Packing and packaging of bulk products: a profitable business with low costs. Search for sales channels for finished products. The main stages of processing raw materials

Mr Cellophane

“We declared in a month such a profit that the “great” Artem Tarasov declared in a year - 3 million Soviet rubles,” said Alisher Usmanov, the richest man in Russia according to this magazine, in an interview with Forbes. In the late 1980s, he was earning profitability, measured in thousands of percent, due to the huge difference between the selling price of raw materials from Soviet factories and the price of packages in "cooperative" retail.

The times when such a margin was possible are long gone. In the 1990s, most of the packages were imported into Russia from Europe, China and Turkey. Novikov says that at that time in Russia packages were produced by several factories left over from Soviet times, but their share was meager. “I was a student at MEPhI and traded in the market for various goods that my older brother brought from Turkey,” Novikov recalls. Calculating the income, the brothers realized that they earn the most from the sale of ordinary packages.

The crisis of 1998 dealt a blow to imports, traders began to think about building their own factories. The purchase of equipment cost several million dollars, says Novikov. He then invested the money earned in trade in two enterprises - one in Protvino near Moscow, the other in Ukraine.

Then, after the crisis, he founded his own company, TIKO-plastic, which grew into one of the market leaders, Nizhny Novgorod businessman Igor Yesin. He owned the privatized Research and Design Institute for Urea and Organic Synthesis Products and sat without orders. To survive, he decided to open a side business for the production of plastic bags, and it turned out to be very profitable. “In the early 2000s, profitability exceeded 50%,” says Igor Fomin, CEO of Dar, a St. Petersburg company that also produces bags.

During the crisis of 2008, many small enterprises went bankrupt, and the rest began to expand production. Novikov from Artplast invested about 500 million rubles. In the construction of a plant in Serpukhov, Esin from TIKO-plastic spent 300 million rubles, doubling the capacity of his enterprise in the Nizhny Novgorod region. Each company produces about 12 thousand tons of bags per year - 1.7-4 billion pieces, depending on the type. According to SPARK-Interfax, the revenue of CJSC Artplast-T, the parent company of Artplast, in 2013 amounted to 3.58 billion rubles, CJSC TIKO-plastic - 1.1 billion rubles.

unnamed plastic

According to participants in the plastic bag market surveyed by RBC, there is not a single company with a share of more than 20%. “There are five to seven manufacturers that produce from 500 to 1000 tons of products per month,” says Andrey Novikov. - And there are several hundred, as a rule, regional producers with smaller volumes - 50-100 tons per month.

It would seem that large market shares could be captured by polyethylene producers - petrochemical companies, subdivisions of Gazprom, LUKOIL, TAIF, Sibur, Rosneft and Bashneft. But none of them have a large package production. It is unprofitable for them, for them it is a troublesome business and much less profitable than the export of petrochemicals, explains Igor Fomin from the Dar company, which produces about 6 thousand tons of packages per year.

The main customers of package manufacturers are non-chain retail, that is, small shops, as well as small and medium-sized wholesalers. They account for more than half of the volumes of even large companies like Artplast and TIKO-plastic. According to Fomin, in general, the market average order is 100,000 packages - about 50 kg. Retail chains place one-time orders for tens of millions of packages, but if you add up the annual sales volumes of packages in X5 Retail Group, Magnit, Dixy and Auchan, the figure will hardly exceed 2 billion pieces. That is, the four largest retail chains account for no more than 3% of the market.

retail margin

Nevertheless, networkers also manage to capitalize on the "package boom". In the mid-2000s, most retailers gave out packages for free at the checkout, but after the 2008 crisis, they began to sell them. “The minimum markup for packages in retail chains is 25-30%, but usually 70-80%,” says Igor Fomin.

The founder of the Magnit network, Sergey Galitsky, figured out how to make money on tons of plastic waste that remains in the warehouses and distribution centers of Magnit, and at the same time provide their stores with packages. He built the Plastictrade plant, which has the capacity to produce 1.15 billion bags a year. The plant produces only two types of packages, which are then sold in Magnit for 1.9 and 3.9 rubles.

The use of recycled materials allows you to get high profitability, Galitsky said in 2014, without disclosing details. In 2012, Magnit's revenue from the sale of packaging materials amounted to 697 million rubles, in 2013 - already 1.17 billion, that is, increased by 68%. The revenue of package manufacturers is growing more slowly: in Artplast it increased by 32% in 2013, and by 15% in TIKO-plastic. If other retail chains build their factories, the manufacturers' business will suffer greatly. The profitability of the production of packages for 15 years has decreased from 50 to 10%, says Fomin.

Now in any store and even a small kiosk, the goods are packed everywhere, more often by the manufacturer, but sometimes by the sellers themselves. In large stores, there are corresponding small workshops for packing, for example, bulk goods, sweets and other sweets. A packaged product looks better and costs more, especially if the packaging is colorful. Our people are used to paying for unnecessary beautiful packaging.

In some stores, sellers themselves pack, for example, sweets. The saleswoman weighs on electronic scales, a sticker with a barcode comes out, in principle, it is also an option, but not for every store. It is not suitable for small shops.

The packing bases have special equipment and areas for quick packing. But they don't have that much variety. Wholesale warehouses selling products have a large assortment, but as a rule they sell non-packaged goods or a packaged manufacturer. Sugar in bags, sweets in boxes, etc. are sold there.

Small shops and kiosks cannot afford a large assortment of bulk goods, for example, you cannot buy each type of candy in a box, as they will sell for a long time and the fact that they will be sold before the expiration date. And buyers want a large assortment and the ability to buy goods not in kilograms, but in smaller packages. For small entrepreneurs, a problem arises, it is impossible to provide a wide range, as a result of the outflow of buyers.

Do you feel there is a niche for business in product packaging? We collect applications from small traders, buy goods in bulk and pack them in the quantity and volume they need.
How the mechanism of this business idea works. You need to buy a product at a wholesale price that you can package and pack in small packages.

You will also need an agreement with retail chains that will sell your product. Also, in addition to packaging your own product, you can provide similar services for small supermarkets that want to have products with their brand logo.
It is best to pack seeds or peanuts. Although their cost is not great, they sell out very quickly in retail. You will be able to earn money consistently. You can also pack cereals or sugar, but then you will have to buy a larger machine and it will cost a little more. But still, there are advantages to this business. This machine can only be operated by one person.

How to start your packaging business?

Packing is of two types, manual, which we have already described above, it is long and unproductive. But for a start, he can also come up, do not immediately purchase equipment for the second method, automated, suddenly the business does not work.

At first, it is wiser to start with hand-packing, make connections, earn some money. Understand what this business can bring. And then you can already open an automatic packaging shop. You can pack any product, both bulk and all kinds of cookies, sweets, etc. It is necessary to establish a chain: wholesale depots - small shops and kiosks. And to make an extra charge for packaging of 1 ruble, then the dirty profit will be up to 300,000 rubles per month, that is how many bags can be packaged on this machine.

Of course, you should not expect such volumes right away, you need to start, as we wrote above, with manual packaging, because you may not find so many small outlets who want to buy packaged goods. Then you will spend only on electronic scales, a table and renting a room. The most difficult thing here is to establish ties with small entrepreneurs, you will have to run around, hold a whole series of negotiations, and interest them. You can attract them with goods for sale, agree on a deferred payment.

Finally, a few tips.

1) The so-called "standing" package is better than the "lying" one. In stores, when the buyer takes it, the same one will be visible behind it, and as a rule, when the packaged goods are lying, the buyer no longer sees the product.

2) With a small packaging, the profit is greater.

Take for example a bag of coffee with cream 3 in 1. Its cost is 7 rubles. What does it contain? The lowest quality cocoa, milk powder and sugar. There are instances that you don’t feel like drinking. Yes, milk curdles in boiling water. However, these bags are in great demand, especially in canteens. Let's decompose the material component of one bag, consisting of quality products. So, the weight of one bag is 20 grams. And now let's consider what we put in a glass of coffee for ourselves for breakfast: 1 teaspoon of instant coffee weighs 10 grams, 1 teaspoon of powdered milk weighs 12 grams, granulated sugar - 10 grams. For many, one spoonful will obviously not satisfy, and most put at least two, as evidenced by a very sweet 3 in 1 coffee drink. What happens? Our 3 in 1 sachet should weigh 42 grams. This means that manufacturers save on coffee and milk, replacing them with ordinary sugar. Thus, for 1 sachet of a 3 in 1 drink, 5 gr. coffee, 5 gr. dry milk and 10 gr. granulated sugar. At the wholesale base, a 100 gram jar of Nescafe classic coffee can be bought for 65 rubles, 250 grams of powdered milk costs 20 rubles, 1 kg of sugar costs 28 rubles. Roughly 1 kg. coffee costs 650 rubles, 1 kg. powdered milk - 140 rubles, 1 kg of sugar - 28 rubles. Thus, observing the proportions and taking 1 kg. coffee, 1 kg. powdered milk, 2 kg of sugar and having spent 846 rubles on the components of the drink, we will get 200 bags of 20 grams with a total cost of 1400 rubles. The difference is 554 rubles. If we take into account that the components from the manufacturer are 10-15% lower than in retail, the cost of components can decrease by another 10%, i.e. roughly 85 rubles, and then the difference in price will already be 639 rubles. Sorry, this is almost 100% profit when using quality ingredients that none of the manufacturers put in existing drinks.

The most important thing left is to find an acceptable "cheap" way to package the resulting drink. This is where innovation or know-how is required. By minimizing these costs, you can get a very good profitability. But the existing packaging equipment is not affordable for a novice businessman, and such turnovers will not be required, since for a home business a net income of 50-70 thousand rubles is considered very good, and this is only 200,000 bags per month with a total weight of 400 kg. What a trifle, pack 8 bags of sugar for 30 days and get 50,000 rubles for it. Only 14 kg will have to be packaged per day. Even if half of this amount is spent on packaging and transportation, 1 thousand dollars a month is not a very bad income.

3) The thicker and more beautiful the packaging material, the more premium the product seems in the eyes of the buyer.

When choosing a type of activity, every novice businessman is looking for a way to get a guaranteed profit with little investment. Therefore, the products produced must be in demand. One of the types of such products are packaging materials: plastic and paper bags. Packaging is an integral part of almost any product. The production of packaging materials allows you to earn income regardless of the season.

Where to start production?

The initial stage of the organization of any production requires the development of the necessary documentation. You will need to register the type of activity, issue a package of permits and endorse them in the relevant authorities. On average, the cost of registration will be 300-400 dollars. This process can take from one to two months.

Every three months, the enterprise is obliged to provide its products for examination for compliance with state standards. An expert opinion costs approximately $25 to $35.

At the initial stage of development of polyethylene production, it is necessary to take care of waste disposal. If you have free funds, you can purchase processing equipment and equip the workshop with it. A cheaper way is to conclude an agreement with organizations involved in the processing of household solid waste.

For the successful implementation of a business project, it is necessary to establish a sales network from the very beginning. As a rule, wholesalers become the main buyers.

The main composition of the equipment

The key to the high quality of polyethylene is high-quality equipment for the production of film. These devices are represented by a wide range, which, together with innovative technologies, even makes it possible to recycle raw materials and use them as starting materials for the manufacture of polyethylene packaging.

The production of packaging materials requires the following types of equipment:

• extruder. It is used for the processing of special blanks, polyethylene granules-balls and the manufacture of finished films from polyethylene.

• Cutting and soldering machine. It is used to cut the film in accordance with the desired dimensions. After that, using the machine, the blanks of the packages are sealed on one side. With the help of this device, bags without handles or garbage bags are made.

• Punching press. Produces plastic bags with handles. He "cuts" holes, forming them.

• Flexographic machine. It is necessary for the manufacture of plastic bags with a pattern or with the logo of a particular company. In addition, a distinctive brand name of the manufacturer can be painted on the package, which is an excellent advertisement.

• Devices for crushing and subsequent granulation of waste are recommended, but not mandatory, additional equipment. Required for the processing of generated waste. In the main production, in the manufacture of garbage bags and packaging materials not related to the food industry, the use of recycled materials is allowed.

Equipment for the production of polyethylene film costs between 100 and 180 thousand dollars, depending on the manufacturer and completeness.

Polyethylene manufacturing technology

Polymer granules from the receiving hopper are fed into a special loading funnel. After that, they fall under the screw and, due to their own friction against the walls of the cylinder, are heated due to forced rotation.

As a result of this process, the granules are compacted and melted. Then, from the extruder, the raw material is fed under pressure to the forming device. The molded product is inflated to the desired size and then cooled. The production of the film is completed by passing through the stabilizing unit and pulling it folded along the guide rollers to the winding device.

Raw materials for the production of plastic bags

For the manufacture of polyethylene packaging, including bags, granular polyethylene of high or low pressure is used. The film made from type 1 polyethylene has high strength and is difficult to break.

In addition, it successfully tolerates sub-zero temperatures. When using low pressure polyethylene, the bags produced are denser and tougher, but less transparent, resistant to high temperatures, chemicals and frost.

The cheapest polyethylene raw materials of Korean or Russian production are considered. The cost of one ton of granulated imported polyethylene ranges from 400 to 650 dollars, and domestic - within 350 dollars. Recyclable materials can be used to make non-food packaging.

Dyes are used to make polyethylene bags. Their cost is from 5 to 20 dollars per kilogram, depending on the color scheme.

Requirements for premises and staff

It is recommended to place a workshop for the production of polyethylene film away from the residential area, since the manufacturing process is accompanied by harmful emissions into the atmosphere. The area of ​​industrial premises should be at least 100-150 sq.m. at a height of at least 10 meters. All workshops must have a forced exhaust ventilation system.

Warehouses should have increased hydro and vapor barrier, since high humidity can reduce the quality of raw materials and final products.

Additional water supply, other than that provided for by sanitary standards, is not required. However, when the workshops are equipped with some devices for the processing of generated waste, water consumption will increase. The voltage required for operation in the mains is 380V/50Hz, 220V.

It is not necessary to use highly qualified employees as working personnel. Film production, thanks to the unpretentious technology and ease of maintenance of machines, allows you to quickly train beginners without the appropriate skills.

Film types

Today, polyethylene film is produced in a wide variety of widths and thicknesses. For a long time, these products were used only as a convenient packaging material. Currently, polyethylene packaging has a very significant and useful function - applying the necessary information about the manufacturer or seller of the packaged goods or any services.

According to its purpose, polyethylene film is divided into the following types:

• food;
• stretch;
• heat-resistant;
• black;
• reinforced and others.

For packaging, in addition to the usual polyethylene film, heat-shrinkable polymer and air-bubble films are widely used.

Production of thermoshrinkable polymer films

Shrink films are called films, which, when heated, shrink and tightly fit the products packed in them.

The technology for the production of shrink film consists in the deformation of the heated polymer and its rapid cooling to room temperature, bypassing the formation of the elastic component of the deformation. The polymer becomes harder and the stretched macromolecules cannot return to their natural equilibrium state. The secondary heating of the film softens the polymer, the molecules try to return to the globular state, and the film shrinks.

Shrink film production is excellent for food packaging. The product, packed in such material, is placed in a heating cabinet, heated to a certain temperature. The film tightly fits it, repeating the shape.

Air bubble film production

The production of air bubble film consists in the formation of bubbles from heated polyethylene filled with dry air. This film, in addition to the usual properties, has the ability to withstand atmospheric influences, vibrations, shocks and shocks.

Bubble film, the production of which is the creation of a layer of polyethylene bubbles, coated on one or both sides with a polyethylene film, is a packaging material with increased strength. All bubbles have clear limits, and therefore, when one of them is deformed, the others retain air inside themselves, thereby maintaining their protective properties.

An alternative to the "polyethylene business" is the production of paper packaging

No less popular, in comparison with the production of packaging materials from polyethylene, is the production of paper packaging. Such products are divided by type into bag, wrapping and packaging. They are made of dense, moisture-resistant, grease-resistant paper, as well as kraft paper or parchment, and, depending on the packaging application, can be recycled.

The production of paper packaging materials consists of six stages:

1. Billet production.
2. Drawing drawings and logos.
3. Gluing and sewing the bottom.
4. Production of a semi-finished valve for a closed bag.
5. Packet bottom fastening.
6. Packing packages in piles.

Paper packaging production lines vary in equipment capacity and cost.

The set of basic necessary devices for the production of environmentally friendly paper packaging includes:

• machine for gluing paper in multilayer blanks;
• device for forming and gluing the bottom of paper bags;
• machines for stitching and gluing semi-finished products.

The capacity of such a production line is about two hundred and fifty bags per hour, the price of a set of such equipment is about 23,000 thousand dollars. Additional units can be purchased as needed.

Payback periods

The simplest line for the production of polyethylene bags is capable of producing about 3000 pieces per hour. With an eight-hour working day, approximately 20,000 bags can be produced per day. The wholesale price of one product is five times higher than its cost price. Profit in dollar terms is approximately 140-180 dollars per day. As a result, the production of packaging materials can pay back the cost of equipment in about 1 year.

The cost of the expanded and supplemented line for the production of paper packaging ranges from 87 to 145 thousand dollars. When organizing a small workshop with a production rate of about 250 bags per hour, cash costs of about 136 thousand dollars will be required.

This includes the cost of purchasing equipment and blanks, repairing the premises, and so on. The area of ​​the workshop for production must be at least 100 sq.m. On average, the profitability of paper packaging production is 30%, the payback period is about a year and a half.