Equipment for the production of paints and varnishes. Profitable business: production of paints and varnishes

Protective and decorative coatings obtained by applying acrylic paints, are durable, chemically resistant and have low toxicity. Enterprises producing them are characterized by a short payback period and low complexity of the equipment used.

What is needed to organize the process

The list of requirements for launching a production line is very small compared to the preparation of non-aqueous paints. The central device in which the process of dispersing the acrylic binder, fillers and additives in water occurs is the dissolver.

TO auxiliary equipment relate:

• wooden and metal pallets;
• containers for collecting and temporary storage of paint;
• containers for bottling the finished product;
• electronic and commercial scales;
• forklift and hydraulic trolley (for large production volumes).

The dissolver can be purchased as a working device or assembled in a workshop yourself. An important step is the acquisition of technology for the production of the finished product. Technological regulations can be developed independently if you have the appropriate skills and time.

Raw materials

The following components are used in the production of acrylic-based paints:

• saturated acrylic dispersion;
• dispersant - to increase the resulting emulsion;
• calcium carbonate is a standard filler and pigment in cheap paints;
• thickener - gives the mixture the necessary fluidity;
• defoamer – prevents foaming of the product when mixing and dispersing;
• coalescent – ​​promotes film formation;
• inorganic based pigment. The most popular among paints white obtained titanium dioxide.

Premises requirements

Suitable for producing acrylic paint non-residential premises with an area of ​​over 40 m2 (no more than 80 m2 at the initial stage). The workplace must have natural and artificial lighting, natural ventilation, water supply and sewerage.

A significant advantage of the production of water-acrylic emulsions is the absence of the need for special exhaust system. The low tendency to evaporate most components requires the use of only standard protective clothing.

Staff

To take into account the specifics of production, a technologist with appropriate experience or education is needed. Organizing a production line without a specialist will not be as effective.

Monitoring and operation of the equipment can be carried out by two workers at the same time. For continuous production, three work shifts per day should be provided.

Acrylic paint production

The technology for preparing a mixture for acrylic paints is as follows:

1. an acrylic mixture and solid pigment are loaded into a dissolver filled with water;
2. mixing of the mass is started until it becomes homogeneous. Pieces of pigment are additionally ground to a specified size;
3. during mixing, other additives are introduced to ensure that the paint achieves the specified qualities (according to technical conditions or regulations);
4. After mixing is completed, the mixtures are packaged and stored at a low temperature (2º). The paint should not be allowed to freeze, since the emulsion will delaminate irrevocably.

The preparation time for the product is 1.5-2 hours. During operation, the temperature is maintained at 16-18º, which requires the workshop to be equipped with air conditioning and heating systems.

For construction

The most large-capacity and highly competitive enterprises produce construction paints(for example, for painting, etc.). Their equipment is represented by large dissolvers with a long operating cycle. Particular attention is paid to the place of storage and packaging of goods, since the demand for construction acrylic paints fluctuates throughout the year.

The process of making façade acrylic paint for construction is shown in the following video:

For nails

The peculiarity of the manufacture of decorative ones is the use of small dissolvers with high degree dispersing solid additives. Since the profitability of producing paints alone color range is low, several parallel mixing streams should be provided.

For fabric

differ from their counterparts for construction work less aggressive liquid environment.

Ensuring dense and uniform impregnation of the woven fabric is possible by using high-quality dispersing additives that facilitate the penetration of the dye and binder between the fibers.

For drawing

They constitute a narrow segment of production in which there is practically no competition. The preparation of high-quality and popular coloring compositions requires a wide range of pigments and high-quality thickeners. Compliance with the technological process plays a special role in the production of acrylic paints for painting.

The production of varnishes and paints for industrial work is one of the most profitable types of business, which quickly pays off and brings large profits. Paint and varnish materials are widely used during construction and repair work, they are not expensive and available. In Russia, the production of this type of product is increasing, new enterprises are being built. However, to achieve high competition paint and varnish materials domestic producers have not yet succeeded, so now new enterprises have a chance for successful business development.

Assortment of varnishes and paints on Russian market is constantly updated with new product names, this has become especially noticeable over the past 6-7 years. The increase in production in Russia occurs not due to domestic output, but thanks to imports, which increased greatly during the economic downturn in our country. The share of foreign paints and varnishes accounted for 20%; now these figures have decreased by almost 3%, as the production of this category of goods in our country is being resumed.

In Russia, enterprises are primarily focused on production:

• solvent-borne materials;
• water-dispersion compositions;
• drying oil; solvents;
• oil paints.

In total, the products account for 2.5% of everything produced in the chemical and petrochemical industries.

Experts involved in market analysis of domestic goods say that in Lately there is a decline in production. This is because enterprises are not operating at full capacity, and can, if desired, increase the production of paints and varnishes. Only 10 factories in Russia manufacture products that occupy the majority of the market. But small factories also produce materials that are widely represented on the Russian market. Experts predict that by the end of this year there will be a significant increase in the output of domestic products.

Schedule. Structure of paint and varnish production in Russia by region, %.

Table. World production of chemical products, billion dollars

	A country	1998	Share, %	2009	Share, %
1	USA	416,7	26,5	689,3	18,6
2	Japan	193,8	12,3	298,0	8,1
3	Germany	124,9	7,9	263,2	7,1
4	China	80,9	5,1	549,4	14,9
5	France	79,1	5,0	158,9	4,3
6	Great Britain	70,3	4,5	123,4	3,3
7	Italy	63,9	4,1	122,9	3,3
8	Brazil	46,5	3,0	126,7	3,4
9	South Korea	39,3	2,5	133,2	3,6
10	India	30,7	2,0	98,2	2,7
11	Russia	23,8	1,5	77,6	2,1
	Other countries	403,3	26	1058	29
	Total	1573,2	100	3698,8	100

There are three groups of paints and varnishes, which can be divided into:

• basic;
• intermediate;
• rest.

The first group includes:

• paint;
• enamel;
• primer;
• putty.

Let's consider distinctive features each material from this list. When applied to the surface of the varnish, a transparent layer is formed that has protective and decorative properties. Paint differs primarily in its coating; it consists of pigment substances that give color and a film-forming agent included in the composition. They can serve as drying oil of any brand or water dispersion on a synthetic basis.

Enamel can be in the form of a liquid or thick substance, like paint, it is applied in a dense layer. The primer provides high-quality adhesion, serves to strengthen the surface, and can be transparent or opaque. And the last of this group is putty, most often it comes in the form of a paste and forms a smooth, leveling layer. Subsequently, other coatings are applied to it.

In order for all components in paints and varnishes to exist harmoniously, additional ingredients are used. The second group of paint and varnish products consists of intermediate materials, which include:

• drying oils;
• resins;
• solvents;
• thinners;
• driers.

Drying oil is produced from processed oil substances using driers. It is used not only in the preparation of oil paints, but often as an independent substance for priming the surface.

The resin is in a solid or semi-solid state, but softens when heated.

Solvents and thinners are added to paint or varnish to change the consistency of the composition.

Dryers are used to reduce the drying time of paint and varnish material; they are made from metal compounds or oxides.

The last group includes the following substances:

• wash;
• mastic;
• hardener;
• accelerator.

To clean the surface from varnishes and paints, a remover is used. When finishing, mastic is often used mainly as a protective, insulating layer. It is a plastic substance, but can also become solid.

The hardener is introduced into the paint and varnish material to quickly dry the composition.

Drying agents increase the strength of drying oils.

There are also some paint and varnish compositions, divided according to the type of substance that ensures the connection of the components.

The basis of such materials can be:

• polycondensation resins;
• natural resins;
• polymerization resins;
• cellulose ethers.

The first thing you need to do to start production is to find a room for it, it must have water and a storage tank for liquid, and have a voltage of 220 V. The space must be at least 3 m². Even a garage will fit these requirements if its area allows for organizing production. Initially, you should focus on producing one type of product, increasing the range over time.

Recently, businessmen have been attracted to the production of water-dispersed compositions. Now in Russia they are represented mainly by imported companies. Domestic enterprises produce oil-based, alkyd paints and enamels.

Therefore, water-dispersed compositions from foreign manufacturers occupy a significant part of the Russian market. The production of such materials requires less capital investment, they have a long service life, and they are environmentally safe.

There is only one negative fact that appears during the manufacture of these compounds. Due to the fact that domestic enterprises produced products of unsatisfactory quality, it was difficult for Russian materials to compete with foreign ones. In order to achieve success and reach a new level of sales, you need to work hard to promote domestic formulations. Manufacturers who are just starting to take their first steps in this business should think about how to sell finished goods.

At enterprises that produce varnishes and paints, two stages are usually observed in the manufacture of materials. Firstly, all substances are prepared, and secondly, they are combined. If the plant is large and it produces a large volume of products, then all the components of paints and varnishes are manufactured here. The smaller the enterprise, the more substances he has to buy from suppliers.

In order to organize your own production of pigments and other necessary substances, you should purchase special equipment. The cost of 1000 kg of mixture obtained per hour will be approximately 160,000 rubles.

To equip the plant, you will have to spend 180,000 rubles for the production of paints and varnishes and 140,000 rubles for the production of putties. It will be necessary to purchase pigment substances and other ingredients of the formulations. The first batch of products will cost approximately 150,000 rubles, and you will have to additionally spend money on packaging.

IN
There is nothing complicated, just purchase quality equipment. To work with water-based compounds, a special apparatus is used; it combines and disperses the particles. Pumps pump but do not destroy the resulting mixtures; they allow substances to remain unchanged and do not affect their properties in any way. The resulting paint undergoes a thorough filtration process, after which it is packaged. To produce water-dispersed compositions, it is necessary that the equipment be made of high-quality materials that are not subject to rusting.

The number of workers involved in it depends on the size of production. A large enterprise usually has many employees who occupy different positions. The success of the entire business depends on the work of each of them.

The production volume of isophorone and isophoronediamine will be increased by Evonik Industries. In the first quarter of 2014, the construction of a number of enterprises in Shanghai is expected to be completed, in which the company will invest more than 100 million euros.

The production of paints and varnishes in Russia occupies a leading place among many types of business. The main consumer demand for products arose due to:

1. Widespread development.
2. Repair work in new houses and the private sector.
3. Planned reconstruction of city buildings and structures.
4. An increase in the number of furniture factories and industrial enterprises.

Market analysis

Statistics regarding the sales market and the consumer power of Russians themselves are ambiguous. Crisis trends affected a huge number of technological aspects, since most of the equipment for production was brought from abroad. However, materials collected by analytical companies and statistics bureaus for the period from 2010 to 2016 show:

• a significant increase in consumer demand and a favorable outlook for domestic exports;
• since 2010, the pace of consumer demand gradually began to return to “pre-crisis times,” which allowed technologists to increase production volumes by at least 10% per year;
• annual profit of large Russian companies amounted to over 172.8 million euros, and the total flow of exported products significantly exceeded the 62 thousand tons mark.

Despite this, competition within the industry is still high. This is due to the fact that the majority of clients are large construction companies and industrial associations that are accustomed to working with one manufacturing company or buying existing products from competitors, thereby getting a good discount for themselves.

Registration and organization of business

Organizing not just a business, but an entire production is not an easy task. To begin with, having assessed everything possible risks and degree of responsibility, you need to choose the most suitable form for registration.
Since the amount of work and the amounts invested in the business are astronomical, it is better to become the founder of an LLC. Representatives of the company do not bear personal responsibility for the affairs of the company and compensate for losses only with the help of property and funds of the company.

In order to register a Limited Liability Company you will need:

1. Write an application to the tax service about your desire to become a founder.
2. Prepare the LLC Charter.
3. Buy a print.
4. Contribute authorized capital - the minimum amount of which is 10 thousand rubles.

Required documents

The procedure for collecting all the necessary documentation will take quite a lot of time, since production of paints and varnishes It is important not only to prepare the premises and organize the work, but also to undergo testing to ensure that the final product meets the stated standards.

Thus, to start a workshop or plant you will need:

• certificate of establishment of LLC;
• LLC charter;
• lease contract;
• fire compliance;
• GOST standard certificate;
• tax payment certificates (rent, regional tax, others);
• workplace briefing log;
• set of labor protection rules.

Classification of paints

All paints and varnishes, regardless of the complexity of their production, are divided according to their composition and scope of application. For paints, there is the following classification, developed and compiled taking into account all the main features of each type of substance:

1. Polymer paints. It is a suspension consisting of polymers or perchlorovinyl resin. This paint has high weather resistance and has served faithfully for more than 12 years. To the number positive characteristics refers to its vapor permeability, which does not interfere with work natural ventilation, but at the same time protect the external steps of buildings from moisture.

This type of dye is used exclusively on external surfaces (building facades) due to its toxicity. TO polymer paints also include:

• rubber;
• coumaron-rubber;
• chlorinated rubber;
• silicon-organic coatings.

1. Latex paints. The coloring composition includes 2 immiscible components, the particles of which are evenly distributed in the total mass fraction of the final product. To prepare a solution that is resistant to delamination, it is necessary to add an emulsifier.
2. Water-based paint. Absolutely non-toxic. Ideal for both indoor and outdoor exterior finishing. It contains:

• film-forming substances (resin or rubber);
• water;
• emulsifier;
• pigment;
• additives that improve paint properties.

The final product is a powder or paste. To carry out painting work, water is added to it.

• water;
• polymer;
• white Portland cement.

Additionally, the composition includes: pigment and filler (lime flour, talc, etc.). Area of ​​application: factory finishing of large panels and blocks, painting of building facades.

1. Enamel paints. This is a composition consisting of varnish and coloring pigment. For better adhesion to the surface and its protection, the following are added to the main coloring agent:

• glyphthalic, perchlorovinyl, alkyd-styrene polymers;
• synthetic resins;
• esters;
• cellulose.

In turn, enamel paints are divided into:

• building enamels from glyphthalic resins. They are mainly used for internal finishing works for plaster and wood, as well as for factory finishing of asbestos-cement sheets, fiberboards;
• nitroglyphthalic and pentaphthalic enamels. They are used for interior and exterior painting work;
• perchlorovinyl enamel paints. They are characterized by increased moisture resistance and are used for exterior decoration;
• bitumen enamel paints. They are obtained by adding aluminum pigment (aluminum powder) to the main composition. These enamels are resistant to water, so they are used for painting sanitary equipment, steel window frames, and grilles.

1. Oil paints. Available in liquid and thickened forms. They are produced by carefully grinding drying oil with pigment and a special fixative.

Premises and equipment

Choosing a production facility is the key successful work the entire enterprise. Technological standards, norms and rules for organizing labor activities, as well as freedom of movement within the warehouse and beyond determine the main characteristics that the workshop must have.

The main qualities of the production space include:

1. Availability of transport interchange.
2. The area of ​​the room must be at least 40m2.
3. Ability to maintain room temperature at least 23°C.
4. Availability of powerful exhaust ventilation.
5. Possibility of installing technical water supply.
6. An effective fire extinguishing system, preferably automatic carbon dioxide.

Requirements for equipment installation are also technically fixed. The choice of the most suitable one depends on the types of paint produced and its quality. Standard set necessary equipment includes:

• bead or ball mill (otherwise known as dispersant)
• dissolver - a device that mixes paint with water.
• electronic balance.
• hydraulic trolley.
• screw pumps for pumping paint to the packaging area.
• filtration and bottling system.
• containers for packaging.
• additional accessories for retail trade.

Raw materials and procurement

It is necessary to purchase raw materials based on the specifics of production. The scale and type of dye are included in these parameters. In order to accurately determine the main composition and quantity of purchased raw materials, let us refer to the summary table for the production of matte water-dispersion paint for exterior use.

The quantity of raw materials is indicated to produce one gallon of the substance.

As it becomes clear from the main indicators, the amount of starting material required is small. It is better to order coloring pigments from Russian manufacturers.

By 2016, production technology at chemical and other factories within the country had reached a sufficient level to avoid the use of emulsifiers and thickeners produced abroad. In addition, this will help you independently determine the cost of material for different groups of buyers (within the limits of the pricing policy, respectively).

Staff

Even to organize the work of a small workshop, it is necessary to correctly determine the personnel composition of the enterprise. The technological process and administrative work must be strictly regulated by the following specialists:

1. Logistics specialist.
2. A manager who will deal with purchasing and sales.
3. Chief technologist. This man designs everything production line from start to finish.
4. HR specialist.
5. Storekeeper.
6. 1C operator or PC operator.

Advertising and sales market

Since there is no particular trust in newcomers, it is better to apply for participation in the tender for transport organizations. It is worth choosing lesser-known companies engaged in passenger and cargo transportation by water transport. It is the specialists in the “water sector” who are happy to start collaborating with newcomers due to the low cost of production.

Additionally, you can hang posters around the city advertising a new store or production base. Launch advertising on popular radio stations for drivers and workers - “Russian Radio”, “Police Wave”, and the like.

It would not be a bad idea to decorate the base or store with a bright sign so that drivers and public transport passengers passing by constantly see the banner and, accordingly, turn to the base (warehouse, store) for goods.

Financial component of business

Calculating production costs is not an easy task. There are always a number of side expenses and investments, which, on the one hand, are directly related to the organization of the business, and on the other hand, were not taken into account when drawing up the business plan. Therefore, it is better to round up the total production costs.

Cost of opening and maintaining

To start and the first month of work you will need at least 1,400,000 rubles. Let's take a closer look at what this figure consists of:

• lawyer's work;
• government payments duties;
• contribution of the authorized capital.

1. Next, you need to select and rent a premises - this is at least another 150,000 rubles. Included in the price:

• monthly rent;
• rental of warehouse premises.

1. At least 100 thousand rubles will be spent on paying workers and administration.
2. Light, water, fire and other systems – 25,000 rubles.
3. Purchase and depreciation of equipment – ​​700,000 rubles.
4. Taxes – 300,000 rubles.

Transport costs are not taken into account in the calculation, since many entrepreneurs choose different methods of transportation, and accordingly, it is not possible to calculate an exact or approximate amount.

The cost of the further working period is calculated using the formula: depreciation of equipment + utility bills + wages + taxes + rent + transportation costs.

Amount of future income

The approximate amount of monthly income consists of consumer activity and the number of transactions concluded with large companies. Many beginning producers receive no more than 150,000 rubles per month. This is due to an insufficiently thought-out advertising campaign and the desire to stand out from numerous competitors.

You can actively earn money and receive a solid income only by working out an economic strategy, regardless of the successes and trading model of other paint and varnish sellers. This approach will help to significantly increase the sales market and receive at least 300 thousand rubles per month. Net profit (excluding company funds) will be 150 thousand rubles.

Payback period

As mentioned above, newbies don't get much. But by wisely using all the possibilities and drawing up a marketing line, the enterprise will fully pay for itself after about 1 year of operation.

It is almost impossible to launch a production line without a well-thought-out business plan. The technological process, administrative work and other technical issues require constant participation in the affairs of the company.

For the most profitable and systematic growth of income, it is better to focus on cooperation in those areas of activity that large enterprises and famous companies have not yet managed to occupy. Better yet, develop and draw up a fundamentally new economic proposal.

This is a semi-automatic line for the production of water-dispersion paints and finishing materials new generation (80 types in total) with automatic loading of liquid components and an automated packaging system for finished paint.

Our dissolvers “PLT-L”, “PLT – 0.75”, “PLT – 1.5”, “PLT – 1.5M”, “PLT – 2.2” and “PLT – 2.2 EURO” are universal mixers for the production of all 80 types of paints and varnishes (paints, varnishes, primers, putties, decorative mixtures etc.).

Unlike other offers on the market, our dissolvers:

• Cheap – the cost of our dissolvers is several times cheaper than standard ones.
• They are universal - with the help of replaceable screws and cutters, you can prepare both light compositions (soils, texture coatings, primers, etc.) and heavy mixtures (putty, coat paste, etc.)
• Compact - mounted on a small area (from 1 sq.m to 3 sq.m), can be used directly at the construction site.
• Adapted for the work of one operator with several installations simultaneously (thanks to a remote control panel, connection to a computer, timer, etc.)

Dissolvers

Dissolver “PLT-L”

(0.7 kW 220/50) – for small experimental volumes and tinting ready-made compositions from 1 to 5 kg. Bosch drive mechanism. Smooth adjustment of cutter rotation (2 gears: 200-850 and 600-2500 rpm). It consists of a holder stand, a motor, a device for smoothly changing engine speed, and two types of cutters. Additionally, it can be equipped with a cabinet.

Dissolver “PLT – 0.75”

(0.75 kW 220/50) – a universal installation for the production of paints and varnishes. Electronic control unit (Japan) provides smooth start and turning off the engine, simple and reliable control of engine speed, automatically increases torque, protects the engine from overloads, one cutter

Dissolver “PLT – 1.5”

(1.5 kW 220/50) – a fairly powerful unit with increased productivity. In addition to the listed functions of the PLT 0.75 dissolver, it is equipped with a weighing platform with an electronic display board, a ramp, and one cutter.

Dissolver “PLT – 1.5M”

(1.5 kW 220/50) – in addition to the options of the PLT-1.5 dissolver, it is equipped with an electronic technical regulations display board, one cutter.

Dissolver “PLT – 2.2”

(2.2 kW 220/50) is the most powerful of the units we produce with maximum productivity, the most rational device in terms of the price-quality system. It is equipped with a weighing platform with an electronic display panel, a ramp, an electronic display panel for technical regulations, and one cutter.

Dissolver “PLT – 2.2 EURO”

(2.2 kW 3800/50) – high-tech dissolver. In addition to the dissolver options, “PLT-2.2” has a hydraulic drive, wheels for moving around the workshop, a control unit with a remote control, communication with a PC, timers, a clock, and one cutter.

Since April 2018, all our dissolvers can also be ordered in the “NEXT” version.

Main features of NEXT series dissolvers:

• protective cover
• monolithic control panel
• LCD screen with touch screen control
• clock, timer
• ability to display and calculate recipes and technological support on the screen

Specifications.

	PLT-L	PLT- 0.75	PLT-1.5	PLT- 2.2	PMT – 2.2 EURO
Installation size, m	330x360x710	730x680x1700	730x680x1700	730x680x1700	1600x850x2020
power, kWt	0,7	0,75	1,5	2,2	2,2
Productivity kg/h heavy trains light mixtures
Power supply V/Hz	220/50	220/50	220/50	220/50	380/50
Weight, kg	11	87	96	100	300

Paint packaging and liquid raw material dispensing systems produced by PLT SYSTEM LLC

To dispense paint components during its preparation and pack the finished product into containers, our mini-factories use the following systems:
1. The unit for packaging paint and supplying liquid raw materials is the most economical and simple system using a manual rotary dispenser.
2. The pump-type pneumatic system is a more convenient system to use, as it uses a pneumatic pump and a special gun with a dripless cut-off device.
3. Semi-automatic pneumatic system is the most rational device in the price-quality system. It has no wearing parts and can be adjusted to suit different paint viscosities.
4. The automatic two-channel pneumatic system is the most convenient to use, as it has automatic dose cutting and two independent channels - one for dosing paint components, the other for packaging the finished product.

The paint packaging and liquid raw materials dispensing unit is designed to automate the operations of packing water-based paints into bucket containers (from a plastic bowl) with manual dose cutting, as well as pumping liquid raw materials for the production of paint and varnish materials from a container with raw materials into a plastic bowl for preparing paint.

The principle of operation of the system is to supply paint components from a barrel to a bowl for preparing paint and packaging the finished product under the action of a rotary dispenser.

The system includes:
– plastic bowl;
– rotary dispenser;
- scales;
– trolley – tipper for barrels.

Specifications:

Plastic bowl 200 l;
Work with metal barrels up to 215 liters when dispensing liquid paint components;
Dosing range, l……………………………………………..……………….……….1 – 50 ;
Practical dosing accuracy, g…………………………………… 10;
Outlet diameter………………………………………………………………………………….……….1/2;
Productivity – 5 liters per 20 revolutions;
The rotary dispenser is made of plastic;
Antistatic housing.

2. Pump pneumatic system

The pump pneumatic system is designed to automate the operations of packing water-based paints into bucket containers (from a plastic bowl) with semi-automatic dose cut-off, as well as for pumping liquid raw materials for the production of paint and varnish materials from a container with raw materials into a bowl for preparing paint.

The system includes:
– pump device;
– packaging unit;
– device for dripless paint cutting;
– cabinet;
– container scales;
- plastic bowl.

Specifications:

Working medium – water-based paints and paint and coating components of low and medium viscosity;

3. Semi-automatic pneumatic system

A semi-automatic pneumatic system for dosing liquid raw materials and packaging paint is designed to automate the operations of packing water-based paints into bucket containers (from a working tank) with semi-automatic dose cut-off, as well as for vacuum pumping of liquid raw materials for the production of paints and varnishes from a container with raw materials through a working tank into a bowl for preparing paint.

The operating principle of the equipment is as follows. To prepare the paint, liquid raw materials are fed into the working tank under vacuum. Then a measured dose of liquid raw material flows into a container for preparing paint under the influence of excess pressure. The operation is repeated until all liquid products are in the paint preparation container. To fill the finished product into containers, the prepared paint is fed into the working tank. From the working tank, the product enters the container under the influence of excess pressure (the magnitude of which depends on the viscosity of the paint) created by the pressure regulator.

The system includes:

- Remote Control;
– packaging unit (semi-automatic);
– cabinet;
- scales.

Specifications:

Working medium – water-based paints and paint and coating components of low and medium viscosity;
Compressor outlet pressure (adjusted by the pressure reducer on the compressor and controlled by the pressure gauge on the compressor), MPa (bar) …………………………………………………………………………………. .0.6 (6);

The pressure in the PP is adjusted by a filter-pressure regulator and controlled by the regulator's pressure gauge. The pressure in the PP is selected experimentally and, depending on the viscosity of the packaged product and the volume of the container, varies from 0.2 to 1.0 kgf/cm2.

Practical dosing accuracy, g……………………………………. 5.

Design parameters:

filling lines……………….……..……………………………………………………………19;
PP replenishment lines and drain lines……………………………………………………….26;
-inner diameter of the replaceable drain tip, mm:….…….…..……….6, 12, 15;
(selected experimentally and varies depending on the viscosity of the liquid and the volume of the container).

Automatic pneumatic packaging system for paint and other types of liquids with an electronic control unit with dose cut-off over time.

The principle of operation of the system is to supply paint components from a barrel to a bowl for preparing paint and packaging the finished product using a pump device.

The system includes:
– working tank (vacuum bowl made from of stainless steel 200l);
- Remote Control;
– packaging unit (automatic);
– cabinet;

Specifications:

Working medium – water-based paints and paint and coating components of low and medium viscosity;
Compressor outlet pressure (adjusted by a pressure reducer on the compressor and controlled by a pressure gauge on the compressor), MPa (bar) ………………………………………………………………………………………… ..0.6-0.8(6-8);
Maximum air flow, m3/hour………………………………………………………6;
Dosage range, l……………………………………………..…………….…….0.1 – 50;
Practical dosing accuracy, g……………………………..…… …….5;
Outlet diameter…………………………………………………………………………………..……..1/2;
Productivity of the pump device…………………………………….48l/min.

An automatic two-channel pneumatic system is designed to automate the operations of packing water-based paints into bucket containers (via the first channel from the working tank) with automatic dose cut-off, as well as for vacuum pumping of liquid raw materials for the production of paint and varnish materials from a container with raw materials into a bowl for preparing paint (by the second channel - using a measuring container).

The operating principle of the equipment is as follows. To prepare paint, liquid raw materials are fed into a measuring container under vacuum. Then a measured dose of liquid raw material flows into a container for preparing paint under the influence of excess pressure. The operation is repeated until all liquid products are in the paint preparation container. To fill the finished product into containers, the prepared paint is fed into the working tank. From the working tank, the product enters the container under the influence of excess pressure (the magnitude of which depends on the viscosity of the paint) created by the pressure regulator.

The dose is cut off automatically.

The system includes:
– working tank (vacuum bowl made of stainless steel 200 l);
– measuring container (30 l);
– control panel;
– packaging unit (automatic);
- Desktop;
– weighing platform for measuring container;
– compressor;
– container scales.

Technical characteristics of the System

Working medium – water-based paints and paint and coating components of low and medium viscosity;
Compressor outlet pressure (adjusted by the pressure reducer on the compressor and controlled by the pressure gauge on the compressor), MPa (bar) ………………………………………………………………………………………… …………………….0.6 (6);
Maximum air flow, m3/hour…………………………………………….………………….6;
Supply pressure of the control unit (adjusted by a filter-pressure regulator using a pressure gauge on the regulator), MPa……………………………………………………….………………………0, 14 10%
The pressure p1 in the PP is adjusted by the set pointer Zd1 (Fig. 1) and controlled by the pressure gauge M.
The pressure value p1 is selected experimentally and, depending on the viscosity of the paint and the volume of the container, varies from 0.2 to 0.8 kgf/cm2.
Dosing range, l……………………………………………..…………….…….1 – 50;
Dosing accuracy, g……………………………………………………………………… 5;

Design parameters:
-internal diameter of hydraulic communications, mm:
lines for pouring paint into containers……..……………………………………………………………..……….19;
PP loading lines………………………………………………………………………………….…….26;
-inner diameter of the replaceable drain tip CH, mm:….…….…..….6, 12, 15;
(selected experimentally and varies depending on the viscosity of the paint and the volume of the container);
– automatic dose cut-off;
– the first channel – packaging of paint using a working tank (vacuum bowl 200 l);
– second channel – dosing of raw materials using a measuring container (30 l).

Mini plants are equipped with packages of technological maps, which include a description of the properties of these types of coatings, chemical composition and a technological solution for preparation. The technological map is compiled in such a way that even an untrained worker can produce a high-quality product the first time, carefully following the preparation instructions contained in the technological map. In total, 80 technological maps are provided for 80 types of coatings (see list of coatings).

Pump-action automatic system packaging and dosing of liquids (APSF) is an innovative development, the main advantage of which is the absence of an intermediate tank - dosing occurs directly from the working capacity of the dissolver. Ultra-precise dosing and high speed pumping.

The system includes:
– diaphragm pump(special modernization);
– damping capacity;
– packaging unit (automatic);
– pneumatic control device;
- Desktop;
- small scales.

Semi-automatic packaging system for viscous products (SFVP) such as putty and decorative plasters(basic equipment). Mobile high-performance installation (up to 1 ton per hour).

The system includes:
– Plastic bowl;
– Installation of SFVP.

Additionally:
– work stand;
- scales;
– fastening to the bowl;
– dispenser holder with adjustable product supply height (depending on the container).

Semi-automatic packaging system for highly viscous products (SFOVP) such as adhesives, plasters, mastics, etc. (basic equipment).

The system includes:
– installation of SFOVP.

Additionally:
- Desktop;
- a frequency converter;
– electric drive for lifting the dispenser or fastening to the bowl;
- scales;
– dispenser holder with adjustable product supply height (depending on container)

Bulk Components Supply System (SPSC)

Automatic system for unpacking and supplying bulk components (chalk, microcalcite, etc.)

• Hopper volume from 50 to 250 l (standard 200 l -300 kg)

The Raduga-LKM company produces and supplies unique, mobile equipment (mini-plant) for quickly organizing the production of water-dispersed paints and varnishes of various viscosities (paints, putties, primers, enamels, varnishes, fire-retardant paints) with the possibility of packaging in containers from 1 or more liters (regardless of product viscosity).

Equipment performance:

• Medium viscosity (paint, enamels) - 250 kg/hour, taking into account pumping (packing) of finished products.
• Liquid (primers, varnishes) - 400 kg./hour
• High-viscosity (putty, plaster, fire-retardant paint) - 150-200 kg./hour

Specifications:

• The power consumption of the dissolver is 3 kW.
• Dissolver volume - 215 liters,
• Pump power consumption is 1.5 kW.
• Filtration system - installed to order.
• Electronic cutter speed control from 0 to 1500 rpm.

When purchasing this equipment from us, we constantly provide technological support, help you choose this or that raw material, and provide consultations over the telephone. Products (water-dispersed paints and varnishes) are not subject to mandatory certification; at your discretion, you can purchase voluntary compliance.

How to open your own business producing paints and varnishes

The production of paints and varnishes has been and remains one of the most promising and profitable investments. Varnishes and paints are the most common and one of the most affordable finishing materials. Despite the fact that the domestic industry is developing quite actively in this segment, nevertheless, the competition is not yet so high, and the new business has every chance of success.

Over the past 6-7 years, the market volume of paints and varnishes has been constantly increasing. However, this growth was mainly due to imports, the share of which before the crisis was more than 20%. Over the past two years, this market has shrunk by 2.4%.

Russian manufacturers produce mainly solvent-based materials (paints, varnishes, primers, putties), water-dispersed paints and varnishes, intermediates (drying oils, solvents) and oil paints. Moreover, in the segment of the chemical and petrochemical industry, the production of varnishes and paints takes up only 2.5% of the total output.

Analysts note that there is a shortage of domestic products on the market for paints and varnishes, although production capacities for the production of these finishing materials are less than half occupied. Only ten Russian factories produce about 70% of the total production of varnishes and paints. However, small enterprises still retain a significant share of local markets on a local and regional scale.

According to experts, by 2015 the market volume will reach 1,511 thousand tons, which is 31% more than in the crisis year of 2009.

Classification of paints and varnishes

First, let's look at the definition and classification of manufactured varnishes and paints.

Paint and varnish materials, according to 28246-2006, are liquid, paste or powder materials that, when applied to the surface to be painted, form a coating that has protective, decorative or special properties. technical properties. All paints and varnishes are usually divided into three groups: basic, intermediate and others. Basic materials include:

• varnish – a paint and varnish material that forms a transparent coating when applied;
• paint - a liquid or paste-like pigmented material that contains various brands of drying oil or an aqueous dispersion of synthetic polymers as a film-forming substance and which forms an opaque coating when applied;
• enamel - a liquid or paste-like pigmented paint and varnish material that has a paint and varnish medium in the form of a solution of a film-forming substance and forms an opaque coating when applied;
• a primer that, when applied to the surface to be painted, forms an opaque or transparent homogeneous with good adhesion to the surface to be painted and to the coating layers;
• putty is a paste or liquid paint and varnish material that is applied to the surface before painting to smooth out unevenness and obtain a smooth surface.

Intermediate paints and varnishes are used primarily as semi-finished products. These include:

• drying oil - a product of processing vegetable oils with the addition of driers (substances that accelerate the film formation of paints and varnishes) to speed up drying;
• resin - a solid or semi-solid organic material that softens or melts when exposed to a certain temperature;
• solvent - a single- or multi-component volatile liquid that evaporates upon drying and completely dissolves the varnish or paint;
• thinner - a single- or multi-component volatile liquid that does not have a harmful effect on the properties of varnish or paint;
• Drying agent is an organometallic compound that is usually added to certain paints and varnishes to speed up the drying process.

There is also another type of paint and varnish materials - the so-called auxiliary and auxiliary materials. This group of materials includes:

• a remover designed to remove old paintwork;
• mastic - adhesive, finishing or sealing compositions based on organic binders and other substances, forming a plastic mass, which under certain conditions can turn into solid state;
• hardener - a substance introduced into varnish or paint to “crosslink” the macromolecules of the film-forming substance;
• accelerator – a substance that accelerates the formation of cross-links between molecules and promotes rapid drying of the paint layer.

In addition, there are several types of paints and varnishes based on the type of main binder. According to this classification, paint and varnish materials can be distinguished:

• based on polycondensation resins;
• based on natural resins;
• based on polymerization resins;
• based on cellulose ethers.

Production of paints and varnishes

For the production of paints and varnishes, it is necessary to select a heated room with an area of ​​3 square meters. m with running water and water storage, as well as a voltage of 220 V. As can be seen from the requirements, at the first stage of your work, a garage of sufficient area will be enough. To begin with, it is best to choose a specific type of product that you will produce. In the future, when your income allows, you can think about expanding the range.

Many entrepreneurs who consider the paint and varnish products segment from the point of view of attractiveness for investment note that the market for water-dispersed paints and varnishes has the greatest development potential. Domestic manufacturers are mostly focused on the production of oil and alkyd paints and enamels. As a result, almost a third of the volume of consumed water-dispersed materials are imported products.

Indeed, in the Russian market the share of this type of product is significantly inferior to global indicators, despite the fact that these materials are easy to use, environmentally friendly and relatively durable. In addition, the production of water-dispersion paints requires a smaller budget than the production of other paints and varnishes.

There is only one significant drawback in the production of water-dispersed materials. Thanks to for a long time this product manufactured domestic producers, was characterized by a low price and even lower quality, the promotion of Russian paints and varnishes (even if they have a high and competitive price) in our market is associated with high costs and difficulties. Therefore, at the very first stage of organizing and establishing own production think over possible distribution channels for your products.

The production of paints and varnishes consists of two stages: the production of semi-finished products (varnishes, pigments, etc.) and their mixing. As a rule, small enterprises purchase the bulk of the materials, while large enterprises produce them themselves.

The choice of technological lines for the production of paints and varnishes depends on what materials and in what volume you are going to produce. approximate cost such equipment ranges from 100 to 200 thousand rubles.

For example, a line for the production of primers, impregnations and other low-viscosity materials with a mixer capacity of 1000 kg/hour will cost about 160 thousand rubles. A technological line for the production of paints, varnishes and other low- and medium-viscosity materials costs approximately 180 thousand rubles. Equipment for the production of construction putties will cost a more modest amount - up to 140 thousand rubles.

From raw materials you will need various fillers, pigments, binders, thickeners. The purchase of the first batch will cost about 150 thousand rubles. Additional costs (approximately 50 thousand rubles) will be spent on packaging finished paints and varnishes.

The technology for producing varnishes and paints is quite simple. For example, for the production of water-dispersed materials, a dissolver-mixer is used, which mixes all components and simultaneously disperses loose paint elements with a milling mixer. To pump finished paint and dispersion through pipelines, special screw pumps, which do not destroy the dispersion and retain all the consumer properties of the paint. If necessary, the finished paint is filtered and packaged in polymer containers. Please note that water-dispersion paints are an aggressive environment with a pH value of 8 and above. Therefore, in production it is highly desirable to use equipment and communications pipes made of stainless steel.

If you plan to work independently at first, you will need the help of another worker. In the future, as production volumes increase, you will have to organize round-the-clock duty and, accordingly, increase your staff. In addition to the working staff, you are unlikely to be able to do without the help of an accountant (he may be a visiting one), as well as a sales manager for finished products, if you do not have experience in this.

So, to organize your own small production you will need at least 350-400 thousand rubles for paint and varnish materials. Add to this the monthly costs of rent, communications and wages(subject to availability of employees).

The cost of finished products, your profit and the profitability of your business directly depend on what materials and in what volume you produce, as well as on whether you can create sufficient demand for them. With proper business management, the payback on such production is very high and can range from 2-3 months.

Profitability of production of paints and varnishes

The profitability (the ratio of net income to gross revenue) of the production of paints and varnishes depends on the specific product and is on average 15% in the industry, while the profitability retail sales such products are 3-4 times higher. According to the most optimistic estimates, profit from one ton of paints and varnishes can reach 30-35 thousand rubles, and monthly income at average production volumes can reach 300 thousand rubles.

Pavel Biryukov

(c) www.openbusiness.ru - portal of business plans and guides for starting a small business

Video about the production of paints and varnishes

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Equipment for the production of primers

The delivery set includes technological and normative documents for organization production of acrylic and latex primers:

Project technical specifications TU 2316-002-00080679-2006 “Water-dispersion primer”.

Technological regulations for the production of acrylic and latex primers.

Recipe and technological production maps:

1. Primer for polystyrene foam boards VD-AK 055
2. Strengthening façade primer styrene-acrylate VD-AK 010
3. Strengthening primer for external and latex VD-KCH 012
4. Universal strengthening primer for external and internal work, styrene-acrylate VD-AK 012
5. Strengthening primer for interior work VD-AK 020
6. Primer (concentrate) VD-AK 010
7. Universal deep penetration acrylic primer for external and internal work VD-AK 011
8. Deep penetration acrylic primer for interior work VD-AK 021

Price of the installation for the production of primers “VD-100”: 130,000 rub. VAT is not provided

Reference Information:

Primers are compositions applied as the first layer to a surface prepared for finishing to reduce its porosity and ensure the required adhesion of the subsequent coating.

They differ from coloring compositions (paints) in the lower concentration or complete absence of dry fillers, and also in the fact that the primer cannot serve as a final coating, incl. with decorative properties.

An additional property of primers is the protection of various materials from moisture, corrosion and decay.

Water-dispersion primers are divided into (depending on the type of dispersion) and subtypes (depending on the purpose). Let's take a closer look at the classification of primers .

1. Acrylic primer

Binder type - acrylic or styrene-acrylate dispersion. Primers based on acrylic dispersions are applicable to almost all construction surfaces (concrete, foam concrete, asbestos cement, fresh and old plaster, wood, fiberboard and chipboard, brick).

Used for priming surfaces special types primers - with corrosion inhibitors (usually phosphating primers).

Acrylic and styrene-acrylate primers differ from latex (styrene-butadiene) primers in their increased resistance to ultraviolet radiation.

Subtypes of acrylic primers:

Facade primer;

Deep penetration primer (including concentrated);

Strengthening primer for interior work;

Deep penetration primer for polystyrene foam boards;

Primer (concrete contact).

A deep penetration primer differs from a strengthening primer primarily in its transparency. The deep penetration primer is translucent, which is due to the size of the dispersion particles (less than 0.05 microns).

Milky strengthening primer. Pay attention when purchasing.

2. Latex (styrene-butadiene) primer

Binder type - styrene-butadiene latex dispersion. Applicable to almost everyone building surfaces(concrete, foam concrete, asbestos cement, fresh and old plaster, wood, fiberboard and chipboard, brick). Not suitable for priming metal surfaces. Less UV resistance compared to acrylic (styrene-butadiene latex deteriorates within 5-6 years).

Subtypes of latex primers:

Facade primer (for local repairs);

Universal strengthening primer for facade and interior work;

Strengthening primer for interior work.

Latex deep penetration primers, unlike acrylate, does not exist due to the difference in the particle sizes of the dispersion.

Additional Information:

• Paints and varnishes. General characteristics
• Equipment for filling paints and varnishes
• Protection of metal surfaces from corrosion with paints and varnishes

Watercolor

We develop and produce equipment for the production of expanded clay concrete building blocks ( cinder blocks) according to GOST 6133-84. Three models are mass-produced equipment for block production- from the 1IKS vibration machine with a mold for 1 block, to the mobile vibration machine “Comanche” with a mold for 4 simultaneously pressed wall blocks(cinder block).

All machines for the production of cinder blocks- palletless type of molding, so-called “layers”.

Vibrating tables for the production of paving BC-700 and BC-1200 series

Molding vibrating tables designed for the production of vibratory casting paving slabs, elements of architectural decor, fences and similar concrete products using vibration casting.

Paint production equipment

Equipment for the production of paints and varnishes(acrylic, latex, polyvinyl acetate) - paints, enamels, primers, “concrete contact”, putties, decorative plasters and coatings - installations of varying degrees of automation and productivity, from simple dissolvers/dissolvers (dispersants) to semi-automatic mini-plants for the production of paints and varnishes.

Paint production equipment in all configurations it is supplied with a set of regulatory, technical and technological documentation.

Gravity concrete mixers (concrete mixers)

Gravitational concrete mixers used for preparing concrete and mortar mixtures of varying degrees of hardness. The volume of the concrete mixer bowl is from 130 to 180 liters. Concrete mixers are equipped with electric motors powered from a 220V household network.

Modular mini-plants for the production of polystyrene foam

Semi-automatic mini-plants for industrial foam production(expanded polystyrene) with adjustable configuration.

The principle of mobile modules allows you to install foam production equipment in almost any production area.

The resulting leaf Styrofoam fully complies with the requirements of GOST 15588-86.

Vibropress B-50 for the production of expanded clay concrete blocks

Palletized concrete block press B-50 for the production of cinder blocks, expanded clay concrete building blocks - the next step after vibrating machines “layers”. Performance block making machine V-50 is 50 blocks/hour, form for 2 blocks, three types of produced building blocks in accordance with GOST 6133-84: SKTs-1, SKTs-2, SKTs-3.

Equipment for the production of permanent formwork

Line performance for production of permanent formwork up to 300 pcs. per shift. Wide degree of automation equipment for the production of permanent formwork. Block production permanent formwork - a necessary addition to the line for the production of polystyrene foam.

Equipment for the production of prefabricated monolithic floors

Equipment for the production of prefabricated monolithic floors. The ceiling is formed by laying hollow block liners on reinforced concrete beams, installing additional reinforcement and steel mesh on top and then pouring heavy concrete.

Equipment for the production of construction putties

Equipment for the production of construction putties- latex, acrylic, oil-adhesive, PVA-based. Time-tested Soviet technologies coupled with modern chemical components give impressive results.

In addition to the production of traditional putties, the capabilities of the equipment allow the production of decorative coatings, for example, the well-known Venetian plaster and energy-saving coating based on perlite.

Thermal insulation coating “Aquarella TM-150”

Ultra-thin thermal insulation coating “Aquarella TM-150” TU 5768-001-99799327-2010 for application to mineral and metal surfaces.

Equipment for the production of prefabricated chimneys

We develop and manufacture equipment for production prefabricated chimneys- enclosing structures made of expanded clay concrete blocks (with ventilation duct, and without) and fiber-reinforced concrete cover slabs.

Equipment for the production of primers

Equipment for the production of water-dispersed primers- acrylic and latex. Performance equipment for the production of primers- 500 l/hour. IN basic configuration equipment for the production of primers - electronic dispenser for acrylic/latex dispersion, water pre-purification filter, dispensing syringes for modifying components.

Equipment for filling paints and varnishes

Equipment for bottling (packing) technical liquids, dispersions and emulsions on a water and organic basis - acrylic coatings, machine oil, antifreeze, adhesives, etc. materials.

Several degrees of automation - installations with visual control of weight and semi-automatic CNC machines. The liquid is pumped using a diaphragm pump from the Swedish manufacturer Tapflo with a Teflon membrane, the dosage of the material is accurate electronic scales with a resolution of 10 g.

Industrial and domestic steam generators

Development and production steam generators- industrial and household steam generators(for saunas and baths). Steam generators are produced serially, with power from 2 kW with operating pressure 0.7 at - 2.5 kg/h, up to steam generators 160 kW with a pressure of 5.5 at - 205 kg/h. Three-level protection system steam generators overload protection, built-in unit preliminary preparation water, phytocontainers.

Equipment for shaped cutting of foam plastic

We produce machines for figure cutting expanded polystyrene- range from manual cutting to CNC machines. The use of high-precision Hiwin profiles, precision manufacturing of machine parts, and professional assembly ensures a hitherto unattainable level of cut products.

Tool for hand cutting polystyrene foam

The RI-01 hand tool is designed for cutting expanded polystyrene (foam) blocks on a construction site. Model "RI-01" tool for manual cutting foam plastic easy to operate, provides uniform, adjustable heating of the cutting string from 0 to 100%, which guarantees high quality cutting of almost any density of polystyrene foam.

Kraskoterka (millstone mill) SO-116A

We produce in series paint grinders(millstone mills), modified versions of the classic model SO-116A. Kraskoterki The millstones are intended for grinding and paste-like non-explosive compositions used for painting outside and indoors (chalk pastes, putties, adhesive colors). The initial components (chalk, pigments, adhesives) are pre-soaked in water before grinding.