• ceiling and floor etc.

Acrylic paint can be applied to any dry and clean surface. Fresh acrylic paint washes off easily, while old acrylic paint will require special solvents.

Acrylic paint has the consistency of sour cream and is packaged in any industrial container: barrels, drums, flasks. For retail acrylic paint is available in tin or plastic cans, tubes.

Acrylic paint production

The production of acrylic paint does not present any particular difficulties: the components are mixed together in a special container (dissolver). The dissolver is a container with a mixing system (frame agitator or cutter on the central shaft). Sequence and blend mode and make up technological process on which the quality of the final product depends.

Paint components are combustible liquid components and loose pigments. Acrylic paints are moderately aggressive, so all processing tanks and piping should be stainless steel, and the main mixing tank should be glazed on the inside. The supply of paint from one container to another is carried out by screw pumps with a supply pipe diameter of 100 mm and a pressure of not more than 8 atmospheres.

Technological sequence of production of acrylic paint

• Water is supplied to the dissolver and the mixer is turned on.
• A complex of components is added according to the recipe.
• The mixture is thoroughly mixed for 1.5-2 hours.
• The dispersion is added followed by mixing.
• The finished paint is poured into containers and stored at a temperature of up to +2 degrees.

Acrylic paint production organization

The data are based on the organization of the production of acrylic paint with a capacity of 3-5 tons per shift.

room

Area production premises should be 40-70 sq. m. The room must be heated (production technology provides for a temperature in the workshop up to 17-19 C).

Communications: electrical supply 380 V, exhaust ventilation, water supply, sewerage. For the warehouse of raw materials and finished products enough space (without heating) up to 40 square meters. m.

Raw material

For the production of acrylic paint is used:

• Dispersion.
• Dispersant.
• Calcium carbonate.
• Defoamer.
• Thickener.
• Coalescent.
• Titanium dioxide.

Equipment

List of main and auxiliary equipment:

• Industrial mixer (dissolver) D-500 1 pc.
• Tanks for bulk components 5 pcs.
• Scales electronic 1 pc.
• Commercial scales 1 pc.
• Forklift 1 pc.
• Hydraulic carts 3 pcs.
• Wooden pallets 10 pcs.

For large-scale productions, economical semi-automatic and automatic dissolvers of higher productivity are used.

workers

Many suppliers offer start-up and commissioning services, as well as time-tested paint formulations. For a workshop with a capacity of up to 5 tons, one process engineer and 2 bottling workers are enough.

Manufacturing economics

The main cost item for preparation of production is the purchase of technological equipment. The calculation is made for new equipment of minimum productivity (up to 5 tons of paint per shift). Costs can be significantly reduced if you purchase used equipment or make it yourself according to drawings.

From the experience of organizing such production, investment costs will be:

• The cost of equipment, start-up and adjustment, personnel training 350-400 thousand rubles.
• Containers, scales 60-80 thousand rubles.
• Forklift, hydraulic carts 200 thousand rubles.

Total: 610-680 thousand rubles.

Current costs per month:

• Rent of premises - 12 thousand rubles.
• Equipment depreciation - 3 thousand rubles.
• Salary of employees - 36 thousand rubles.
• Advertising - 12 thousand rubles.
• Electricity - 4.5 thousand rubles.

Total: 67.5 thousand rubles.

Facade water-dispersed paint is most demanded in the market. Calculate the profitability of the production of such paint for one work shift:

• The cost of raw materials for the production of 1 kg facade paint- 15 rubles.
• The productivity of the equipment is 3,000 kg per shift.
• The raw material component in the cost will be 45,000 rubles.
• Production costs - 2,800 rubles.

Total: total cost - 50,815 rubles.

The average cost of 1 kg of facade paint is 45 rubles. The total amount from the sale of paint produced per shift will be: 135,000 rubles. Monthly profit - about 2 million rubles.

According to calculations, the payback of the project will be less than a month, however, do not flatter yourself. The production of acrylic paint is indeed economically very attractive, but there are obstacles that cannot be avoided.

At first, it is not necessary to count on maximum productivity with the full sale of products. If you start with 50% of your possibilities, it will be very good. Consider also seasonality: the peak of sales will occur during the “construction season”, when the need for paint is greatest. Inevitable problems of lack of assortment at first: the production must gain experience.

In general, the production of acrylic paint is economically very profitable and, with the right attitude, can bring a quick and good economic result.

The production of paints and varnishes has been and remains one of the promising and profitable investments. Varnishes and paints are the most common and one of the most affordable finishing materials. Despite the fact that the domestic industry is developing quite actively in this segment, nevertheless, the competition is still not so high, and new business has every chance of success.

Over the past 6-7 years, the volumes of the paint and varnish market have been constantly increasing. However, this growth was mainly due to imports, whose share before the crisis was more than 20%. Over the past two years, this market has declined by 2.4%.

Russian manufacturers mainly produce solvent-borne materials (paints, varnishes, primers, putties), water-dispersion paints and varnishes, intermediates (lining oils, solvents) and oil paints. Moreover, in the segment of the chemical and petrochemical industry, the production of varnishes and paints occupies only 2.5% of the total output.

Analysts note that there is a shortage of domestic products on the paint and varnish market, although the production capacities for the production of these finishing materials are less than half loaded. Only ten Russian plants produce about 70% of the total production of varnishes and paints. However, small enterprises still retain a significant share of local markets of local and regional scale.

According to experts, by 2015 the market volume will reach 1511 thousand tons, which is 31% more than in the crisis year of 2009.

Classification of paints and varnishes

To begin with, we will understand the definition and classification of varnishes and paints produced.

Paints and varnishes, according to GOST 28246-2006, are a liquid, pasty or powder material that, when applied to a surface to be painted, forms a coating that has protective, decorative or special technical properties. All paints and varnishes are usually divided into three groups: basic, intermediate and others. The main materials include:

• varnish - a paintwork material that forms a transparent coating when applied;
• paint - a liquid or pasty pigmented material that contains drying oil as a film-forming substance various brands or an aqueous dispersion of synthetic polymers and which forms an opaque coating upon application;
• enamel - a liquid or pasty pigmented paintwork material that has a paintwork medium in the form of a solution of a film-forming substance and forms an opaque coating when applied;
• a primer that, when applied to the surface to be painted, forms an opaque or transparent homogeneous coating with good adhesion to the surface to be painted and to the top layers;
• putty - a paste or liquid paint and varnish material that is applied to the surface before painting to even out irregularities and obtain a smooth surface.

Intermediate paints and varnishes are used mainly as semi-finished products. These include:

• drying oil - a product of processing vegetable oils with the addition of desiccants (substances that accelerate the film formation of paints and varnishes) to speed up drying;
• resin - a solid or semi-solid organic material that softens or melts under the influence of a certain temperature;
• solvent - a single or multi-component volatile liquid that evaporates when dried and completely dissolves varnish or paint;
• diluent - a single or multi-component volatile liquid that does not harmful effects on the properties of varnish or paint;
• desiccant - an organometallic compound that is usually added to certain paints and varnishes to speed up the drying process.

There is another type of paints and varnishes - the so-called auxiliary and auxiliary materials. This group of materials includes:

• washer designed to remove old coatings;
• mastic - adhesive, finishing or sealing compositions based on organic binders and other substances, forming a plastic mass, which under certain conditions can turn into a solid state;
• hardener - a substance introduced into a varnish or paint for "crosslinking" the macromolecules of the film-forming substance;
• accelerator - a substance that accelerates the formation of cross-links between molecules and contributes to the rapid drying of the paint layer.

In addition, several types of paints and varnishes are distinguished according to the type of the main binder. According to this classification, paints and varnishes can be distinguished:

• based on polycondensation resins;
• based on natural resins;
• based on polymerization resins;
• based on cellulose ethers.

Production of paints and varnishes

For the production of paints and varnishes, it is necessary to select a heated room with an area of ​​3 sq. m with a water supply and water storage, as well as a voltage of 220 V. As can be seen from the requirements, at the first stage of your work, a garage of sufficient area will be enough. To begin with, it is best to choose a specific type of product that you will produce. In the future, when your income allows, you can think about expanding the range.

Many entrepreneurs who consider the segment of paint and varnish products in terms of attractiveness for investment note that the market for water-dispersion paint and varnish materials has the greatest development potential. Domestic manufacturers are mainly focused on the production of oil and alkyd paints and enamels. As a result, almost a third of the volume of water-dispersion materials consumed is imported products.

Indeed, on Russian market the share of this type of product is significantly inferior to world indicators, despite the fact that these materials are easy to use, environmentally friendly and relatively durable. In addition, the production of water-dispersion paints requires a smaller budget than the production of other paints and varnishes.

In the production of water-dispersion materials, there is only one significant disadvantage. Due to the fact that for a long time these products, manufactured by domestic manufacturers, were distinguished by a low price and even more poor quality, the promotion of Russian paints and varnishes (even if they are of high quality and competitive prices) in our market is associated with high costs and difficulties. Therefore, at the very first stage of organizing and setting up your own production, consider possible channels for distributing your products.

The production of paints and varnishes consists of two stages: the production of semi-finished products (varnishes, pigments, etc.) and their mixing. As a rule, small enterprises purchase the bulk of the materials, while large enterprises produce on their own.

The choice of technological lines for the production of paints and varnishes depends on what materials and in what volume you are going to produce. The approximate cost of such equipment is from 100 to 200 thousand rubles.

For example, a line for the production of primers, impregnations and other low-viscosity materials with a mixer capacity of 1000 kg / h will cost about 160 thousand rubles. Process line for the production of paints, varnishes and other low- and medium-viscosity materials costs approximately 180 thousand rubles. Equipment for the manufacture of building putties will cost a more modest amount - up to 140 thousand rubles.

From raw materials, you will need various fillers, pigments, binders, thickeners. The purchase of the first batch will take about 150 thousand rubles. Additional costs (approximately 50 thousand rubles) will go to the packaging of finished paints and varnishes.

The technology for the production of varnishes and paints is quite simple. For example, for the production of water-dispersion materials, a dissolver-mixer is used, which mixes all the components and simultaneously disperses loose paint elements with a milling mixer. For pumping the finished paint and dispersion through pipelines, special screw pumps are used, which do not destroy the dispersion and retain all consumer properties of the paint. The finished paint, if necessary, is filtered and packaged in a polymer container. Please note that water-dispersion paints are an aggressive medium with a pH value of 8 or higher. Therefore, it is highly desirable to use stainless steel equipment and communications in production.

If you plan to work on your own for the first time, you will need the help of another worker. In the future, with the growth of production volumes, you will have to organize round-the-clock duty and, accordingly, increase the staff of your employees. In addition to the working staff, you can hardly do without the help of an accountant (he may be visiting), as well as a sales manager for finished products if you do not have experience in this.

So, to organize your own small production of paints and varnishes, you will need at least 350-400 thousand rubles. Add to that the monthly expenses for rent, communications and wages(if there are employees).

The cost of finished products, your profit and the profitability of your business directly depend on what materials and in what volume you produce, as well as on whether you can create sufficient demand for them. With proper business management, the payback for such production is very high and can range from 2-3 months.

Profitability of production of paints and varnishes

The profitability (the ratio of net income to gross revenue) of the production of paints and varnishes depends on the specific product and averages 15% in the industry, while the profitability of retail sales of such products is 3-4 times higher. According to the most optimistic calculations, profit from one ton of paints and varnishes can reach 30-35 thousand rubles, and monthly income with average production volumes - 300 thousand rubles.

Video about the production of paints and varnishes