Own business: production of sandwich panels

Repair and construction business Building and decoration materials

Sandwich panels are called modern building material, which has a three-layer structure (like a sandwich, which is why it got that name). It consists of two sheets of hard material (metal, PVC, fiberboard or magnesite plate can be used as such) and a layer of insulation located between them. All three layers of which the panel consists are glued together by hot or cold pressing. Depending on the purpose of the material, roofing and wall panels are distinguished. Wall panels, in turn, are divided according to the type of external profile into smooth, simple profiled and decorative profiled (siding and log) panels. Roofing sandwich panels are profiled on both sides or only on one outer side. According to the type of external sheet coating, sandwich panels are divided into panels with galvanized steel, drywall, various plastic sheets based on PVC and other polyurethane compounds, oriented chipboard (OSB). As a heater, polyurethane foam, fiberglass, expanded polystyrene, mineral wool (based on basalt fiber) can be used.

Sandwich panels are used everywhere for the construction of new and reconstruction of old facilities. These materials can significantly reduce the construction time of buildings. They are used in the construction of residential buildings, warehouses, industrial halls, garages and even shopping centers. Such panels have excellent heat and sound insulating properties, so they can be used for both external and internal decoration. The popularity of this material is explained by its practicality, economy and extreme ease of use in the construction of various objects. Sandwich panels are lined with multi-storey buildings (office and residential) and small retail outlets, so that they acquire an aesthetically attractive appearance.

Sandwich panels have a number of undeniable advantages over traditional building materials. They are very light (a square meter of the panel weighs no more than 4 kg), durable and shockproof, made from difficult to combustible materials, resistant to ultraviolet, frost and heat resistant. At installation of panels additional fitting is not required. Due to their light weight, sandwich panels can significantly save on transportation and installation, since they do not require complex and expensive lifting mechanisms and special heavy equipment to work with them.

They reliably retain heat indoors, while not letting cold and heat outside. Individual panels, which have a beautiful appearance and do not require additional decoration, are easily assembled in a monolithic design. In addition, they are produced in various colors, so you can choose the right shade for the design.

However, it was not without drawbacks either. The main one is the relatively high cost of components for the manufacture of sandwich panels (when compared with the production of materials such as chipboard, fiberboard, MDF, TsSP, corrugated board, OSB). However, even with this in mind, the final cost of construction of a sandwich panel is ultimately lower than the cost of a similar structure built using traditional materials (due to ease of installation, low transportation cost, better wear resistance, etc.). Thus, the production of sandwich panels, which are always in high demand in the building materials market, is an excellent and profitable business idea. If you are going to engage in this type of business, first of all, you need to decide on the range of products. Despite the fact that the choice of panels on the market is quite large, experts advise beginning entrepreneurs to focus on one or two main areas, and subsequently, when your company starts to generate stable profits, it will be possible to think about expanding production. The most popular wall sandwich panels made of galvanized steel with mineral wool as insulation. Such materials are bought mainly by companies involved in the construction of residential and industrial facilities, commercial premises, retail stalls and pavilions. In addition, a significant share of sales is provided by private buyers who use sandwich panels in individual construction (residential low-rise buildings, summer cottages, etc.).

As raw materials for the production of panels, galvanized steel with a thickness of 0.5 to 0.7 mm is used. This steel is delivered in rolls of 1250 mm wide. The inner part of the steel sheet is usually primed, and the outer is painted. You will also need a basalt fiber insulation (mineral wool), which comes in a package of 1200 mm by 600 mm per 100 mm. To connect the layers, one-component polyurethane-based adhesive is used.

For the manufacture of sandwich panels from profiled galvanized sheet, special automated lines are used. The process itself is quite simple and includes several basic operations. First, on the machine, by molding or cutting, the insulation is cut into lamellas of specified parameters (width, length and thickness). On the milling machine (the so-called slot selection device) a lamella lock of the insulation is formed. The metal roll is placed on a special rotating drum. When unwinding, the metal sheet passes through the input device of the rolling mill. On this device, if it is provided for the manufactured products, a protective film is applied to the sheet, after which its surface is profiled with a pattern. Here, the hidden lock of the future panel is formed. Then, a sheet is placed on the assembly table with the primed side up, onto which glue is subsequently applied using equipment or manually. Insulation lamellas are also automatically or manually placed on this adhesive layer, on which a layer of glue is also applied. On top of this glue, a third layer is planted - this time a profiled sheet. A three-layer structure is placed under the press, where, under the influence of high temperature and pressure, the sheets adhere firmly to the insulation. Finally, the panel is transferred to the reception table and transported to the warehouse, passing first through the sandwich panel packaging device. For this, automated packaging equipment can be used. But often, in order to save money at small enterprises, packaging is carried out manually.

For the production of sandwich panels, the following minimum equipment will be required: a line for the production of sandwich panels, a beam crane, a loader, an auxiliary tool. Lines of various manufacturers, including domestic ones, are represented on the Russian market. Many of them offer equipment in various price categories, which differs mainly in performance. The cost of the simplest line with a capacity of 120 square meters. meters of panels 9 meters long per shift is 2.8 million rubles. A line with a capacity of 500 square meters. meters of panels up to 12 meters long per shift will cost 2-2.5 times more expensive. Even if you are limited in funds, do not rush to purchase the cheapest line. First of all, you need to carefully analyze the demand for such products in your region, agree on sales with construction companies, and forecast sales dynamics at least 1.5-2 years in advance. If the competition in your region is high and you cannot offer your partners more favorable prices than other manufacturers, then you should give preference to simpler and cheaper equipment. With real prospects for a rapid increase in sales, you should not save, otherwise you will still have to sell your equipment with a loss in money and acquire new, more powerful equipment in a few months or a year. You can start this business with one line with a productivity of up to 120 sq. meters of panels per shift. In addition, for loading and unloading, transporting raw materials and finished products to the workshop and warehouse, you will need a forklift (its cost is 100 thousand rubles) and a beam crane for five tons (market price - 160 thousand rubles).

To accommodate the production of sandwich panels, production areas of 1, 500 square meters will be required. meters with good ventilation and heated rooms (temperature in them should not be less than 18 ° C). With production volumes up to 120 tons of products per shift, the help of three to four workers is needed. If you want your company to work around the clock, the number of employees will increase to 9-10 people. Since working with equipment does not require special skills and all the wisdom of the production process can be studied on the spot, there is no need to hire highly qualified specialists (accordingly, it will be possible to save on wages, but spend time and money on staff training). You will also need to hire an accountant, sales manager and financial director. Consider in advance the issue of delivery of finished products. To do this, you can use your own transport (in this case, costs will increase significantly) or conclude an agreement with a transport company (the best option for a small business).

It takes about thirty business days to locate production from scratch. With the choice of suppliers of raw materials, too, problems should not arise, since there are more than enough offers on the market. There is a choice both in terms of raw materials, in price, and in quality.

Capital investments for organizing the production of sandwich panels include: the purchase of an automated line (about 3 million rubles), the purchase of lifting equipment (1-1.5 million rubles), the cost of equipment delivery, installation and commissioning (about 500 thousand rubles), the purchase of raw materials (per month about 1 million rubles), other expenses (250 thousand rubles). Thus, total expenses will amount to about six million rubles.

With a half-load of equipment (and most of all, most likely, at first it will not be needed, since you will still need to establish sales) and a 22-day working month with eight-hour shifts, the productivity of a small enterprise will be 1320 sq. meters of finished panels per month. The cost of one square meter of sandwich panels, taking into account the use of raw materials (depending on its type), is from 500 to 800 rubles.

Wholesale price ranges from 1000-1250 rubles per square meter. The implementation of panels in products (hangar, change house, house, block box) is 2000 p. per square meter. Thus, the company's revenue can reach 1.6 million rubles per month. The payback of such a project with estimated investments is two years. Demand for sandwich panels, as well as for all other building materials, depends on the season. The peak of sales is from spring to autumn. In winter, you should not count on big sales.

Sysoeva Lilia

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