Dry building mixes are carefully prepared mixes for various purposes, which consist of mineral binders, aggregates and fillers, mixed in strictly proportioned proportions, and polymer modifying additives. To give the mixtures the special properties necessary in a given situation, they can also include various accelerators or, conversely, hardening retardants, blowing agents, defoamers, water repellents, coloring agents and other additives. In construction, two main types of mixtures are used - commercial and dry. The first are made according to traditional technology and arrive at the facility in a form ready for use. The second ones, as the name implies, are delivered to the construction site in dry form. There they are brought to full readiness for use by adding to them in water in a given amount. Sometimes after mixing the dry mixture with water, it must be maintained before re-mixing for 10-15 minutes.
Dry building mixes have a large number of advantages over commodity (liquid) mixtures, which explains their popularity and relevance. In particular, they are distinguished by a more stable composition, which is ensured by careful preparation of all components and their exact dosage. They can be stored for a long time (including at low temperatures) without deterioration of the initial properties of the mixture, they are convenient and beneficial to transport (dry mixes weigh much less than commodity).
Unlike traditional dry mixes in finished form are characterized by higher homogeneity, since they are prepared immediately before use, increased cohesion and, therefore, higher non-separability and better water retention capabilities, better adhesion to substrates and higher strength of the applied layers. Dry mixtures have a lower consumption (they can be mixed with water, if necessary, even in small portions and applied in thin layers). Accordingly, their use allows to increase labor productivity (since the preparation and use of the mixture does not require much effort).
Finally, there is a large selection of dry building mixtures that are intended for one or another purpose - facing and finishing work. There are several main classifications of the types of mixtures: by type of binder, dispersion of the filler and the main purpose. In the first case, cement content and cementless mixtures are isolated. According to the dispersion of the filler mixture, there are coarse-grained (with the largest aggregate fineness up to 2.5 mm) and finely dispersed (with the fineness of filler grains no more than 0.315 mm). According to the scope and purpose of dry building mixes, there are plaster protective and finishing (for exterior and interior decorative sections), plaster (leveling - for leveling walls and ceilings), primers (to improve the adhesion of finishing layers to the base), and putty (for sealing shells and irregularities before finishing), painting (for interior and exterior decoration of buildings), glue (for laying tiles, gluing heat-insulating materials and reinforcing mesh in light plaster thermal insulation translational systems and grouting between the tiles).
Thus, the production of dry building mixes for specialized stores, bases, wholesale trading and construction companies, private customers is a profitable business, which, which is especially pleasant, practically does not depend on seasonal fluctuations in demand (at least, like other types of construction products ) Its organization requires a relatively small start-up capital. A high profitability (it is 23%) and a large demand for high-quality and competitively priced mixtures allows you to quickly recoup all costs at the initial stage.
Any dry mix consists of a binder, fillers and additives. White and colored cements, gypsum, lime, and also Portland cement act as an astringent. All these components, of course, must meet the requirements of regulatory documentation. Fractional quartz sands are used as fillers. They, in turn, are obtained by crushing marble, limestone and other rocks, as well as finely divided fillers of various types (marble and limestone flour, etc.). To give the mixtures certain qualities and properties, various water-retaining, plasticizing, air-entraining, polymer and other additives are used. To add color to the mixture, certain pigments are added to them. Powdery superplasticizers are used as plasticizing additives, which make it possible to reduce the water saturation of the mixture and, therefore, improve the stability of the prepared mixture and increase the strength of the hardened solution (mainly domestic production, but additives from foreign companies are also found). Depending on the purpose of the finished composition, a separate formulation is developed and a certain ratio of all components in the mixture is used.
When drawing up a business plan for your production of dry building mixtures, you need to decide on the range of products. There are positions that are always in high demand. These include various adhesives (facade, tile, wallpaper), mixtures for cement screed, waterproofing compounds, compositions for bulk floors, putties (gypsum, cement, finish, facade), mounting mixtures, gypsum plasters.
The production process of dry construction mixtures includes certain stages: preparation of components and their transshipment, sieving, placement of raw materials in consumables, dosage, mixing, packaging, storage. This process itself, as you can see, is quite simple, but it requires the use of special equipment. You will need a production line (a set of typical equipment and molds). For its location, depending on the type and configuration of the line, you need a room with an area of 120-180 square meters. meters (industrial premises 100-120 square meters. plus a warehouse of 50-80 square meters.), and for maintenance will require at least four workers and one technologist. The temperature regime in the production room should be maintained at a level of 16-18 degrees Celsius, so that it should be heated and equipped with a hood.
There will be no problems with the search for equipment for the production of dry mortar. The composition of one line includes: a mixer, a filling hopper with an auger, sand drying, a vibrating screen, an automatic auger. You will also need electronic scales, commodity scales, various devices, tools and Euro pallets. You can buy an inexpensive installation with a capacity of 5 tons of products per hour (although packaging on it is carried out only in a semi-automatic mode). The cost of such a line is about 1.6 million rubles. An installation with a productivity twice as high (10 tons of products per hour) with a filling machine will cost almost twice as much (about 2.9-3 million rubles). From raw materials you will need Portland cement (white and gray), quartz sand, calcium carbonate, hydrated lime, chemical modifying additives, etc. Their cost is from 10 to 170 (the most expensive - modifying additives) rubles per kg. To work in production on one shift, you need a workshop master technologist, a metering and mixing station worker, a packer and a loader.
So, we will calculate the main expenses: rent of production and storage facilities (from 18 thousand rubles per month), purchase of equipment (1.6-3 million rubles), transportation (200 thousand rubles), purchase of raw materials for the first two months of operation ( about 400 thousand rubles), wages by employees, other expenses (100 thousand rubles). To organize a small production of building dry mixes (with a productivity of about 12 tons of products per shift), a minimum of 2.5 million rubles will be required.
The raw material cost of one 25 kg bag of adhesive composition is, for example, 60 rubles. The production capacity of the equipment is 480 bags. Thus, the raw material cost per day is 22 thousand rubles, plus production costs - 4 thousand rubles. Total, the total cost (excluding taxes) is 26 thousand rubles. The average market price of one adhesive bag is 160 rubles (over 72 thousand rubles for 480 bags).
However, in order to get such a profit, you need to establish marketing of your products. These can be shops (regular and online stores) of building materials, construction bases, construction companies, etc. Bear in mind that in the first months of operation, your production will work at best at 50% of full capacity. And the competition in the market of dry mortar is already quite high. At the same time, it makes sense to sell such products only to your region. As experience shows, it is advantageous to transport dry construction mixtures at a distance of not more than 300 km from production. The farther the distance, the higher the transportation costs.
Manufacturers and sellers of equipment and production technologies claim that already in the third month of work, you will produce and market all 12 tons of products produced in one shift. But this is only possible if you can produce a wide range of mixtures and at the same time as quickly as possible (while maintaining high quality and attractive prices). In addition, do not forget that although dry mixes are not considered seasonal goods, there is still a slight decline in this segment from November to March. This also needs to be considered when calculating payback periods. On average, they make up, under other favorable conditions, from one year.
Sysoeva Lilia
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