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Example Business plan for production of polymer sandy hatches sewer


Let us consider an example of calculating the prime cost of manufacturing polymer sand sewer hatches, which can be taken as a basis for compiling a business plan and a feasibility study of production.

All calculations are shown as an example. 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.



              Material specifications:             

  •   lid diameter 620mm, case diameter 740mm, cover thickness 30mm, case height 100mm
  • the weight of one piece is 36 kg.
  • 500 cycles frost resistance

                 The composition of the line for the production of polymer sandwich hatches:             


             Basic Settings         


             The work is done in two shifts, lasting for 12 hours. The productivity of one mold is 4 pieces per hour. &Nbsp; for a day the line issues 96 pieces of finished products, for a month 2   880 pieces         


The full cost of the complete set of equipment, including the cost of commissioning "turnkey" is: 3   972   034 rubles without VAT.

Name   Price, rub.
Commissioning works 50 000.00
ALP 567 000.00
Hydraulic press for obichayki
Hydraulic press for cover
1   116,754.00
947 280.00
Full mold molding 2pcs 693 000.00
Crusher of raw materials - waste * 385   000.00
Mixer 213 500.00
TOTAL 3   972 034.00

  - 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.

- You can use one hydraulic press and produce parts in turn.


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.

Thus, the cost of wages by 1pc. is 46.88 rubles.

UST - 30%, gives 14.06 rubles. in the cost of 1pc. finished products.


To accommodate equipment and storage areas for raw materials and products, it is necessary to provide about 100 m 2 production areas and 100 m 2 warehouse (may be located outside the premises). The production room does not need to be heated, the heating occurs at the expense of the equipment, finished products during the cooling period,   heat. 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 cost of renting for 1pc. product is 3.47 rubles.


                 Raw materials for the production of tiles:             

  • Polymer granules or flakes
  • Sand construction
  • Pigment dyeing

                 Composite composition: 24.58% polymer, 75% sand, 0.42% pigment. Average price as of 04/01/2016   (polymer 18,000 rubles + sand 320 rubles + pigment 80,000 rubles) per ton.             


  Based on the data for 1 ton of composite:

1.           Polymer - 4   424 rubles. 40 kopecks.

2.           Sand -240 rub.

3.           Pigment - 336 rubles.

Cost of materials   is 5 000 rubles. for 1 ton of the mixture. A ready-made sewer hatch requires a weight equal to   32 kg. From a ton of the mixture we get 31.25 pieces. Thus, the cost of raw materials per 1 sewer is 160 rubles.


  • A crusher with a capacity of 300 kg/h consumes 22 kWh. For the production of a mixture in an amount of 3? 720 kg, 755 kg of polymer is necessary. To make it, the crusher will work for 2.5 hours and will consume 55 kW of energy
  • 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 formed, the program on presses is designed for the consumption of 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   96 pieces x 40 seconds. = 3   840 sec. = 64 min. = 1,07 hours of work of the press
  • The daily consumption is 5.89 kW.  
  • Hydraulic press - 11 kW/hr   consumption per day: 11.77 kW  
  • Mixer   - 5.5 kW/hr   1 batch - 3 minutes. Mixes 0.5 tons per peremes. For the change of 3.072 tons of mixture for 96 pieces of hatches   . Per day, 18.4 minutes. Power Consumption   1.83 kW.-
  • Lighting - 12 kW/h

Total electricity consumption per day is 260.49 kW/day, a change over 12 hours 130.25 kW.

The cost of electricity for 1 kW/h - 4.03 rubles. Thus, the cost of electricity is 525 rubles. In 12 hours   when manufacturing 48 hatches. Consumption per 1 hatch will be 11rub.

Amortization of equipment is established by the company independently

  Cost of a single hatch

Cost element   by 1.
Raw materials   160
Electricity   11
Salary   46,88
UST, 30%   14.06
Premises for rent   3.47
Amortization of equipment   8.12
TOTAL   243.53


Name   Luke
Cost price 1 piece, rub.   243.53
Overhead expenses, rub. (1%)   2.43
Market price 1 pcs., Rub.   850
Profit before taxation for 1 pc., Rub.   604.04
Tax on profits (6%), rubles. 51
Profit c 1 pcs., Rub 553.04
Profit per day only, rubles (96pcs)   53,092
Profitability,%   69.1%
Payback period, days   74.8

  Net profit per day 53 092 rub., Gross revenue per day 800 rub. 96 pieces. = 76   800 rubles. &Nbsp; Net profit/Gross revenue x 100   Profitability is 69.1%

This business is highly profitable as of 2017. The rate of return is 69.1%


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