Production of plastic parts to order allows the customer to obtain products of a certain shape in any quantity at an affordable cost. For each order, molds are developed using a special technology, which reduces the cost of products and makes them competitive in the market.

Production stages

Here are the steps in the manufacture of plastic products:

The production facilities of the Plastmassy Plant allow casting products of any shape and batch. For production, molds of our own design or provided by the customer can be used. Raw materials are used own or given.

During the production process, the extruder hopper is filled with polyethylene, propylene or other thermoplastic granules, which are melted to the technical melting temperature and fed under pressure into the mold. High pressure makes it possible to produce products of increased strength and complex shape. After being removed from the mold, the plastic blank undergoes additional processing to eliminate minor defects and quality control. In high pressure injection molding, the product is ready for shipment to the customer after being removed from the mold.

The advantage of the company "Plastic Plant"

The advantages of Zavod Plastmassy, ​​which has been operating on the market since 1997, are obvious, because it:

The company works with various thermoplastics, in particular, granular polystyrene, polypropylene, polycarbonate and other thermoplastics are used.

From the moment the contract is concluded to the shipment of a batch of plastic products, a minimum of time passes, the cost of molding does not exceed the average market mark, and there are no questions about the quality of products.

You can also send us an email
to get the exact price and terms

A beginner "caster" should not do this, since each type of plastic has only its own inherent properties, so it would have to be melted at different temperatures. In addition, in production, parts are usually cast in special installations where high pressure is maintained.

Even if you manage to pick up pieces of plastic of the same kind and crush them, melting will result in bubbles. So it's best to go to a hardware store and buy liquid plastic, from which the parts are no less durable than factory ones. Epoxy can also replace plastic. You will also need:
- silicone;
- large capacity;
- .

If you still decide to make something out of plastic scrap, do not do it indoors. Plastic fumes are toxic.

Making a shape

Make a model of the part to be cast. Lubricate it with lithol or other lubricant. After that, make a shape. Silicone molds are becoming more and more popular. This is understandable, it is easy and convenient to work with this material, but several circumstances must be taken into account. Firstly, there are two types of silicone, pouring and coating. Secondly, each species has its own elongation coefficient and its own viscosity. As for the first parameter, silicone with a coefficient of 200% is suitable for plastic injection.

Pay attention to the viscosity coefficient. The smaller it is, the more accurate the shape will be. This is especially important if you are going to work with potting silicone. Consider also the polymerization time. If you have casting silicone, place the master model in a flask (it can be made of steel or, for example, bronze) and fill with silicone. Gently apply the coating material with a brush, taking into account all the irregularities. Let the silicone harden and then remove the master model.

The flask is a metal container. It should be slightly larger than the master model.

Pour detail

Production of plastic products: plastic characteristics + material classification + market analysis + opening instructions + premises requirements + 3 types of raw materials + 10 suppliers + process features + equipment + product sales + start-up investments.

Experts consider the production of plastic products one of the priority areas of business. It has great potential and prospects, since Russian enterprises do not fully provide the country with finished products.

Basically, plastic goods are bought from China or Europe. Based on this, the question arises: does it make sense to open an enterprise for the manufacture of items from this material or not? How much money will be needed? What organizational issues will need to be addressed?

Let's figure it out in order.

What do you need to know to carry out the production of plastic products?

First you need to understand what the entrepreneur will have to deal with if he decides to manufacture plastic products.

Before delving into the technology, assortment, you should get acquainted with the subject of labor, i.e. with plastic mass.

Plastic (plastic) is a material that is created using natural or synthetic polymers. Remarkable for plastic is that it can retain the specified dimensions and shape after cooling.

Fillers, pigments, inorganic fibers and other components can be added to the polymer for various purposes in the production of plastic materials. Therefore, plastic is mostly a multi-component mixture.

These products are widely used in all areas.

Plastics are not known for their high density and strength. Heating, compression affects it destructively. But the material is also characterized by many positive properties. For example, it has low thermal and electrical conductivity. Also, plastic products are not afraid of moisture.

There are also such properties of plastic:

• a light weight;
• resistance to strong acids, corrosion;
• susceptibility to processing;
• low cost;
• frost resistance;
• shock insensitivity.

The plastic substance can be of various types. It is classified depending on the composition, scope, binder.

An entrepreneur whose production is somehow connected with plastic must know that its waste does not decompose over time. Therefore, large volumes of landfills are formed on Earth.

There are 5 garbage spots in the oceans due to plastic waste, which poses a danger to the environment in general. Due to the mass production of plastic items, nature, marine animals and those that live on land are dying.

Plastic products also pose a threat to human health. During the production process, toxic gases are released that can spread over long distances and fall in the form of precipitation, which harms vegetation, pollutes water and soil.

Being engaged in the production of plastics, the entrepreneur must
control the content of vinyl chloride in the air above the enterprise.

Before the products are introduced into the industrial economy, the food industry, medicine, an examination is carried out regarding the composition of toxic substances.

If possible, the manufacturer should either label them so that consumers do not dispose of plastic products by incineration.

1. What kind of plastic products can be produced?

The number of products made of plastic material today is very large. There is a huge variety of their types - of various shapes, dimensions, capacity and purpose.

Plastics are widely used in the automotive industry. This allows you to achieve comfort, save weight and even fuel, reduce noise, increase safety and service life, reduce operating costs.

You can find up to 100 kg of plastic parts in a car! In addition to the automotive industry, the production of plastic products is beneficial for modern architecture and construction, medicine. In general, for almost all industries.

Plastic products serve as the basis for the manufacture of stretch ceilings, pipes, floor coverings, window profiles, electrical tape, tarpaulins.

Plastic is also needed to create:

• bottles,
• packaging,
• lids,
• blisters,
• oilcloths,
• detergents,
• packages,
• utensils,
• children's toys,
• furniture,
• spare parts.

Most household and garden items are plastic products (buckets, dustpans, wastebaskets, toiletries).

That's not all. You can set up production:

• pet supplies (trays, portable baskets for dogs and cats, bowls);
• canisters, basins;
• packing handles;
• fan heaters, cases for equipment;
• pump, bottles;
• food containers, dryers for dishes;
• flowerpots, flower pots;
• cutting boards and other kitchen utensils.

As you can see, the choice is huge. If products are metallized during production, the list of products will be even longer.

2. Is it worth opening the production of plastic products?

The domestic market of plastic products is developing, and this is facilitated by:

1. Active policy of import substitution.
2. Expansion of the "range" of polymers.
3. Capacity availability.

But there are also factors that hinder the development of the industry. Thus, the production of plastic products is subject to a considerable tax, equipment and raw materials are expensive, there is an oligopoly on the market, and there is a shortage of Russian-made polymers.

Over the past years, a positive growth trend has been observed in the production of plastic materials:

More than 5 million tons of plastics are produced annually. Compared to Europe, Russia consumes 6 times less plastic products. One person has at least 42 kg.

Polymer production increased by 37% and consumption by 6%, while imports decreased by 25%. The market for products from plastic raw materials narrowed by 5.7% - specifically for pipes and films.

More than 200 thousand workers are employed in this industry, more than 6.5 thousand companies are engaged in production. The output per person is less than 26 tons.

The main areas of application of plastic materials in Russia are:

• package,
• construction,
• Automotive industry.

There are more than 1.4 thousand especially large enterprises producing plastic products, with. They provide the country with 1.6 million tons of products. Their list includes Polyplastic, Kopeysk Plastics Plant, Lada List, PZPI, Rosturplast, Polimerbyt, Pro Aqua, LPZ.

More than 2.5 thousand companies are classified as medium and small producers, the production volumes of which reach 3 million tons of plastic products.

Namely:

• ZPI Alternative (Bashkortostan);
• Maxiplast (Golitsino);
• Mplast (St. Petersburg);
• Plastics St. Petersburg (St. Petersburg);
• Polyplast (Izhevsk);
• Triton Plastic (Moscow);
• NZP (Kemerovo region);
• Polymer (Lipetsk);
• Aelita (Leningrad region);
• Apal (Tolyatti);
• NZPM (Tver region).

Experts give not entirely comforting forecasts about the production of plastic goods:

• First, it is the growth of consumer prices by at least 14%.
• Second, a 17% decline in purchasing power is expected.

From this we can conclude that the development of the production of plastic products will be constrained by the growth in prices for the raw material base, the fall in the level of consumption, and other factors.

As a result, the volume of the plastic products market will decrease by 5%. But the situation is not critical. The engine of production will be export and import substitution.

In order for an entrepreneur to strengthen his position, it is necessary to reduce the cost of plastic products and strengthen competitive advantages.

Step-by-step instructions for opening the production of plastic products

We will immediately designate: the orientation will go further to small business.

Anyone who has decided to produce plastic products, analyzed the market, all the pros and cons of polymer production, should write a business plan. Not a single serious enterprise or event can do without a clear action plan that structures all the information needed in the future and sets the right direction.

For legal business, you will need official registration, the choice of a taxation system. Suitable for a small enterprise for the production of plastic products. OKVED codes are indicated depending on the goods produced.

Production of products is impossible without obtaining permits. Products must be certified. Conclusions will be required from the fire service, SES. Permission must also be obtained from local authorities, Gosnadzorohrantrude, electricians, gas inspections and thermal workers.

If the owner of the enterprise has a knack, the time and money costs will be reduced. Usually everything about everything takes up to 3 months. Next, you need to decide on the nomenclature. This will help a detailed study of the market for plastic products.

Research your competitors carefully. To choose the right type of plastic products for production, you need to look at what they produce. It would be advisable to manufacture those products that competitors offer on the market in small quantities (if demand outstrips supply).

In the course of the analysis, you will understand: maybe it is worth setting up the production of those plastic products that are not produced at all by domestic enterprises, but by Europe.

A win-win option would be to produce:

• sheets,
• pipes of various sizes
• panels,
• disposable tableware,
• containers,
• packaging.

Plastic pallets, necessary for packing chicken meat, are also considered to be in demand.

When the production of plastic products is established, increasing profits will become a paramount task. It is carried out by improving the technological process, optimizing costs, expanding the range and distribution channels.

Focus on deliveries to other areas and cities.

1) What kind of facility is required for the production of plastic products?

A workshop for the production of plastic products must have standard communications (heating, ventilation, sanitation, water supply, electricity). Special requirements are imposed on those premises where pentane is used in the production process.

When searching for a suitable object, you should select options located in industrial areas. The production of plastic products can also be located on the outskirts of the city, away from sleeping areas.

The size of the area - from 40 to 200 square meters. m. The warehouse needs a large one. The weight of plastic products is small, but it takes up a lot of space. The room must be protected from moisture, dust, drafts and wind. In a dry, heated building, the quality of plastic products will improve as less moisture is adsorbed.

In addition to the areas for the warehouse of finished products and raw materials, the premises should have:

• bathroom,
• room for workers and administration.

2) Raw materials used in the production of plastic products.

If you constantly change contractors and raw materials, the output products will not be the same. We will have to reconfigure the equipment, re-work out the technology for the production of plastic products.

Usually acquire polymer granules of heterogeneous composition. Depending on the type of plastic products, the composition of raw materials is selected, because each type of it has its own physical and chemical properties.

The main indicator that you need to pay attention to is the resistance of plastic to various temperatures.

Conditionally share 3 types of raw material:

Depending on the purpose of the plastic product, polyvinyl chloride, PE, PET, polycarbonate, APB, polystyrene, etc. can be used. Not only domestic, but also imported polymers are supplied.

Previously, the rates were as follows:

• high-quality polyethylene - from 56 rubles. for 1 kg;
• polypropylene - from 50 rubles.

In addition to the main raw materials, modifying additives and dyes will be required for the production of products.

Among domestic suppliers, you can conclude supply contracts with:

• Stavrolen is one of the largest chemical plants producing more than 400 thousand tons of polymer raw materials using modern technology.
• PoliTer is a company that supplies granulated polypropylene to the market from Ufaorgsintez manufacturing plants and the Turkmenbashi refinery complex.
• Centropolymer is a leading distributor of polymers, additives and colorants.
• NPP Neftekhimiya is an enterprise engaged in the production of Rispol (branded polypropylene) and other grades of granular raw materials.
• Tobolsk-Polymer- the third enterprise in the world for the production of polypropylene, which annually synthesizes about 500 thousand tons of material.
• Unitrade is a company that organizes the supply of polymer of the required grade and quality for the production of various plastic products.
• Tomskneftekhim is a production site that provides Russia with more than 30 grades of polypropylene raw materials.
• Koros - specializes in the supply of polymeric materials, engineering plastics from any country in the world.
• Poliom is a company producing over 90 grades (180 thousand tons) of material.
• Kartli - organizes complex cargo transportation of polymer and other oil products, purchase by installments is possible.

3) What technology is used for the production of plastic goods?

The choice of technology is influenced by the type of products that the entrepreneur plans to manufacture.

To produce bottles, bottles, flasks, they resort to extrusion method. The production of plastic blisters, cups, packaging is achieved through vacuum forming. Most often, work is carried out according to the method blowing and casting(toys, bottles, etc.)

But there are other techniques as well:

The casting algorithm takes the form:

First mix all the ingredients. If a homogeneous mass is obtained, gas under pressure is introduced mechanically by foaming. The gas filling of raw materials is also carried out by introducing additives into the heated plastic, which, at the required speed, lead to boiling.

When the mass is brought to the required consistency (the state of flexibility and elasticity), they begin to create a matrix form. The model is made of aluminum, fiberglass, resins in accordance with the required shape and dimensions of the products.

If the production of plastic products will be small-scale, use composite molds; aluminum matrices will fit for large-scale production.

Then they move on to the actual education and refinement:

4) Workshop equipment: equipment for the production of plastic products.

The production process requires special equipment. For this purpose, separate machines are used or automatic lines are purchased.

Depending on the type of plastic products, the technological method, these types of products are acquired.

a) extruders.

These are machines that produce window profiles, plastic pipes, hoses, sheet film, etc.

Flat-slot units consist of elements:

b) Injection molding machines.

They are machines that are used in the process of molding a plastic mixture under pressure. With their help, the mass is poured into the matrix, after which it is cooled. This is how handicrafts are made.

On the planet, about 75% of all plastic products are produced from such installations. Injection molding machines make it possible to produce products of complex shape, hollow, multi-colored, reinforced, hybrid.

The design consists of:

Such equipment for the production of plastic products is expensive and has various innovative solutions. It is of several types.

c) Blow molding machines.

Suitable for enterprises producing jerry cans, large bottles, barrels, other hollow containers with large volumes and thin walls. The machine heats the plastic material to a certain temperature and then blows it into the desired shape.

d) For the production of PET.

In order to be engaged in the production of PET containers, it is necessary to purchase injection-blow molding units that combine 2 methods, for example, extrusion-blow molding mechanisms.

These machines make a variety of plastic products: tanks, buckets, packaging for dairy products, ketchups and sauces, bumpers, toys, bottles.

The production process is controlled by a microprocessor.

The device of the machines contains:

e) Thermoforming machines.

A technique designed for the production of products, the raw material of which is a film of various thicknesses. Typically, the thermoforming machine is used in the production of cups, plastic containers.

They can be operated manually or configured automatically/semi-automatically.

Machines are of different types:

• tape,
• single position,
• rotary, etc.

The main mechanisms are listed above, but additional devices are used to facilitate the production process.

For example:

• loaders, conveyors;
• dryers, mixers;
• crushers, conveyors;
• refrigeration units (chillers), etc.

If you are going to be engaged in the production of small plastic items in small quantities, the best option would be a mini-machine weighing up to 15 kg. Some models are even equipped with a table.

Extrusion lines controlled by special programs can be bought from China. They quickly pay off, are cheaper than European counterparts, uninterrupted in operation, unpretentious in maintenance, and have safety certificates. Production facilities are also often provided with domestic equipment.

5) Personnel policy at the enterprise for the production of plastic products.

The workshop will require 2-10 workers. The number of employees will be affected by the equipment purchased (if it is an automatic line, fewer people are needed). The scale of production is also an influencing factor.

Be sure to hire a technologist who will be the main link of the staff. Therefore, his salary is higher. In addition, the production of plastic products needs an administrative department, a sales manager, an accountant.

You also need to improve the logistics. And for this you need: a driver, laborers for loading and unloading, a vehicle. The duration of one shift is 10 hours.

6) Features of the implementation of plastic products: marketing and advertising policies.

For the implementation of plastic products, it is better to use all kinds of distribution channels. However, first think about how you will advertise the products. If the budget allows, place ads on the radio, the media.

Invest in building your own website. All serious companies have web resources on the Internet in order to attract as many customers as possible. This makes it possible to place orders online, which is also beneficial for entrepreneurs.

Someone needs to be instructed to monitor the content of the site. Therefore, you will have to hire one or two more people who will publish new content, interesting articles on the site, accept and process orders.

Organize the distribution of leaflets with the contacts of your company for the production of plastic products. You can offer products to various retail outlets, construction bases, department stores.

Everything will depend on the type of product. If you plan to engage in the production of plastic toys, you need to sell goods to children's stores. As you expand, include special offers, promotions, etc. in your sales policy. Events.

It is better to work directly with the consumer or through a single-level distribution channel. If you use multi-level distribution channels, the final price will be high for the buyer, and he will most likely not buy your products.

When the product distribution system is designed in advance, problems with product sales rarely arise.

Production of plastic buckets as a business idea.

How is the technological process carried out?
Description of equipment from China.

7) Start-up investment required for the production of plastic products.

It is impossible to draw an accurate financial plan without knowing the nomenclature and production volumes of plastic products. Therefore, here are some excerpts based on real examples.

Profitability can reach 20-30%. The economic benefit is formed depending on the products that are produced, their cost and selling price.

The items of expenditure will be:

• rent and repair of premises;
• utilities;
• purchase of raw materials and equipment;
• wage fund;
• fare;
• tax payments;
• advertising and distribution costs;
• registration costs;
• unexpected costs.

Equipment can take 1-3 million rubles. For 1 ton of plastic material, you will have to pay 60 thousand rubles. Imported brands are more expensive (80-150 thousand rubles). You also need to take into account the cost of additives (330-450 rubles per 1 kg). At least 300 thousand rubles should be allocated for salaries.

For the production of buckets and similar goods from plastic, 3 million rubles will be enough. The organization of the production of plastic children's toys requires an initial investment of about 5 million rubles. For the manufacture of disposable tableware, you need to have from 8 million rubles.

With a competent approach to the organization of production, sales, monthly income should be about 500 thousand rubles. The investment will pay off in 1-2 years.

The production of plastic products should be opened with an adequate assessment of one's own capabilities. Such an intention has undeniable advantages, but also disadvantages. Therefore, before starting such a business, weigh the pros and cons well.

Useful article? Don't miss out on new ones!
Enter your e-mail and receive new articles by mail

For the production of more than 30% of all products created from polymers, such a common method as plastic injection molding is used. It allows you to get a very wide range of products that find their application in various fields.

Plastic injection molding refers to the process of injecting a polymer alloy into a special mold. After that, the workpiece is cooled. As raw materials for such production, special powders with thermosetting properties are used, as well as thermoplastic granules. In this case, the first type of material can be used only once - during the casting process, irreversible changes occur in it. The second one is quite suitable for further processing, which makes it possible to reduce the cost of products from such "used" plastic.

Modern high-quality equipment makes it possible to make the casting process fully automated, but do not forget that the technology itself is quite complex and requires constant monitoring at each stage of production. In addition, devices that carry out injection molding of plastics are characterized by a rather high cost, and also require sufficient qualifications of craftsmen working with them.

For the above reasons, plastic injection molding is usually carried out on a production scale, because with only small volumes of orders, the acquisition of such devices simply does not pay off. However, sometimes firms need plastic parts or other custom-made products. In this case, our company will come to the rescue, because we perform plastic injection molding to order, and we do it as quickly and efficiently as possible. We will produce for you the necessary batch of products, while guaranteeing that all the details of the process during their casting will be observed.