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Business plan for the production of polymer sandwich paving slabs

Let's consider an example of calculation of the cost price for the production of tile paving polymer sand, which can be taken as a basis for compiling a business plan and feasibility study of production.

The data are relevant for January 1, 2011 for the Udmurt Republic. All prices are without VAT. For the calculation, a simplified system of taxation is taken.

 
 You can also order Business plan in Excel format and substitute your data.


INITIAL DATA


                 Material specifications:             

            
                    
  • the size of 330 * 330 * 35 mm
  •                 
  • The weight of the tile is 3.1 kg.
  •                 
  • number of pieces in one m 2 - 9 tiles
  •                 
  • weight 1m 2 - 27.9 kg
  •                 
  • water absorption 0.37%
  •                 
  • tensile strength of 152 kgf/cm 2
  •                 
  • Compressive strength 300 kgf/cm 2
  •                 
  • abrasion of 0.003 g/cm 2
  •                 
  • 500 cycles frost resistance
  •             

              Line composition for production of polymer sandblast tiles:             

            

          Basic settings.         

        

             The work is carried out in two shifts, the duration of the shift is 12 hours. The productivity of one mold is 5.83 m 2 per hour. Thus, over a 24-hour period, the line issues 140 m 2 finished products.         

INITIAL   INVESTMENTS


The full cost of the complete set of equipment, including the cost of commissioning "turnkey" is: 2   382,780.00 rubles excluding VAT.  

Name   Price, rub.
Commissioning works 50 000.00
ALP 567 000.00
Hydraulic press 947 280.00
Press-form PP TP 220 000.00
Crusher of raw materials - waste * 385 000.00
Mixer 1 cubic meter. 213 500.00
TOTAL 2   382   780.00

- A plastic crusher may not be necessary when using ready-made primary or secondary polymers, but this will lead to a rise in the cost of the product;

- The mixer can be replaced with a concrete mixer, but with loss of productivity.


  FUND   PAYMENT   LABOR


The work of the site is sufficient for three people - a manager (25,000 rubles), an operator of the APN (20,000 rubles), an auxiliary worker (20,000 rubles). The payroll fund is 65,000 rubles per month for one shift and 130,000 rubles. from the calculation of 2 shifts.

The volume of finished products per month 140 sq. M. X 30 days = 4   200 sq. M. m

The payroll for the month is 130,000 rubles. : 4   200 sq. M. = Salary costs for 1m 2 is 30.95 rubles.

UST - 30%, gives 9.3 rubles. in the price of 1m 2 finished products.


NECESSARY   PRODUCTION   SQUARES


To accommodate equipment and storage areas for raw materials and products, it is necessary to provide for the order of 100 m 2 production areas and 100 m 2 warehouse (may be outside the premises). The production room does not need to be heated, the heating occurs due to the heat generated by the equipment. Finished goods are stored in the shop, and then moved to the warehouse.

With a rental rate of 100 rubles per sq.m. the cost of renting production space will not exceed 10,000 rubles. Thus, the rental price for 1m 2   products is 2.38 rubles.


PRICE   POWER SUPPLY   &Nbsp; MATERIALS


Raw materials for the production of tiles:             
                    
  • Polymer granules or flakes
  •                 
  • Sand construction
  •                 
  • Pigment dyeing
  •             
    

                Composition of polymer sand mixture:             

            
                    
  • 75% - sand,
  •                 
  • 0.42% - pigments,
  •                 
  • 24.58% polymer (in one ton 245.5 kg of polymer)
  •             
    

                Average price in Russia:             

            
                    
  • sand - 0.32 rub. per kg,
  •                 
  • Pigment - 80 rubles. per kg,
  •                 
  • polymer - 18 rubles. per kg.
  •             


In total, the cost of raw materials (polymer + sand + pigment) per ton is 5,000 rubles. Thus, the cost of raw materials per 1m 2 tiles is 139.5 rubles. For 1 piece 15.5 rubles.



CONSUMPTION   ELECTRICITY per shift
 


  • A crusher with a capacity of 300 kg/h consumes 22 kWh. To produce a mixture in an amount of 3 * 906 kg, 960 kg of polymer is needed. For its preparation the crusher will work 3.2 hours and will consume energy with 70.4 kW
  • APN - 29 kW/h with heating, when working around the clock with a warmed-up ALP, the consumption is reduced by 4 times, ie calculation: 7.25 kW x 24 hours = 174 kW/day
  • Hydraulic Press   - 5,5 kW/hour.   When the product is molded, the program on the presses is designed to consume electricity. Energy in the mode of raising and lowering the upper punch, while forming the electric. Energy is not consumed. The travel time of the slider is 40 seconds per day   1260 pieces x 40 seconds. = 50,400 sec. = 840 min. = 14 hours of press work
  • Consumption per day is 77 kW.  
  • Mixer   - 5.5 kW/hr   1 batch - 3 minutes. Mixes 0.5 tons per peremes. For a day 3,906 tons of a mixture for 1 260 pieces of tiles   . Per day 23.0 minutes. Power Consumption   1.8 kW.
  • Lighting - 12 kW/h


Total electricity consumption per day will be 335.2 kW/day, in a shift for 12 hours 167.6 kW.

The cost of electricity for 1 kW/h - 4.03 rubles. Thus, the cost of electricity is 675.4 rubles. in 12 hours   for the production of 630 pieces of tile, Consumption "for 1litke" will be 1.07 kopecks.


Amortization of equipment is established by the company independently


  The cost of 1 m 2 tiles paving

Cost element   for 1 m2
Raw materials 139.5
Electricity 1.07
Salary 30.95
UST, 30% 9.3
Premises for rent 2.38
Amortization of equipment 2.33
TOTAL 185.53

 

 

FINAL   CALCULATIONS

Name   TP tile
Cost of 1 square meter, rubles. 185.53
Overhead expenses, rub. (1%) 1.85
Market price of 1 sq.m., rub. 540
Profit before taxation per 1 sq. M., Rub. 352.62
Income tax (6%), rubles. 32.4
Profit c 1 sq. M, rub 320.22
Profit per day total, rub. 44   830.8
Profitability,% 59.3
Payback period, days with 100% implementation   51

   

Net profit for the day 44   830.8 rubles. Gross revenue per day 600 rubles. х 140 sq.m. = 75,600 rubles. &Nbsp; Net income/Gross revenue x 100   The profitability is 59.3%

This business is highly profitable as of 2017. The rate of return is 59.3%


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