Production of foam blocks as a business

Today, the production of foam blocks can become a profitable business.

This is related primarily to the growing demand for this building material. The advantages of this business include the fact that mini foam blocks production can be organized with only 150 thousand rubles — this is the minimum investment in this type of business.

Start a business: planning and registration

In this case, it is recommended to create a business plan in which you need to carefully analyze the possible ways of marketing, suppliers of raw materials, prices for foam blocks in your region or city, and also work out other details. How to compose a business plan step by step can be read in this material. Of course, the key factor in this sale and research of its ways should be given maximum attention.

The market analysis of foam blocks in Russia shows that approximately two thirds of buyers of this building material do not hesitate to change the supplier if they are offered a lower price or a higher quality. About 15-20 percent are not ready under any circumstances to terminate contracts with their suppliers. That is, we can conclude that, despite the competition, it is quite possible to find ways of marketing.

In any case, it is necessary to dump, that is, to offer lower prices. This is either a higher quality at regular prices (and quality requires expenditure), or ordinary quality, but low prices. Of course, this is a superficial analysis of the foam concrete market, but it allows us to understand the key point. And if we talk about market research in different regions of Russia, then they are usually conducted on individual orders.

After evaluating their financial capabilities, it is necessary to study offers for the sale of equipment. Again, it is necessary to proceed from the potential sale — equipment of greater productivity will require large areas for accommodation and costs more. The room should be searched based on the required areas for equipment placement, if we talk about fixed lines, then the values ??start from 100 square meters. Well, homemade mini-manufacture can be organized even in a barn, even in a garage, although we will not write about this option in this article (more details can be found in the article about equipment for the production of foam blocks, the link will be below). It is also necessary to provide a room for storing finished products and for raw materials.

The room has the following requirements:

• Availability of water supply;
• Heating;
• Ventilation;
• Height is desirable from 3.5-4 meters.

The business registration form can be either an IP or an LLC, in this case it does not matter much. For small production, of course, the PI with a simplified taxation system is preferable. It is also worthwhile to think about the staff, although in this type of production it is possible to find employees easily, because no special knowledge and skills are required.

These are the main points of the business organization for the production of foam blocks.

Equipment and raw materials

As we mentioned at the beginning of the article, the minimum prices for equipment for the production of foam blocks start from 150 thousand rubles, but for this money you can buy only a set of equipment for small production. If we talk about more or less serious volumes, the cost of equipment starts from 400 thousand rubles and depends on a number of factors, such as:
Presence of a cutting complex;
The presence of automatic nodes.

Automation of the line for the production of foam blocks affects the price quite significantly. Completely equipped and automatic lines will cost 2-2.5 times more expensive. In general, for 600-700 thousand rubles you can buy equipment capable of producing up to 40 cubic meters per day (per shift).

Buy equipment can be both domestic manufacturers, and foreign, which are mainly represented by Chinese equipment. The best option is to buy a ready-made plant from a company that not only sells the equipment, but also produces foam blocks.

As raw materials, you will need cement (grade M500), fine sand, water. Obviously, there will be no problems with these components, the ways of purchasing raw materials should be taken into account when developing business plans. A foam concentrate, which serves for the preparation of foam, stands apart. They are synthetic and organic. The latter allow you to get much better products from any point of view (environmental friendliness, functionality, etc.), but they are more expensive.

Additional substances can also be used, for example, expanded clay, pouring accelerator, etc. The decision to apply these or those additives in each production is made individually, depending on the desired result. In detail, it is impossible to describe all such technological nuances in one article, but the corresponding documentation should be supplied with the equipment.

You will also need to buy a forklift, which will be required for convenience (you can do with a stacker, but this is not the best option). The cost of 250 thousand rubles for second-hand. To the additional equipment that may be required, you can include a number of others, it all depends on the configuration of the line you are buying. It can be a compressor, forms, etc.

Technological process of foam blocks production

The process is simple enough and does not require special skills, that is, everyone can learn. The first stage is the dilution of foam concentrate with water and the preparation of foam in the foaming agent. After that, the raw materials (cement, sand, etc.) are filled in the mixer, after which the entire mixture must be mixed very thoroughly, since the properties of the foam blocks depend directly on the uniform mixing of sand and cement.

After that, water is poured into the mixer and all this is mixed until a homogeneous mass is obtained, after which foam is added from the foaming agent. Further, all the ingredients are mixed for 3-5 more minutes, after which they are poured into molds, which are pre-lubricated with molding oil or special lubricant. The molds are dismantled after 11-12 hours, after which the foam blocks are put on pallets (they also need to be purchased) and dried. The drying time at a temperature of +20 +22 degrees Celsius is 48 hours. However, this period is not up to complete drying, but to the so-called brand strength, which in 48 hours at this temperature will be 70 percent (the minimum value for sale).

Many companies equip individual drying rooms or install thermal equipment. For example, at temperatures above 45 degrees Celsius, the drying time of foam blocks is reduced by 5-6 times. Important: this is one of the nuances of this business, which can be called seasonal. In summer it is possible to produce large volumes, with good weather, products can be kept even on the street. But in winter, the foam blocks will have to be dried indoors, which increases costs (primarily for heating).

Production figures

When drawing up a business plan and planning the costs and incomes, the following figures should be guided:
To produce 1 cubic meter of foam block, it is required: 210 kg of sand, 300 kg of cement, 1.2 liters of foaming agent (organic), lubricant of forms — 0.5 liters. If you plan to use a hardening accelerator, then it takes 0.5 liters to produce 1 cubic meter.

Knowing these figures, you can easily calculate how much in your region will cost the production of the foam block. Let’s try to calculate, for example, for the Leningrad region (the prices are taken by the first caught).

• Cement — 1250 rub;
• Sand — 50 rubles;
• Frother — 55 rubles;
• Lubricant and accelerator for hardening — 35 rubles.

Total costs for the production of one cubic meter of foam blocks will amount to 1,390 rubles (excluding water, electricity, wages — we consider only raw materials). The cost of foam blocks in the same region starts from 3200 rubles per cubic meter. By the way, the cubic meter is 28 standard blocks of 600x300x200 mm size. Such calculations can be done for any region independently, using search engines.

A turn-based business organization is as follows:

• Business registration;
• Search for a room;
• Search for suppliers of raw materials;
• Purchase of equipment;
• Search for colleagues;
• Start of production.

This business can be called very promising, which is supported by a considerable demand for foam blocks, which remains high even in the midst of an economic crisis that, by the way, will end sooner or later, which will mean a surge in construction, hence a surge in demand.