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Disposable plastic utensils are no longer a novelty. It's affordable and convenient way reduce the time for cleaning and the weight of luggage on vacation or during transportation. Despite the noise periodically rising in the press about the harm of plastic containers, it is in wide and constant demand. Because this is comfort for little money, and the “danger” of plastic for food is easily neutralized by its correct use. This product will always have its buyer. But will its production be profitable? Let's consider it step by step.
Areas of application and possible marketing
Plastic products on the market today disposable tableware: plates, cups, shot glasses, skewers, drink stirrers, spoons, knives, forks, trays and food storage containers of various shapes and sizes. Dishes are made of plain and foamed polystyrene (for cold products) or polypropylene (for high temperatures, microwave ovens).
Applications plastic tableware:
- catering points operating on the principles of "fast food" (pancake shops, pizzerias, children's cafes, canteens);
- delivery companies ready meals to your home or office;
- grocery stores;
- food production enterprises;
- outlets with goods by weight (confectionery, dairy products, ready-made salads).
A huge segment of the disposable tableware market is occupied by plastic cups - they are used almost everywhere: in offices, sanatoriums, children's and sports facilities (for coolers, in vending machines for hot and cold drinks, in catering). Of course, the level of competition here is much higher than in the manufacture of other plastic tableware products.
To start production, you should decide on the product range. To do this, it is necessary to assess the presence of competing enterprises in the region, their range and pricing policy. Despite the large number of offers on the market of plastic products, it is possible that there will be no worthy competitors, since great amount plastic tableware is brought from China, and, as practice shows, the buyer is more loyal to a domestic manufacturer, even if the price of his products is higher.
Organizational issues of registering a business for the production of plastic utensils
The choice of organizational form for legal registration business depends on the size of the planned profit. It can be either an individual entrepreneur (for a small enterprise) or an LLC. The latter, despite the greater number of document flow, is much easier to agree on cooperation with large enterprises both when purchasing a raw material base, and when concluding contracts for the supply of finished products. To legal entity, traditionally, there is more trust. Yes, and VAT refunds are important in the tax optimization procedure. Therefore, the optimal organizational form to open production - LLC on the general taxation system, including VAT.
The following code should be indicated as the main activity: 25.24.2 Manufacture of plastic tableware, kitchen utensils and toiletries
The activity for the production of plastic utensils is not licensed, but certificates and technical specifications for compliance will be required finished products SanPiN standards and GOST requirements.
Pay attention to the following regulatory documents:
- GOST R 50962-96 - “Utensils and household items made of plastic. General technical conditions”;
- GOST 15820-82 - "Polystyrene and styrene copolymers";
- GN 2.3.3.972-00 - instead of SanPiN No. 42-123-4240-86 "Permissible amounts of migration (DKM) chemical substances released from polymeric and other materials in contact with food products and methods for their determination”;
- SP 2.2.2.1327-03 - " Hygiene requirements to the organization technological processes, production equipment and workplace";
- GN 2.2.4.1313-03 - "MAC of harmful substances in the air of the working area".
The nuances of choosing a production facility
If it is planned to manufacture a full cycle with the operation of an extruder, the following requirements must be met:
- the height of the room is not lower than 4.5 m;
- floor - concrete or tile;
- walls - 1.5-2 m from the floor surface are finished with non-combustible material;
- good ventilation; - possibility of connection to the water supply system;
- connection to a 3-phase power supply.
If the finished film is used as a raw material (in fact, work is carried out on a thermal press and packaging), the ceiling height is acceptable lower, but not less than 3.5 m.
By function production room should be divided into the following zones:
- Workshop for the production of plastic utensils;
- Administrative and amenity premises;
- Warehouse for storage of raw materials;
- Warehouse for storage of finished products;
- Locker rooms for staff;
- Bathroom.
Raw materials - choose quality
Technological process of plastic tableware production
Depending on the type of product, there are two technologies for the production of plastic utensils: molding and casting. Thick-walled tableware (cutlery, premium-class goods: glasses, wine glasses, glasses according to individually made forms) is made by the casting method. The casting process is rather slow, the production cost is high, since here the weight determines the quality and strength of the finished product. For example, the weight of a standard cup with a capacity of 200 ml is 3 g, made by injection molding - up to 10g.
The manufacture of dishes by the molding method is more promising for mass consumption. The automated molding line can produce up to 30 million cups (13-18 million plates) per month.
Let's consider step by step the technology of manufacturing plastic utensils in this way:
1. Raw materials in the form of polyester residues (recycled) or finished pellets are fed into the extruder. If it is planned to produce colored dishes, colored ones are added to white granules.
2. In the extruder, the granules are heated to the melting temperature, the melt is constantly mixed with a screw press. Having reached the desired consistency, the mass passes through the press, forming a plastic sheet, about 2 mm thick. Basic requirement- uniform thickness of the resulting product.
3. Ready film roll enters thermoforming machine, where, depending on the type of product, molds of various configurations are used.
4. But before forming blanks for future dishes, the film must be heated. To do this, it is sent through a 3-meter furnace, which heats the material to a plastic state.
5. In the thermoforming machine, the web is sucked tightly into the molds.
With the help of a press, row after row is squeezed out finished goods(cups, plates, packaging).
7. The resulting film cuts are disposed of for further use. Thus, the production process is waste-free.
8. The trimmer transfers the products to the machine, which stacks the products and transfers them to the conveyor belt.
9. The tape transfers products to packaging. Or for further modification (heating and rolling of the upper edge of the cups, to form rounded rims; applying printed images and logos), and then on the packaging.
We draw up a business plan for the production of plastic dishes
1. Enterprise LLC "X" plans to produce the following product
- cutlery (spoons, knives, forks);
- glasses (with a capacity of 200 ml);
- plates.
2. Raw materials
- for the manufacture of cutlery and plates - polypropylene;
- for cups - polystyrene.
The manufactured products will be transparent (glasses) and white (the rest of the goods), since the color additives contain dyes-chemicals that are harmful to health. Waste-free production (film residues are remelted in an extruder for further use).
3. Sales
- stationary catering points (50%);
- population and offices (20%) - seasonal outdoor retail outlets (20%);
- cafe (5%);
- lunch delivery, baking and confectionery (8%).
4. Room
Rented industrial premises - 500 m 2 * 1400 rubles / m 2. Rental price - 700,000 rubles / month. (8,400,000 rubles/year)
5. Capital investment
BUT) Technological equipment(the price includes delivery of the line to the production workshop, installation, commissioning, personnel training):
- Extruder - 1,048,950 rubles,
- Thermoforming machines - 2 pieces * 672,000 rubles = 1,344,000 rubles,
- Molds - 5 pieces * 241 710 = 1 208 550 rubles,
- Compressor - 600,600 rubles.
B) Additional equipment:
- 2 computers and office equipment - 65,100 rubles,
- transport (Gazelle car) - 3 * 82,950 = 248,850 rubles.
Total - 4,516,050 rubles.
6.Calculation of production capacity
M = release rate (according to technical data) * equipment operating time
It is planned to work in 2 shifts of 8 hours with a break for lunch (Saturday, Sunday, official holidays - days off).
Projected equipment operation time = (calendar days - weekends - holidays) * number of working hours * number of shifts \u003d 249 * 7 * 2 \u003d 3486 hours / year
Excluding 60 hours/year of downtime for maintenance and repair work - 3426 hours/year.
Production capacity \u003d productivity rate * number of equipment in operation * equipment operation time
In accordance with the characteristics of the equipment, we will calculate the production capacity for each type of product:
M (glasses) \u003d 20,000 pieces * 1 * 3426 h \u003d 68,520,000 pieces / year
M (plates) = 18,000 pieces * 1 * 3426h = 61,668,000 pieces / year
M (knives) = 21,000 pieces * 1 * 3426h = 71,946,000 pieces / year
M (forks) = 21,000 pieces * 1 * 3426h = 71,946,000 pieces / year
M (spoons) \u003d 21000 pieces * 1 * 3426h \u003d 71,946,000 pieces / year
7. Calculation of material costs
Material costs for the production of 1 unit of output = quantity consumable* purchase price of the material.
Plates (0.005 kg x 61,668,000 pieces) x 40 rubles = 12,333,600 rubles.
Cups (0.004 kg x 68,520,000 pieces) x 36 rubles = 9,866,880 rubles.
Cutlery - (0.002 kg x 71946000 pieces x 3) x 40 rubles = 17,267,040 rubles.
Other material costs (packaging, fuel, etc.) - 9,866,880 rubles.
Total material costs - 49,334,400 rubles / year.
8. Personnel and payroll
Number and total fund wages per year (including vacation pay and bonuses during the season) to ensure 2-shift operation of the enterprise:
- Director - 435,600 rubles,
- Accountant - 382,800 rubles,
- Technologists (2 * 211,200 rubles) - 422,400 rubles,
- Equipment adjusters (2*204,600 rubles) - 409,200 rubles,
- Workers (20 * 198,000) - 3,960,000 rubles,
- Loaders (4 * 184 800) - 739 200 rubles,
- Drivers (4 * 171600) - 686 400 rubles,
- Cleaners (2 * 165,000) - 330,000 rubles.
Total total wage fund - 7,365,600 rubles / year
Payroll taxes (UST) will amount to 1,915,056 rubles/year
During the high season (April-September), it is planned to create additional places and flexible working hours for general workers (students).
9. Calculation of the cost of production
The cost of a unit of production is calculated as the sum of material costs, wages and social needs (UST), depreciation and other costs (rent + advertising).
Plates - 14,309,976 (material costs) + 1,473,120 (salary) + 383,011.2 (UST) + 1,578,821 (depreciation) + 1,741,000 (rent + advertising) = 19,485,928.20 rubles
The cost of 1 plate is 19,485,928.20 rubles / 61,668,000 pieces = 0.32 rubles
By analogy, we calculate the cost of other products:
- cups - 0.25 rubles / piece,
- cutlery - 0.18 rubles / piece
10. Determination of the selling wholesale price
Unit price \u003d Cost price of 1 piece + Profit margin (according to standards - 25%)
We calculate the minimum sales price threshold for wholesale:
- plates - 0.32 + (0.32 * 25%) \u003d 0.40 rubles.
- glasses - 0.25 + (0.25 * 25%) \u003d 0.31 rubles.
- cutlery - 0.18 + (0.18 * 25%) \u003d 0.23 rubles.
11. Calculation of the production program
Sales proceeds \u003d number of pieces of products / year * price per piece
Glasses - 68,520,000 pieces / year * 0.31 rubles = 21,241,200 rubles / year
Plates - 61,668,000 pieces / year * 0.40 rubles = 24,667,200 rubles / year
Knives - 71,946,000 pieces / year * 0.23 rubles = 16,547,580 rubles / year
Forks - 71,946,000 pieces / year * 0.23 rubles = 16,547,580 rubles / year
Spoons - 71,946,000 pieces / year * 0.23 rubles = 16,547,580 rubles / year
Total revenue for the year: 95,551,140 rubles / year.
12. Calculation of balance and net profit
Based on the calculated data, we compose financial plan production of plastic tableware in value terms:
- Sales proceeds - 95,551,140 rubles / year,
- The cost of dishes - 75 217 160 rubles / year,
- Profit from sales (balance sheet) - 20,333,980 rubles / year, (Revenue - Cost)
- Income tax (20%) - 4,066,796 rubles / year, Net profit \u003d Balance sheet profit - Income tax \u003d 16,267,184 rubles / year.
13. Profitability calculation
Product profitability is calculated by the formula: P = (Balance profit: Cost) x 100% P = 20,333,980: 75,217,160 * 100% = 27%
Conclusion: The plastic tableware business is profitable with large scale sales. Subject to the estimated load of production capacities, the initial investment in a business project can pay off within 2-3 months.
In today's world, the production and sale of disposable tableware is constantly growing, and this trend has been observed for a number of years. The popularity of such dishes is quite justified - plastic glasses, plates, forks and spoons are very inexpensive, absolutely safe for health and hygienic (they are simply thrown away after use). Disposable tableware is of particular importance for enterprises fast food, in which it is used extremely actively and in large quantities.
The history of plastic utensils in the United States
The birthplace of plastic tableware is the United States of America. It was in this country in the middle of the last century that a certain William Dart invented a plastic cup, the very first in the world. He patented his revolutionary invention and founded the Dart Container Corporation. Today it occupies a third of the entire US disposable packaging market. A little later, in addition to plastic glasses, they began to produce plates, forks, spoons and knives. The production of disposable tableware in Moscow and other cities of our country began only in the mid-90s of the last century. Prior to that, it was imported from abroad, which at some point became economically unprofitable. Now in Russia there are many large and small enterprises for the production of disposable tableware, which almost completely cover the needs domestic market in her.
Equipment for the production of plastic tableware
Modern technology for the production of disposable tableware involves the use of specialized equipment, which includes:
- Extruders;
- thermoforming machines;
- Automatic production lines.
Extruders are needed in order to produce a plastic sheet from which dishes are further molded. This process is carried out using thermoforming machines. The largest and most modern enterprises are equipped with specialized automatic production lines with high productivity. As for the cost of equipment for the production of plastic disposable tableware, it is quite high. For example, a new European-made high-performance extruder costs about $500,000, and a thermoforming machine costs about $40,000.
Raw materials for the production of plastic tableware
In Russia, the main raw materials for the production of disposable plastic tableware are polystyrene and polypropylene. These materials meet all sanitary and hygienic standards, do not emit any substances harmful to human health. For production, they are delivered most often in the form of granules.
Production of disposable plastic tableware – current and profitable business with a relatively fast payback period. Despite the fact that this category of goods has appeared on the market for a long time, it continues to enjoy stable demand from consumers. Every year, the world produces products worth more than 40 million dollars, most of it is sold in large metropolitan areas. It should be borne in mind that there is high competition in this area, in order to attract potential customers, novice entrepreneurs need to competently approach the organization of a business project.
Benefits of plastic utensils
Plastic products have many advantages, they are practical, hygienic, easy to use, and have an affordable price. The range of such products is diverse. It can be glasses, forks, spoons, plates, knives and many other goods. Disposable tableware is often used in offices, summer cottages, during outdoor recreation. It is indispensable in various bistros, summer cafes, pizzerias, canteens and other similar establishments.
This product can be made from polystyrene or polypropylene. Polystyrene tableware is designed for chilled drinks and food. Polypropylene products have a high melting point, if necessary, they can be heated in a microwave oven.
Video - making polypropylene reusable tableware:
Stages of building a business
To commercial activity soon began to bring high profit you need to draw up a detailed business plan. It includes the following steps:
- registration of a company in the form of LLC or IP;
- choice of the form of taxation and registration of permits;
- purchase of raw materials and equipment;
- workshop rental;
- recruitment;
- production of products;
- conducting a marketing campaign;
- sale of goods.
Production technology of disposable tableware
The production technology of products consists of several stages:
- the raw material is heated in the extruder and mixed to the desired consistency;
- hot mass is processed by a special press, resulting in a plastic film;
- the canvas is placed in a thermoforming machine, which allows you to shape the future dishes;
- using a trimmer, individual blanks are cut out of the film;
- finished products are stacked and packaged.
Video - how plastic forks, spoons and cups are made:
Financial calculations
The organization of this business requires significant capital investments:
- purchase of a production line for the production of dishes - from 1,000,000 rubles;
- ordering the first batch of raw materials - from 70,000 rubles;
- paperwork - from 30,000 rubles.
The cost of production of one unit of goods is from 0.25 rubles. It includes the cost of renting premises, salaries, utilities, advertising and purchase of raw materials. If about 8,000,000 products are produced monthly and each product is sold at a price of 0.31 rubles or more, the net profit will be from 480,000 rubles per month.
Total:
- starting capital: from 1,100,000 rubles;
- monthly profit: from 480,000 rubles;
- payback period: from 3 months.
Required documents
No license is required to open a business. Businessmen need to complete the following documentation:
- product certificates;
- permits from the fire service and SES;
- permits from Rospotrebnadzor.
Requirements for the premises
For organization production process it is recommended to choose a room with an area of 500 m2, located away from the city, in an industrial area. It should have several functional areas:
- a workshop where equipment for the production of plastic disposable tableware will be installed;
- warehouses for storage of raw materials and finished products;
- bathroom;
- locker rooms for staff.
The room must meet all the requirements of the State Standard, it should be repaired, and equipped with all necessary communications.
The workflow of making plastic packaging in the production workshop:
Equipment
Equipment for the production of plastic tableware includes:
- thermoplastic installation;
- extruder;
- thermoforming machine.
Staff
The efficiency of the production process largely depends on the skill level of the staff, so it is recommended to hire experienced employees. The company must include:
- director;
- technologists;
- equipment adjusters;
- loaders;
- handymen;
- accountant;
- drivers;
- cleaners.
Advertising
A well thought-out strategy will help to attract potential customers. marketing strategy. Advertising on the Internet can give a good effect, it is recommended to place it on specialized resources, forums and in in social networks. Creating your own website, which contains photos of goods, will attract an additional flow of buyers.
Sales of products
In order to successfully sell finished products, you need to take care of finding distribution channels in advance. The product can be delivered to various establishments Catering:
- Cafe;
- bistro;
- pizzerias;
- pancakes;
- canteens;
- kiosks selling takeaway food and drinks.
You can also work with catering companies and home delivery companies. Additional profit can be obtained by supplying plastic utensils to large stores and supermarkets. You can also offer products to individuals by organizing your own wholesale and retail outlets sales.
Bogdana Zhuravskaya
The production of disposable tableware is a promising and profitable line of business for an entrepreneur who is not afraid of a high threshold for entering the market. Along with significant capital investments, it is necessary to be ready to overcome a number of risks. The main one is the lack of a large number of highly qualified technologists and open information about the details of the production process. In addition, the environmental movement is becoming more and more popular in our country. This means that it is necessary to build your activities taking into account the fact that sooner or later you will have to reformat the enterprise for the production of a biologically degradable product.
In anticipation of the launch
There are many types of disposable tableware. Conventionally, products can be divided into several large groups: plastic, paper, wood and the so-called environmentally friendly. The latter category includes both dishes made of biodegradable plastic, and recent developments, when cups and plates are made from a wide variety of raw materials, such as cereals (edible dishes), cane, corn starch, leaves, bamboo, etc.
Before launching a project, an entrepreneur needs to clearly indicate what type of product he will produce. Universal lines on this moment does not exist, and the launch of an enterprise with a large number of installations for products from different materials will require huge investments. Another difficulty is to obtain an efficient technology for the production of disposable tableware. Find detailed information in open access is not easy, and qualified technologists are worth their weight in gold. Therefore, the easiest way to set up the process is to train personnel from the equipment manufacturer.
Further, agreements should be concluded with suppliers of raw materials. There are not so many of them on the territory of the Russian Federation, so we can consider options for cooperation with foreign partners. In any case, it is not advisable to focus on only one manufacturer, because a supply failure can cause downtime for a new enterprise.
Having decided on the listed questions, you can begin to search for equipment and develop project documentation. As already mentioned, the financial threshold for entering the market is quite high. So, just for the purchase of a minimum set of equipment for the production of plastic disposable tableware, about 12 million rubles will be required. Having a well-developed business plan in hand, it makes sense to start working using investors' funds.
Basic risks
Potential clients do not rush to conclude preliminary agreements with a new manufacturer and are ready to consider proposals only if the required volume of finished products and a package of documents confirming the compliance of goods with the requirements of GOST and SanPiN are available.
As for competition, here you will have to deal with a pool of domestic and foreign companies, most of which hold a strong position in the market, have a certain experience and, what is important, the trust of customers. For example, Chinese manufacturers, due to the huge volumes, are able to offer very attractive price offers.
Another conditional difficulty is the seasonal demand for products. Keeping the balance will help expand the range.
The main consumers of disposable tableware
Among the wholesale buyers that the manufacturer of disposable tableware needs to focus on:
- , canteens, pizzerias and other catering establishments;
- seasonal stalls selling takeaway food;
- food delivery services;
- markets of various formats, catering companies with their own culinary production;
- agencies for organizing picnics and outings;
- enterprises engaged in the sale of vegetables and fruits.
As you can see, the list of opportunities for marketing products is quite wide. The entrepreneur only needs to create profitable proposition and convey information about it to as many partners as possible.
Types of disposable tableware
In order to comprehensively meet consumer demand, the manufacturer's assortment should include disposable tableware for drinks, soups, second courses, snacks, packaging of various products, as well as salad bowls, cutlery, tubules, plastic lids takeaway drink glasses and stir sticks.
For the manufacture of products, several types of raw materials can be used: plastic, including its degradable variety, special paper, wood. In addition, dishes from natural materials.
Disposable plastic tableware
Plastic cookware has a number of advantages. It is convenient, hygienic, practical, and is very inexpensive. The versatility of the material allows the production of a wide range of products - plates, cups, cutlery, straws, stirring sticks of various colors, shapes and sizes. If necessary, you can apply a logo or a bright pattern.
Equipment for the production of plastic tableware
The standard line for the production of disposable tableware contains:
- thermoforming machine;
- extruder;
- mold;
- compressor.
The minimum cost of a set of equipment is about 3 million rubles. costs for the first batch of raw materials - from 100 thousand rubles.
Manufacturing technology + Video
Two types of plastic are used for the production of dishes:
- polypropylene foam (durable, plastic, resistant to heat, dishes from it can be used for hot dishes and drinks, denoted by PP with the number 5);
- polystyrene (products do not withstand heat, food cannot be stored in them, denoted by PS with the number 6).
The raw materials for the production of plastic dishes are granular polymers that look like balls of. The price per ton of granules fluctuates in the range of 45-100 thousand rubles, which depends on the brand, diameter and other characteristics.
This raw material is used by full-cycle enterprises, where it is supposed to melt the granules and make a film from which plastic utensils are produced. In an incomplete cycle, the manufacturer uses finished film worth 100-190 thousand rubles. per ton.
The full production cycle of disposable tableware includes the following steps:
- Pellet melting. White or, if we are talking about the manufacture of colored dishes, multi-colored balls are placed in an extruder, where the raw material is heated to the melting point with constant stirring screw press.
- Film making. Having reached the desired consistency, the mass is fed to a press, through which a plastic sheet 2 mm thick is obtained.
- Shaping products. The film enters the thermoforming unit, warms up to a plastic state and is pulled into molds.
- Cutting elements. The whole web with the formed dishes is moved to the trimmer, where the individual elements are separated from the solid web. Plastic pieces are sent for recycling.
- Next, the dishes are sorted and fed to the conveyor, where they are modified - applying logos, bending the edges, etc.
- Package. The machine selects the required number of products and places them in a film.
In a similar way, the production of dishes from biodegradable plastic is carried out.
Video how to do it:
Disposable tableware made of bioplastic
Disposable tableware made of biodegradable plastic is positioned as “green”, but the material, although to a lesser extent than its biodegradable counterpart, still pollutes environment, since methane is released during decomposition and carbon dioxide. However, green lifestyle advocates welcome this “lesser evil” decision and are happy to use the product.
Main competitors
Among the giants of the disposable tableware market are following companies: U2B, My Dishes, GORNOV GROUP, Plastic Step, Mystery, Papperskopp Rus, Huhtamaki, Trial Market, PapStar, The Paper Cup Company.