Paving slabs continue to maintain a leading position in the construction products market. For exterior decoration, owners of private houses and organizations traditionally choose this material. This means that the production of paving slabs as entrepreneurial activity can be a profitable and promising endeavor.

Nevertheless, any entrepreneur who decides to open his own business in this direction needs to prepare for the fact that great competition awaits him. However, since this business is currently one of the most profitable, in demand and promising, to achieve success you only need to develop a competent business plan for the production of paving slabs.

Main properties of the project

Target of this project– determination of the economic efficiency of creating an enterprise for the production of paving slabs. Ready business plan can be used as a commercial proposal during negotiations with potential investors or creditors.

The relevance of the paving slab manufacturing business lies in the high performance qualities of this material and its popularity in the market. Paving slabs are environmentally friendly, durable, easy to use, and also economical. And thanks to new technologies, the life and quality of its service increases significantly.

Creation project manufacturing enterprise for the production of paving slabs is designed for 2 years - during this period, according to the plan, all starting investments will pay off. The business plan takes into account all risks and possible force majeure situations that can reduce the company’s profits and even contribute to its unprofitability.

There are three main goals for creating a workshop for the production of paving slabs:

— creation of an enterprise with a high level of profitability;

— meeting demand in the relevant market segment;

- obtaining high profits during the period indicated in the plan.

To achieve these goals, it is planned to open an enterprise that will produce paving slabs intended for arranging sidewalks in populated areas of any nature and purpose.

General funding indicators are as follows:

— the cost of the project as a whole, including all types of costs, is within 5.5 million rubles. It is envisaged that a commercial loan in the amount of 5.5 million rubles will be received for opening and developing a business. The interest rate will be 16%;

— the investor’s income, or the total amount of interest paid on the loan, will be 270.9 thousand rubles;

- general economic effect from the implementation of a project for the production of paving slabs within a specified period - 34 million 413 thousand rubles or more under favorable economic circumstances.

The preliminary payback period will be 1 year. But in the event of force majeure or additional costs, this period can be extended to 2 years.

Technical features of making paving slabs - in the video:

Stages of starting a business

The main list of stages for opening a workshop for the production of paving slabs from scratch includes:

— development of a plan and preliminary financial calculations;

— registration of the enterprise with the Federal Tax Service;

- rent of a plot and production premises(if you have your own material and technical base, prepare it for the start of the production process);

— purchase of equipment and raw materials;

— personnel selection;

- start of the production process.

Considering a two-year period of enterprise development, you can draw up the following detailed step-by-step plan:

Stages	Execution conditions	Deadlines
Start of the project		1 – 2 year
	1 month project	First 30 banking days
Getting a loan	Availability of a mandatory package of documents	1 month
Entry into the state register, registration with administrative and tax authorities	Concluded investment agreement	From 1 to 30 calendar days
Selecting a location, completing documentation	Preliminary work	1 month
Concluding a lease or purchase agreement for a land plot	Investment agreement	1 month
Purchase of equipment	Conclusion of an investment agreement	Up to 30 calendar days
Equipment installation	Receiving investment funds	Up to 30 calendar days
Hiring	Production activities	Up to 30 calendar days
Training	The end of the stage of organizing the production process	Up to 30 days
Conducting a marketing campaign	30 calendar days	Up to 360 calendar days
End of the project		12 – 24 months

Business registration

To get started, it will be enough to register as individual entrepreneur. The law does not require registration of a legal entity for such activities, and at first the individual entrepreneur format will indeed be more successful.

The process of registration of an individual entrepreneur requires the submission of a minimum of documents of the founder: copies of the passport, identification number, as well as a receipt for payment of state duty in the amount of 800 rubles. These documents are submitted by first filling out an application for registration of an individual entrepreneur using the standard form. In addition to the personal data of the entrepreneur, it contains a code according to the OKVED classifier. It must be selected using the valid classifier (). If there are no additional activities, code 23.31 (“Production of ceramic slabs and tiles”) is suitable. The prepared package of documents must be submitted to the territorial office of the Federal Tax Service, and after 3 - 5 days the applicant is issued a completed certificate.

If there are several founders, an individual entrepreneur will not be suitable for registering a company - you will have to choose one of the existing formats of a legal entity. The best option– limited liability company. In this case, the list of documents to be submitted will be more extensive, and a special entry fee will also be paid - authorized capital in the amount of at least 10 thousand rubles. The procedure for registering and operating an LLC is regulated by special federal law 14-FZ (http://www.consultant.ru/document/cons_doc_LAW_17819/).

Paving slabs do not require careful certification. This feature greatly simplifies the process of business legalization. But if you wish, you can obtain a product quality certificate. This document will be a good help in competition and will help a newcomer to the market acquire regular customers and partners. You can obtain such a document from a special certification service. Products must first be tested for strength, resistance to frost, moisture and other qualities. If the verification is successful, the manufacturer will receive the required certificate without any problems.

Regulatory documents useful for doing business:

Equipment

Paving slabs are made by two different methods:

• vibration pressing,
• vibration casting.

Depending on which technique is chosen, the purchase of various production equipment will be required.

To produce tiles using vibration pressing technology you will need:

• Vibropress (its cost is about 20 thousand dollars)
• Concrete mixer (about 6 thousand dollars)
• Punch (about 3 thousand dollars)

Equipment for manufacturing by vibration casting is much less expensive. The list will include the following items:

• Vibrating table (about 4 thousand dollars)
• Molds (about $1-$18 each)
• Concrete mixer (about 600 dollars)

Other types of equipment that will be needed for the production process:

• — hyperpress (makes it possible to obtain large volumes of products under high pressure;
• — conveyors for moving materials;
• — dispensers;
• — cement silos for storing cement;
• — control panel for automation of dosing, weighing and supply of solution;
• — cleavers for splitting concrete products;
• - shelving. It is better to choose steel racks that have high strength.

You can purchase a ready-made production line. It will cost more than purchasing individual pieces of equipment, but will greatly simplify the manufacturing process.

Technology business plan for the production of paving slabs

When developing a business plan for tile production, you need to take into account the technological features of this process. First of all, you need to familiarize yourself with the diagram of the vibrocompression method. This technology is also used in the manufacture of borders, wall and partition stones.

Production steps include:

1. Preparation of concrete. First of all, you will need a concrete mixer. In this case, the number of layers should be taken into account (if there are two of them, two concrete mixers are needed). The finished molding mixture is placed in the matrix of a vibrating press (mold).
2. Molding. Then the punch and vibrators are launched, resulting in a reaction of vibration pulses, and the material is gradually compacted. Next, the product is sent to dry in a tray.
3. Drying. To bring the tiles into a finished form, heat and moisture drying is used, for which water steam is used. If you need to reduce production costs, you can dry the product directly indoors, without using the heat-moisture drying method.

The production of paving slabs using the vibration casting method occurs as follows:

1. Prepare the mixture.
2. Concrete is placed into molds on a vibrating table.
3. The finished forms are placed on a pallet.
4. The resulting mixture is left for 48 hours.
5. The hardened form is heated, then the product is knocked out.

Making tiles requires sufficient quantity forms They can be rubber, plastic or polyurethane. Since production technology can vary significantly depending on the choice of material, it is worth familiarizing yourself in advance with the significant features and differences of each of them.

PProduction and organizational features of tile manufacturing are below:

Selection and preparation of production premises

There are no special requirements or restrictions on the location of the workshop. The main thing is the size of the area, which should allow all equipment to be placed, as well as compliance with all technical specifications. Geographically, the workshop can be located on the outskirts of the city, in an industrial zone or outside settlement. It is advisable that it be adjacent to a highway or major road, which will facilitate the delivery process.

To equip a workshop, it is best to rent a former production facility - it usually initially has all the necessary conditions, including sufficient power electricity, water supply and other necessary communications.

The most suitable size is from 70 sq. meters or more. To operate the equipment, you will need an uninterrupted electrical voltage of 360 V or more. Special conditions requires a drying chamber - it needs to maintain the desired temperature within 45 degrees.

When renting a workshop, you should pay attention to the presence of a large and dry warehouse, a heated office for communication with clients and partners, as well as the work of management and administrative staff. For these purposes, it is necessary to have a telephone connection and the Internet. Care should be taken in a timely manner to equip utility rooms and bathrooms for official use.

Staff

If the production volume does not exceed 50 sq. meters of finished tiles per day, there is no need for a large number of personnel. In such cases, a team of three people will be sufficient, who will be involved in the process of directly preparing concrete, pressing and sending the batch for drying. To service large-scale production, a larger staff will be needed.

At first, while the workshop produces a small amount of products, the role of sales manager and accountant can be performed by the manager himself. When expanding production, the customer base will increase, and to work with them you will need a separate employee with experience in sales. Accounting will become more complex as the enterprise develops. Therefore, within the first year you will need a full-time specialist in the field of accounting and tax reporting. In the first months of the company's operation, these services can be provided by outsourcing specialists.

The staff will also need support staff - loaders, security guards, cleaners.

Sales of finished products

An important stage will be the sale of products. To acquire a wide and stable customer base, you should provide them with the entire range of tiles produced. The right action would be to organize production in such a way that the assortment includes a variety of products that satisfy the needs of all groups of potential buyers. At first, you should not take on large orders; it is better to firmly consolidate your position among small firms or individuals.

With the development of production, it makes sense to enter into long-term contracts with large enterprises that purchase large volumes of paving slabs for construction, repair work or further sale. The specifics of the marketing campaign and the choice of advertising methods depend on the type of potential buyer.

Marketing plan and advertising

The general structure of the world and national market suffered negative changes during the crisis years of 2013–14. At this time, there was a decrease in sales, and therefore in the production of all types of construction and finishing materials. At the same time, the crisis also had some stimulating effect on the industry: the struggle for clients between market representatives intensified, as a result, the quality of the products of surviving enterprises improved.

In order to easily enter a market where there is no shortage of tile manufacturing enterprises, you need not only to offer the buyer a quality product at an attractive price, but also to attract attention. To do this, you need to immediately set priorities and decide on your target audience. So, you can focus on selling finished products to retail customers or focus on wholesale sales. In the first case, the cost of sales will be higher, but you will have to spend more time and money on advertising and attracting buyers. Having chosen wholesale sales as a priority, at the first stage it is enough to conclude long-term contracts with several large buyers.

One of the features of the sale of paving slabs is the presence of a concentrated consumer market. This means that it is usually easier and more profitable to sell products within your region. Consequently, the advertising campaign will be aimed at a limited circle target audience.

Taking into account the already known characteristics of the market, it is possible to determine the most accurate circle of the target audience. Main categories of buyers:

• — construction organizations carrying out orders from municipal authorities;
• — construction companies working privately;
• — individuals or organizations purchasing tiles for personal needs.

One of the trends in this industry is a slight but stable increase in demand from private buyers by 10 - 15% annually. But in order to maintain and increase this indicator, you need to resort to the main working methods of advertising:

— dissemination of information via the Internet: your own website with detailed information And feedback. In addition, you need to advertise your products on thematic websites and forums, online bulletin boards;

Timely placement of advertising will play a very important role. Since the greatest peak of construction and renovation work occurs in spring and autumn, the main emphasis on advertising activities should be done just before this time.

The participation of the enterprise in thematic events - specialized exhibitions and fairs will be effective. There you can present samples of your products, exchange contacts with potential buyers and partners, and study the structure and dynamics of the market.

Financial plan

The main cost items required to open and further development companies, in terms of several:

• Initial investment:

1. Commissioning works - RUB 110,000.00.
2. APN - 540,000.00 rub.
3. Press D2430 - 470,000.00 rub.
4. Concrete mixer SBR-500 - RUB 69,000.00.
5. PP TR mold - RUB 210,000.00.
6. Scales MK-15.2 - RUB 4,200.00.

Total: RUB 1,403,200.00

2) Remuneration. Calculation for a minimum staff of 3 people:

• manager (salary from 25 thousand rubles),
• APN operator (salary from 25 thousand rubles)
• auxiliary worker (salary 20 thousand rubles)

Thus, the wage fund must be at least 70 thousand rubles (for one shift per month; 140 thousand rubles for two shifts). With the development of the enterprise, wages should increase, which will allow retaining qualified workers.

When paying the unified social tax (UST) - 26% of the total income.

• Production area

It is advisable to allocate about 100 sq.m. area in order to place the necessary equipment and create an area for storing materials and the products themselves. The warehouse can be located outdoors, but also requires at least 100 sq.m. Heating in a production area is not a mandatory requirement for working conditions. If rent for 1 sq. m. is 100 rubles, then the total cost of renting the entire premises should not exceed 10,000 rubles. The rental cost per 1 sq. m. is also calculated. m of product. It will be 2.38 rubles.

4) Cost of materials and energy. The total cost of raw materials, which includes polymer, sand and pigment, per 1 ton will be 3,794 rubles. This means that the cost of raw materials per 1 sq.m. finished tiles is 136.58 rubles.

Cost of 1 sq. m. paving slabs:

The profitability of this type of business, when properly organized, exceeds 100 percent. This is facilitated by the fact that even defective products can be used (for example, in construction), so the loss rate will be minimal.

A detailed cost plan for opening an enterprise for the production of paving slabs will include the following items:

Expense item	Expenses per month	Expenses for the year	One-time costs	Total expenses for the year
Buying a concrete mixer			127400	127400
Vibrating tables (pouring, stripping)			90000	90000
Forms			33600	33600
Transformer			61600	61600
Pallet truck			20160	20160
Loader/beam crane			3800000	3800000
Baths (for washing molds, for stripping molds)			22400	22400
Wheelbarrows, trowels, shovels and other equipment			28000	28000
Production technology, technology training			61600	61600
Cost of raw materials (per 2 thousand km of tiles)	100000	1200000		1200000
Salary	250250	3003000		3003000
Website creation, promotion	55000	660000	110000	110000
Wiring			214200	214200
Unexpected expenses			456800	456800
Total	405250	4863000	5025086	5073626

Regardless of the chosen business format fiscal year for any enterprise begins in January. From this month, the necessary tax payments are calculated. The list and tax rates of main contributions to the Federal Tax Service are standard and include the following:

To calculate the amount of income of an enterprise, in addition to the cost, you need to analyze the current market prices for finished products. The price list will be based on the average prices of the corresponding market segment and the amount of production costs.

Average cost of paving slabs, in rubles per sq. meter:

The cheapest traditionally will be gray tiles, the most valuable and expensive is white, produced without the use of dye. The higher the quality of the materials used in production, the more expensive the cost will be, and therefore the price of the finished product.

The company's sales forecast will be determined based on the following criteria:

— results of analysis of consumer demand for paving slabs;

— market analysis data for tile production enterprises;

— general conclusions regarding the state of the paving slab sales market.

The calculations take into account the lowest profitability threshold. The plan must consider all existing risks in the industry. These primarily include a high level of competition and a significant barrier to entry into the market. So, in order to open production, significant initial investments are needed for the purchase of equipment and raw materials. At the same time, without a high-quality marketing policy, it is impossible to fully enter the market and take a strong and profitable position in it.

Taking into account the main stages of creation and development of the enterprise, a service provision plan is drawn up:

Period	Type of service	Volume of services provided per month	price, rub.	Sales revenue, thousand rubles.
1 – 6 month of investment		2000 sq.m	500 – 540 per sq.m.	1000 – 1100 thousand rubles
1 – 6 month of investment		2000 sq.m	From 560 per sq.m.	From 1120 thousand rubles.
	Production of paving slabs	2000 sq.m	540 sq.m	1000 – 1100 thousand rubles
7 – 12 months of operation	Laying tiles and related work	2000 sq.m	From 580 per sq.m.	From 1150 thousand rubles.

At the moment, the market growth rate is at the level of 10–15 percent. If this level continues over the next 1 - 2 years, the growth in sales volumes will reach 26.7 million per year or more. The main condition that will help overcome the entry barrier is to provide the enterprise with modern and high-quality equipment. The second important advantage of a tile production workshop will be the selection of qualified personnel. An active marketing campaign and a well-designed advertising plan will speed up the process of business promotion.

A business plan for the production of paving slabs includes average cost calculations and an approximate profit forecast for the production workshop. Specific financial indicators may differ due to objective and subjective factors, risks and changes in the market. Taking into account the high level of demand for paving slabs among individuals and enterprises, it is possible to make next output: with good preparation of the material base and careful study of the sales market, a tile manufacturing workshop will be a profitable and promising undertaking.

Features of the business of producing scarves from scratch - in the video:

• Where to begin
• Search for premises
• Paving slabs
• Glowing paving slabs
• Curbs
• Which equipment to choose

Production technology

Do I need permission to open?

• • • Similar business ideas:

This article will discuss the organization of a small production workshop for the production of paving slabs and related materials or mini-production. Why "mini"? Because the lion's share of those interested in this business want to start with small capacities, due to the lack of proper capital. And then, as volumes grow, move to another level. Those who have a lot of money, as a rule, are not interested in such articles.

Where to begin

Before setting up production, you can do one simple thing - try to resell paving slabs. Believe me, this is the most difficult thing not only in a particular case, but in any other manufacturing business. Spending your hard-earned investments on equipment and setting up technology is not so difficult; it will be much more difficult to sell the entire volume produced. To completely reduce any risks, you can work for a similar company for some time. The best position is sales manager. Such an employee, due to his job responsibilities, usually knows the entire “kitchen” of any production. And for you, as a future business organizer, best option and you can't imagine it. This is an invaluable experience that will help save you millions in the future. You won’t find in any article on the Internet everything that you will find in practice.

Search for premises

What you can definitely save on at the beginning is the premises. The quality of the tiles produced does not depend in any way on where you are - in a perfectly renovated room or in the courtyard of your home. At first, any large rental costs can be detrimental to your business, so if you decide to rent something, take the cheapest options. For example, in the industrial area of ​​the city. Of course, you shouldn’t take the entire “departure” of the workshop. The main thing is the availability of convenient access roads and uninterrupted electricity. The rest of the “delights” can be neglected at first.

Assortment of goods - what to produce in a mini-production

What you shouldn’t skimp on at the beginning is developing the range and technology for making tiles. As noted above, the buyer does not care where the tiles were made. He cares about quality and price. If you can make a product that is competitive in terms of price and with the proper quality, you are guaranteed success. If you study the reviews of existing businessmen, you will understand that it took many manufacturers years to perfect the technology for making paving slabs. For the most part, this is due to the fact that the organizers did not really invest in this direction, but did everything themselves, by trial and error. I don’t think you are interested in such a scenario.

It will be interesting:

• Feasibility study for the production of paving slabs
• Production of paving slabs - profitability from 50%

Hiring an experienced technologist familiar with this production can help in developing the technology. As an option, you can contact a company that has been producing tiles for a long time and which at the same time sells technology. Such companies exist, you just need to look for them. As a result, you can come to an agreement and generally become an official representative office in your region. This is good for you because you receive full advice on starting a business, from choosing equipment and developing technology to advertising and establishing sales. What exactly can be produced in a mini-production environment? Read on.

Paving slabs

A popular material for covering paths, approaches to buildings and street sidewalks. Very easy to install and resistant to temperature changes. Does not melt in the sun and does not emit harmful substances when exposed to direct sunlight. It can be made from several types of raw materials, but concrete (a mixture of cement, sand, plasticizers and water) is considered the most popular and affordable. Portland cement grade 500 should be used optimally. The most common product shapes are rectangular tile, hexagon, coil, thick, square, diamond and wave. In the production of paving slabs, two well-known technologies are used - vibration pressing and vibration casting. We'll talk in more detail about choosing a production method below.

Glowing paving slabs

A slightly more expensive, but increasingly popular coating is considered to be luminous paving slabs. In its production, concrete is used as the top layer with the addition of a luminous component - phosphor, which does not lose its properties for 200 years. Phosphor is a chemical composition that has a light-accumulative memory. The light energy collected during the day is then released at night. Imagine how unusual a night path made of luminous paving slabs looks. If you correctly convey to the buyer all the advantages of this product, you can earn very good money. Of course, you should not place the main emphasis on the production of these products, but as an expansion of the assortment, luminous tiles can be a good help. Because from time to time you may come across clients who are ready to overpay for a highlight in the design of their local area or recreation center.

Curbs

Often, in parallel with paving slabs, a road curb is also made. This is a popular material used in the construction of courtyard driveways and sidewalk paths. The technology for making curbs is similar to the technology for making paving slabs. The main difference is that heavier grades of concrete (B 30) are used for the curb. The most frequent customers of road curbs are: government agencies who take large orders through a tender (auction). Most purchased lines for the production of paving slabs also have the ability to produce wall and partition blocks. This material is used for the construction of non-load-bearing walls in low-rise and high-rise construction. The raw material for wall blocks is high-quality concrete produced from cement, purified water, inert filler and plasticizers. They are produced using the same vibration pressing method.

Vibration pressing or vibration casting

All manufacturers, from small to large, agree that the best way to produce paving slabs today is the vibrocompression method. It has a number of advantages over the vibration casting method. To understand the difference, let's first briefly describe each technology.

Production technology using vibration casting

When vibrating casting, compaction of the concrete mixture occurs in special polypropylene forms placed on a vibrating table. Vibration is carried out using an electric motor. After 18 - 24 hours, the product is removed from the mold and sent to the warehouse. The resulting tile is almost perfectly flat. In fact, this is the only advantage of this method, not counting the low cost of the equipment and technology itself. Video - production of paving slabs using vibration casting method

Several obvious shortcomings immediately catch your eye. The first is production speed. Due to the fact that each product must be kept in the mold for a long time, productivity will be extremely low. Or you need a lot of forms (and places to store them), which will require corresponding costs at the start. Moreover, each forum needs to be poured, then formwork must be done, and all this requires time and manual labor. Another common problem that occurs when using vibration casting is that the tiles are of different thicknesses. As a result, this affects the quality indicators of the entire batch. When laying such tiles, protrusions and depressions are possible. The vibration casting method is most often chosen by small manufacturers with extremely limited capital, who are ready to reduce the productivity and quality of manufactured products just to save money at the initial stage. But will this do any good? Controversial issue.

The vibrocompression method requires several large investments at the start, because it is necessary to purchase the appropriate installations - vibropresses. The price of even the lowest-power press is at least 300,000 rubles. During vibrocompression, the concrete mixture is placed on a mold standing on a bed. The bed constantly vibrates. At the same time, a pressure of 35 atmospheres is applied to the mixture using a punch. The punch also vibrates continuously. The entire process takes no more than 6 seconds, after which the punch rises and the finished product remains on the pallet. As a result, even the most budget presses are capable of producing 45 square meters per shift. m of paving slabs (in monetary terms this is about 16,000 rubles in revenue). The tiles are more dense, frost-resistant, much less manual labor is required and raw materials are significantly saved. Moreover, a decrease in the water-cement ratio allows the use of budget cement grade M-400. Ultimately, this all affects the lower cost of manufactured products, in contrast to tiles produced using vibration casting technology. This results in higher net income from 1 quarter. m.

Selection of equipment (brick presses)

The choice of equipment depends entirely on the amount of capital that the entrepreneur is willing to spend. The more expensive the equipment, the higher its automation, as a rule. That is, the more you invest in the strategy, the more you can potentially earn. For example, you can simply purchase a machine that will press tiles. And the remaining operations will have to be done manually. At the same time, you can purchase additional equipment that will, for example, stack tiles on a pallet. There are even separate lines that automatically place products on racks and send them to the steaming chamber. The savings on manual labor are colossal, but the difference in price can amount to hundreds of thousands of dollars. e. Also, when planning your budget, it is worth taking into account the costs of purchasing press forms. Because each individual type of tile (triangle, square, etc.) requires its own unique shape. That is, the higher the range of products, the more varied forms are required. The price of a new form can reach up to 10,000 USD. It often happens that purchasing a set of molds costs several times more than purchasing the brick making machine itself.

When producing large volumes of paving slabs and other products, the question of purchasing a batching unit may arise. BSU is an installation that prepares large volumes of concrete mixture (1-2 tons each) in just 2-3 minutes. Such devices are prohibitively expensive. For small volumes, at first a regular concrete mixer will do. As for the choice of manufacturer, Finnish and German presses have proven themselves well (for example, Hess). European equipment is distinguished not only by reliability, but also by extremely high productivity and production quality. True, the price for such equipment is appropriate. Plus, with the recent increase in the exchange rate, the purchase of foreign presses is becoming less and less justified.

Which equipment to choose

The best option is to purchase Russian-made equipment. For example, a lot good reviews You can find information about the Rifey and Condor installations produced by Stroytekhnika Plant LLC, which is based in Chelyabinsk. The advantages of their equipment are the versatility of production. For example, the Condor - 2 installation is capable of producing wall blocks (70 pcs./hour), partition blocks (100 pcs./hour), paving slabs (6 m2/hour) and Lego bricks (30 pcs./hour). The price of such a device is 310 thousand rubles. True, for each type of product you will need to purchase several types of punch dies, each of which costs from 29 thousand rubles. Therefore, the estimated amount of investment in equipment of this type will be 700 - 900 thousand rubles.

Brief calculation of the cost and profitability of the production of paving slabs using the vibrocompression method

Cost calculation for 1 sq. m. paving slabs 100x200 mm:

• Cement - 150.8 rub.
• Sand - 55.0 rub.
• Pigment - 36.0 rub.
• Water - 0.34 rub.
• Electricity - 5.53 rub.
• Operation of capital equipment - 0.78 rub.
• Operation of production premises - 5.11 rubles.
• Operation of auxiliary equipment - 8.0 rub.
• Indirect costs - 7.73 rubles.
• Salary - 40.99 rub.
• Contributions to the Pension Fund and Social Insurance Fund (25% of salary) - 10.25 rubles.

Total - 320.52 rubles. Retail price one sq. m of paving slabs in the regions averages 510 rubles. Profit before tax is: 510 - 320.52 = 189.48 rubles. Taking into account taxes (USN, 15% of profit), net profit from the sale of one sq. m. is 161.06 rub. When selling only 1500 sq. m of paving slabs per month, the company’s net profit will be 241,590 rubles.

Where to start opening a business

If you decide to create own business to create paving slabs, you need to start such a business with the following steps:

• choosing the premises in which the production of paving slabs will take place (the ideal place would be an industrial zone located close to raw material bases);
• selection of equipment that will be used to create paving slabs (to increase productivity, preference should be given to automated equipment);
• choose the technology that will be used in the tile manufacturing process;
• Certification is optional, which will allow potential buyers to purchase goods from you more confidently.

How much money do you need to start a business?

To open a business for creating paving slabs, the initial capital can be about 170 thousand rubles. The list of costs includes:

• 10 thousand rubles. - purchasing desks for work;
• 70 thousand rubles. - purchase of vibrating screens and vibrating tables;
• about 6 thousand rubles. - purchase of a drill;
• 14 thousand rubles. - necessary equipment;
• 20 thousand rubles. - purchase of concrete mixers;
• about 20 thousand rubles. - rent of premises if necessary;
• 15 thousand rubles. necessary for the design of racks on which finished products will be sold;
• 1 thousand rub. - registration with the tax office;
• 14-20 thousand rubles. will be required for other expenses associated with the purchase of necessary materials.

Which OKVED code to indicate when registering a business?

Manufacturing of various concrete products used in the construction process - OKVED code 26.61. You can also indicate OKVED code 26.30 - production of plates and ceramic tiles and OKVED code 26.66 - production of other products from gypsum, concrete and cement.

What documents are needed to open

To open your own paving slab production business, you must prepare the following documents:

• a document confirming the opening of an individual entrepreneur or LLC;
• photocopies of birth certificate, passport data and identification code;
• statement;
• a receipt confirming payment of the state duty.

All documents are submitted to the tax office at the place of registration of the future entrepreneur.

Which taxation system to choose for business registration

When choosing a taxation system for the production of paving slabs, preference should be given to a simplified or unified taxation system.

Production technology

When starting production of paving slabs, you should prepare the following materials.

The construction segment today is second only to the telecommunications sector in terms of the level of implementation of new technologies. Literally every day they talk about “new breakthroughs” and the emergence of new “unique” technologies. Such activity does not always correspond to real needs and, even more so, to real market opportunities. Practice shows that good old technologies not only remain in demand, but also provide excellent chances to start your own business with small investments. The realities of small business in 2015 show rather illusory prospects for the construction market, but the question remains, what should construction teams do, how to look for an alternative to make money?

The answer can be found in related areas, in optimizing the business itself. As one of the alternatives (in truth, the option is good for organizing a new business), you can consider organizing the production of paving slabs using the vibration casting method.

How much does it cost to produce paving slabs?

The level of depreciation of fixed assets is not just high, but very high, this applies to all aspects, including sidewalks. If we talk about the roadways, those same roads, the situation is no better; this issue belongs to the sphere of interests of the “big” bosses, as a result they are, at the very least, repaired. The situation is completely different with sidewalks; no money is allocated for them; the specifics of their repair do not allow for much acceleration. From practice, I can say for sure that 3-4 times more can be “appropriated” from one square meter of road. Most sidewalk repairs in cities, small towns, and private households are left to small businesses. What does this mean in practice?

At organizing a full cycle from production to laying paving slabs, the business receives significant benefits in the form of:

• - flexible pricing policy. The final price of the finished product will not include the price of an intermediary (as in retail sales - 20-50%, the cost of a foreman's services - 20-30%). In fact, this means that tiles can be laid at a 50% discount without losing average profitability.
• - individual approach to the client. Selection of shape, color, it is possible to take into account the individual characteristics of the site.
• - full range of services. If we consider that for the mini workshop itself, raw materials (screenings, cement) will be purchased at wholesale prices from established suppliers, then de facto the client pays and actually receives everything at once at the optimal price.

By and large, it is this complex option that makes it possible to talk about the business of producing paving slabs as an option for construction crews to repurpose.

Do not forget about the profitability of the business, two main points:

• - the production of sidewalk tiles has a profitability of 40-50% for wholesale sales and about 80-90% for retail sales;
• - using the same equipment (except for molds) you can produce very wide range products, not just tiles.
• - profit from laying sidewalks also reaches 50%.

In total, due to the full cycle, it is possible to achieve about 100% profitability, and due to the wide range of products, “smooth out” seasonal fluctuations in demand.

For example, for the period of the “winter season” we can repurpose ourselves into the production of concrete countertops and figures.

Technologies for the production of paving slabs

If we consider the market as a whole, we can distinguish three main technologies:

1. Clinker tiles.
2. Vibrocasting
3. Vibropressing

Relatively clinker tiles, one thing can be said, expensive. Moreover, in all other respects, high-quality clinker products are better. Such products are made from clay and then fired at high temperatures. Such production is expensive to organize and requires special permits and high-quality raw materials. In the end, it turns out to be expensive, this technology goes into the realm of big business. In terms of their technology, they also have a lot of nuances, ranging from the availability of really high-quality raw materials (not all clay is suitable) to the need to maintain a constant technological cycle. Recently, a friend’s “lights” were turned off for a couple of hours, and then they spent a week “picking out” the frozen clay.

One more The manufacturing technology for paving slabs is vibration compaction. The method is undoubtedly good and has its advantages:

• - firstly, the possibility of widespread use of automatic processes. If you have money and desire, about 90% of all processes are done by automatic machines.
• - secondly, higher wear-resistant performance.

There is a downside though:

• -expensive equipment. Such a workshop cannot be called small; its organization will require quite a lot of money, as a result, it is necessary to immediately aim for large sales volumes.
• - the cost of such products is higher than that of tiles made by vibration casting.
• - higher stability shows itself effectively only in cases of intense loads. For example, if you use tiles as paving stones on a road with heavy traffic (cars) or a very large flow of people.

Vibrating casting - in this option for the production of paving slabs we are talking about traditional casting using a vibrating table, this option is suitable for home businesses. The technology itself simply does not require any additional, much less special, equipment other than the table itself. In fact, the procedure is a chain:

Concrete (cement-sand mixture) is prepared in concrete mixers, consisting of:

• cement;
• sand;
• granite crushed stone fraction 5-10 mm;
• plasticizer C-3;
• air-entraining SNV additive;
• pigment.

Ready concrete is laid out into molds on a vibrating table;

The mixture in the molds is given the required density on a vibrating table;

The forms with the solution are put on racks, covered with PVC film and kept for 24 hours;

The molds with the frozen mixture are heated in a bath of warm water;

The products are being stripped;

The tiles are laid on pallets, where they are kept for a certain period until they are completely ready.

pros

• - low cost of the finished product;
• - small starting investments;
• - maximum business flexibility. Products can be made in small batches of any shape and color.

Minuses

• - high level of manual labor;
• - strict linkage of production volume to the workshop area.

What equipment and premises are needed?

The total area for a small workshop should be about 60 square meters, plus rooms for final drying of paving slabs. The main condition is:

• - availability of electricity and water.
• - heating. To obtain a strong product, it is necessary to comply with the drying conditions; in cold periods, you need to “raise” the temperature, and in hot periods, lower it. Drying too quickly leads to loss of quality.

Among the equipment it is necessary to highlight

Concrete mixer - about 20,000 rubles.

Forms for pouring tiles. It must be emphasized that today there are four variations of forms on the market:

Metal forms. The most expensive, one of the advantages is the possibility of long-term use, and the disadvantage is the cost.

Rubber, can be used up to 500 cycles.

Plastic – 250 cycles

Polyurethane – up to 100 production cycles.

Which forms to buy is a rhetorical question; practice shows that when choosing forms you must be guided by one principle - rationality. Expensive, more durable rubber or metal molds will work for popular molds. But when making non-standard or one-time orders, it is worth buying cheap and short-lived plastic or polyurethane.

Vibrating table. Its cost largely depends on the size, quality, and supplier. By and large, you can make it yourself.

Table for stripping. Simply an irreplaceable thing and assistant, especially in conditions of seasonal intensity.

Bath for washing molds. After making the tiles, all molds must be thoroughly cleaned; a “dirty” mold is almost 100% defective.

Rokla hydraulic. Also, at first glance, it is a rather unnecessary thing, but when working with working volumes of tiles, its transportation and transportation without a roller is a tedious, labor-intensive process of palletizing.

and activities

It is very difficult, one might even say unrealistic, to calculate the real cost without specific information about the region and the availability of raw materials. On average in the market, the level of profitability of production is about 30-45%, while it fluctuates significantly depending on the remoteness of the resource base, this is due to the presence of cement factories, granite and sand quarries. The closer, the cheaper the raw materials, the higher the level of profitability. One of the most significant factors for a small mini paving slab workshop is the low dependence on fixed costs, which allows you to “freeze” production very quickly and start it up just as quickly, without using significant financial resources.

Advertising and sales of finished products

Very often, small businesses (especially if the business belongs to the home business category) do not attach much importance to advertising and beautiful presentation of their goods; this is perhaps one of the most common mistakes, as a result of low sales volumes at the beginning of the project. Subsequently, “popular rumor” and “word of mouth” do their job, but this happens later. I would advise you to take product advertising seriously and suggest the following options:

• - first. Preparation of bright advertising brochures. Moreover, the booklets should contain high quality photos, a large selection of various shapes (you can take it from sites selling ready-made forms for paving slabs) and colors. The fact is that even for a small order you can always save money and buy cheap molds made of plastic or polyurethane. Plus, the cost of several thousand advertising brochures will not be that expensive. When distributing brochures, the main thing is to choose the right place and contingent.
• - second. Advertising in newspapers is required, especially since you will have the opportunity to lay tiles. For a small paving slab workshop, you can rent a large banner; again, the main thing is to choose the right location.

Alternative and related activities

Small-scale production of paving slabs has another significant advantage, this is the ability to expand the range of products and services offered, in particular:

• - tile laying services.
• - production of fences, curbs, gutters.
• - using almost the same set of equipment you can make concrete garden figures or kitchen countertops, window sills, and even fountains.
• - a minor modernization and you can start producing cinder blocks, and if you have money, then foam concrete (you need to buy a high-speed concrete mixer).

The list can be continued; today there are great amount concrete products, most of which can be produced at home, including paving slabs and paving stones.

Video example of making paving slabs with your own hands

DIY paving slabs

We organize a small mini workshop with our own hands for the production of paving slabs

• Step-by-step business plan for the production of paving slabs: where to start
• How much money do you need to start a business?
• Production of paving slabs: what documents are needed
  • • • Similar business ideas:

The starting investment in opening a paving slab production business is no more than 200 thousand rubles. Business profitability reaches 50%, and equipment payback is only 3 months.

Characteristics of paving slabs

The attractiveness of tile production lies in the fact that the state and private individuals are beginning to increasingly use it for laying sidewalks and personal plots. And this is logical, because paving is more reliable, easier to repair and looks much more attractive than concrete or asphalt. And the laying process itself is understandable to many homeowners, in contrast to the same asphalt, the laying technology of which is known by at most 5% of the country's population.

To produce paving slabs with a volume of 1000 m2 per month, you will need to rent a premises with an area of ​​at least 100 m2 with a warehouse and space for installing a drying chamber. The cost of renting such premises ranges from 20 to 30 thousand rubles per month, depending on the region.

To organize a mini-production of paving slabs, it is enough to attract no more than 3 people. At the initial stage, you will need one molder, molder and accountant.

What equipment to choose for making paving slabs

The total cost of purchasing such a set of equipment will be about 130 thousand rubles, taking into account the purchase of plastic molds.

When choosing equipment for the production of paving slabs, it is recommended to pay attention to domestically produced equipment. It can and does partially lose in manufacturability and level of automation imported analogues, but our equipment is cheaper, easier to repair, easier to find spare parts and, due to its simplicity, does not require hiring highly qualified workers.

The starting materials for the production of paving slabs are screenings of crushed stone, sand, Portland cement, chemical additives (plasticizers, concrete modifiers, etc.), dry pigments and water.

Paving slab production technology

The technological process for the production of paving slabs is not complicated, and includes such steps as preparing the concrete mixture, preparing molds, forming on a vibrating table, holding the products in the molds, stripping the products and packaging the finished tiles.

The key element in tile production is the molds. Molds can be plastic, rubber and polyurethane. Rubber molds are considered the most practical, as they can withstand up to 500 cycles of use. Plastic molds are slightly inferior in strength, they last for 200-250 cycles, and polyurethane molds last only 100 cycles.

Before pouring concrete, forms are lubricated with chemical additives based on the C-3 plasticizer, which improves the mobility of concrete when spreading, increases the strength and frost resistance of products.

To prepare concrete, it is recommended to use cement grades M500 and M400. Crushed stone with fractions of 0.5-0.10 cm is used as coarse aggregate, and construction sand with a particle size of at least 2 is used as fine aggregate. Crushed stone and sand are mixed in proportions 1:1.

After preparing the concrete mixture, it is placed in molds and compacted on a vibrating table. Then the vibrated products are placed on a pallet and sent to a drying cabinet, where they are kept in molds for 24 hours.

The molding of the tiles is carried out on the molding table using attachments. Unmolding one tile takes about 5 seconds.

Upon completion of stripping, the finished tiles are placed on pallets. Products are packaged using packaging scissors, tape and metal staples. The tile gains its final strength within 21 days.

The cost of producing 1 m2 of paving slabs is on average 250 rubles. In this case, the main costs consist of material costs and wages of hired personnel. The wholesale price of tiles reaches 450 rubles/m2.

How much can you earn by starting a paving slab production business?

Net profit after paying all taxes is 120 rubles/m2. When producing paving slabs with a volume of 1000 m2 per month, the entrepreneur’s profit is about 120 thousand rubles.

The payback of the equipment, provided 100% of the produced tiles are sold, can be only 3 months.

It’s not easy to make tiles, and it’s even harder to sell them. The market is overflowing with all kinds of offers. Tile manufacturers in last years a lot appeared. When opening a business, you must solve the problem: to whom and how to sell tiles. This is very important because after hiring labor and purchasing equipment, you will have more serious problems. And it’s even worse if at this time you have no distribution channels for your products.

“The production of paving slabs is a business with low threshold occurrences. I bought a concrete mixer, a couple of molds, some raw materials, hired workers - that’s the whole business. Such mini-productions are opened even in garage conditions,” says Alexandra Leonidova, deputy. Development Director of CJSC Irkutskzolotoproduct.

“The competition in our business is so great that, despite the rise in cement prices by 30%, we are forced not to increase prices for tiles,” says Mikhail, one of the tile manufacturers.

In addition, most products are far from ideal in quality. Saving at the start, manufacturers purchase cheap equipment and use simple production technology using vibration casting. As a result, their products are much inferior in quality to those produced by companies with expensive and technologically advanced equipment.

Therefore, the only correct way today is to produce high-quality tiles at an affordable price (not higher than the market average). This is the only way to ensure that your products will be in demand.

It is also worth considering the fact that the production of paving slabs is a seasonal activity. It is produced when the construction market revives, that is, in the spring. At other times of the year, it will not be possible to sell tiles, especially if production is opened in the northern regions. For this reason, for many enterprises this is more of an additional profile of activity rather than the main direction.

How much can you earn?

Income from the production of paving slabs, even with the same selling price from two different manufacturers, can differ dramatically. And the reason for this is cost. The costs of producing paving slabs greatly depend on technology and raw materials. For example, the vibration casting method, which traditionally requires more manual labor, will increase labor costs, hence the cost of the finished product will also increase.

A lot depends on the type of raw materials used. To produce a high-quality product that will have increased frost resistance, it is necessary to use washed sand. But such raw materials are several times more expensive than ordinary sand. This again increases the cost of production. It is not advisable to save on components: due to low-quality raw materials, your tiles will crumble in 2-3 years, which will damage the company’s reputation. There is only one thing left - to optimize production processes and survive due to the volume of output.

The average cost of paving slabs produced by vibration pressing is 270 rubles/sq.m. The sales price is about 350 rubles/sq.m. Profit per square meter is only 80 rubles. It turns out that in order to earn 80 thousand rubles a month, you need to sell 1000 sq.m. finished products. This is from 15 to 20 buyers per month.

Equipment and technology

The cost of purchasing equipment depends entirely on the technology used. Today, two main technologies for the production of paving slabs are known: the vibration casting method and the vibration pressing method.

The first option is more often used by beginning entrepreneurs who do not have large investments. To start a business using vibration casting technology, you will need to purchase a minimum set of equipment: a concrete mixer, a vibrating table, a set of molds, as well as available tools: mittens, shovels, buckets. The cost of the entire set, including the purchase of raw materials, will amount to no more than 150 thousand rubles.

To produce one square meter of tile, 40 to 50 molds are required. The mixture poured into molds is kept for about 2 days. Thus, continuous production will require at least two sets of molds. This technology allows you to organize a business virtually at home, and labor process involve family members and relatives.

Experienced market players point out several disadvantages of this technology:

1. Very low performance. One square meter will take two days to dry, but what if you receive an urgent order for 100 square meters? To perform such work, you will have to purchase an incredible number of forms (several thousand), as well as have a large staff of workers. Many people note considerable losses of cement with this method. Hence the high cost of production.

2. Low quality of the resulting products. The tiles produced using this technology have low frost resistance, and their service life is no more than 4 years.

“The production of paving slabs using the vibration casting method cannot be called a serious business,” entrepreneurs say.

Video of the production process of paving slabs using the vibration casting method:

Another technology - the vibrocompression method - is designed to eradicate all the shortcomings of the above method. The essence of this technology is that the tiles are produced by vibrating the mixture with a small amount of water. The equipment used is special installations (mini-factories) - brick presses. Concrete produced by vibrocompression has a low cement to water ratio. This means that this reduces the consumption and loss of cement, increases the strength and frost resistance of finished products. The main advantage is the productivity of the line. With the help of even a small Russian-made brick press you can get from 20 to 30 sq.m. tiles per hour. Accordingly, in an eight-hour work shift, 160 – 240 sq.m. can be produced. tiles At the same time, only 3-4 people are enough to service the installation. With such capabilities, you don’t have to worry about even the most urgent orders.

The method has only one drawback - investment in starting a business. Purchase new installation— the line will cost from 850 thousand rubles, depending on the productivity of the line and the types of products produced. For example, the Rifey Udar brickmaking press (Zavod Stroytekhnika LLC) will cost about 1.7 million rubles:

Expensive, but the machine is universal and can produce not only paving slabs, but also lawn grates, curb, pillar, wall and facing stones. Thus, it is possible to expand the list of products and significantly increase the capabilities of the enterprise.

Production of paving slabs using Condor installations

Who is the client and how to sell tiles

Buyers for paving slabs are different. It is bought by both owners of small summer cottages and pensioners, who take 2-3 sq. m. Shop owners buy from 20 to 40 sq. m. m., and the owners of the cottages - 60-70 square meters.

Selling products is a whole science, and each manufacturer has its own methods in this regard. You can offer goods to wholesale resellers, but they ask for the goods at a discount. You can also supply tiles to retailers, construction markets and retail chains specializing in the sale of building materials.

For smaller, artisanal producers, the classic way of selling products may be suitable. You can stand by the road, lay out several product options and hang a “Paving Slabs” sign. If the road has a large flow of cars and there are large cottage communities nearby, then an influx of buyers is guaranteed.

A more expensive, but most effective project is creating your own online store selling paving slabs and other things. building material. Internet trade is gaining momentum today, which can be a promising channel for selling products. The creation and promotion of an online store will cost up to 150 thousand rubles. The service will also require hiring a certain number of sales managers and a web resource administrator.

Business development options

Some entrepreneurs combine production and laying of paving slabs to increase profitability. The price of one square meter of tile is on average 350 rubles, and its installation costs the customer 400 rubles per square meter. It turns out that having your own team of stackers, you can earn another 40 - 60% of the profit. But this is more often done by small manufacturers; large players are not interested in this process.