Instead of boring walls and ceilings, painted with ordinary paint, came wallpaper with beautiful prints and stretch ceilings. However, despite this, the volume of water-dispersion paint produced (which is often called water-based paint) continues to grow. Moreover, such a production is considered one of the most cost-effective and profitable, as there is no fierce competition in this segment of paints and varnishes.
The volume of the Russian paint market is about 500 thousand tons of products per year. Moreover, imported paint occupies a little less than half the market (about 45%). The share of imports is constantly growing. The main competitors of domestic manufacturers include Finnish (approximately 40% of imported paints), Polish (16% of the total foreign paint market) and German (14%) companies. The remaining small part falls on Ukraine, Slovenia, Turkey, France and Italy. Products of 150 brands are represented on the paint market (80 of them are of foreign origin). Thus, domestic manufacturers still have room to grow. The first place in distribution is given to the Dufa brand, and the second to Tikkurila. The third place belongs to the products of the Russian brand Tex. Then come Poli-R, Sadolin, "Halo", "Aquatex", "Yaroslavl paints" and Alpa.
Foreign products still dominate the segment of water-based paints (in contrast to the segment of oil and pentaphthalic enamel). As surveys and studies show, domestic paints and varnishes are in demand among consumers with middle and lower than average incomes, as well as among small construction organizations. Foreign products, on the contrary, are more popular among consumers with an income level above the average and among large construction organizations. Now in Russia there are about 200 enterprises that produce paint and other paints and varnishes.
Water-dispersion paint is a pigment dispersed in an aqueous medium and binders that together form a homogeneous emulsion. These polymer components do not dissolve in water, but are in it in suspension in the form of tiny particles. After applying the paint to the surface, the water evaporates, the dispersed particles come together and adhere to each other, forming a dense polymer film. This coating is characterized by good density and abrasion resistance. There are several varieties of water dispersion paints that differ in manufacturing technology, as well as in the binder polymer used in the production. In particular, the paint is acrylic, acrylic latex, silicone and silicate water-based.
What is the reason for the popularity of water-soluble, as they are also called, paints? First of all, with efficiency and ease of application. Most often they are used for painting walls and ceilings. However, furniture and other wood products are also coated with acrylic paint. Such paints do not contain organic solvents, therefore, they do not have a sharp unpleasant odor and are considered environmentally friendly. Water-dispersion paints are applied with a brush, roller or spray. Such a coating perfectly adheres to the base, is easy to clean, resistant to moisture and has a long service life.
If you plan to engage in the production of paints and varnishes, first of all, you need to register a legal entity, choose a room for the workshop, purchase equipment and raw materials, hire workers. The main requirements for the premises are the availability of heating and ventilation, an area of more than 30 square meters. meters, the presence of a water supply or storage for water, the voltage in the network 220 / 380V. The type and cost of the necessary equipment depends on the paint technology you plan to use. The minimum amount required to purchase a production automatic line is 250-300 thousand rubles. Production lines include a vacuum system for the injection and delivery of raw materials. The main equipment includes bead mills, vacuum loaders, dissolvers (there is also such a spelling - disolvers), mills, cooling systems, filters, packaging equipment.
About 100-150 thousand rubles will be required to purchase the first batch of raw materials - fillers, binders and modifying additives, thickeners and pigments. Let us consider in more detail the technology for the production of water-dispersion paint. This process includes several basic steps: connecting and mixing an aqueous solution of a polymer dispersion with a filler and a pigment, dispersing the obtained pigment paste, introducing additives that help bring the paint composition to the TU standard, filtering and packing the finished product. As a result of a procedure called dispersion, the liquid and solid components are ground to a state of dispersion. This is how aerosols, emulsions, powders and suspensions are made.
Mixing and dispersion of all components of water-based emulsion paints is carried out in bead and ball mills, which are called dispersants. The pigment paste, which is obtained as a result, is fed into dissolvers-mixers, with the help of which the components are mixed with a frame mixer. At the same time, the equipment allows dispersing loose paint components (pigments and fillers) with a milling mixer. The frame (it is also called anchor) mixer mixes components at revolutions from 60 to 120 revolutions per minute. Bulk components are crushed on the mill with a higher shaft rotation speed of 1000-1200 rpm. Often, instead of a multifunctional dissolver-mixer, dissolvers with a central shaft with a mill without a frame mixer are used. All equipment for the production of paint, including communication pipelines, must be made of stainless steel (or at least coated with glaze from the inside). Screw pumps are used as pumps for pumping finished paint to the water-dispersion paint production line, as other pumps (for example, centrifugal and gear, which are more common in the paint industry) destroy dispersion, as a result of which the paint loses its properties.
At the last stage, the finished paint passes through strainers and is poured into cans using automated equipment. It consists of a conveyor belt of cylindrical rollers made of stainless steel, a system for feeding and orienting containers, feeding, orienting and capping lids, as well as a storage system. An important requirement for the conditions of production: the entire cycle of work should take place at an air temperature of at least five degrees Celsius.
The following components are most often used as binders in water dispersion paints: polyvinyl acetate (PVA), styrene butadiene (BS), styrene acrylate (CA), acrylate (A), versatate (BC). Each of them has its pros and cons. For example, PVA-based paints have a limited scope, since they are not waterproof enough, although they have the lowest price. Styrene-butadiene dispersions are resistant to water, but change color when exposed to sunlight. They are also inexpensive, but are used only for internal work. Styrene-acrylate dispersion paints are more expensive, but they are more versatile, form porous (rather than dense, like paints with PVA and BS), vapor-permeable coatings with high light fastness and excellent adhesion (adhesion). Versatate dispersions appeared not so long ago. They have the properties of acrylic paints, but are cheaper. Acrylic paints are more expensive than styrene-acrylate paints, are similar in properties to them, but are more rigid and resistant to ultraviolet. They are used for painting wood, the production of facade coatings and other materials.
The initial capital, which is necessary for organizing our own production of paints and varnishes, is about 500-600 thousand rubles. This amount includes rent, the purchase of equipment and raw materials, a salary fund for the first month of the enterprise, registration costs. Monthly expenses include rent, payment of electricity and water, salaries to employees.
Competent pricing is of great importance. As you know, the cost of production and profit from its sale is determined by the volume of production and assortment. According to various sources, the average profit from one ton of manufactured materials is about 30-35 thousand rubles. However, it is not enough just to paint. We must also be able to sell it profitably. In order for the new enterprise to compete in the middle and upper price segments, its products must be of high quality. Of great importance is the marketing policy of the company. The costs of advertising and promoting such products depend on the target audience and market (whether you work only at the regional level or at the national level). For example, about 15 years ago in our country no one heard about the paint brand Tikkurila. However, the Finnish company, thanks to competent marketing, managed to quickly conquer most of the market. Despite the fact that the products of domestic manufacturers have their undeniable advantages. First of all, this is the price. The cost of domestic products, comparable in quality to Western paints, is much lower. For this reason, large foreign companies open subsidiaries in our country. The quality of domestic manufacturers, unfortunately, is still lame. Experts attribute this to the fact that many Russian entrepreneurs have not yet realized the importance of this factor and prefer to save, not strictly observing production technology. The most far-sighted of them have already acquired their own laboratories, constantly monitor new trends in the production of paints, and invest in research to improve quality and reduce production costs. But, of course, in these cases, the payback period for the production of water dispersion paints will be longer - about 2-2.5 years.
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