Tape for the manufacture of gypsum plasterboard profiles. The production process of making a profile for drywall. Sales of finished products
Given the high demand for building and decorative structures based on, those components that are used for its installation are also in demand on the market building materials... And this includes a metal profile. The conclusion suggests itself - if you buy a machine for the production of profiles for drywall, work out the range and technology, you can start making money today. It has already been proven in practice that the profitability of production is quite high. Plasterboard fixing profile - metal product, made for the convenience of mounting the material in different versions. It is actively used in the construction of buildings and their decoration.
Our business valuation:
Initial investment - from 600,000 rubles.
Market saturation is medium.
The complexity of starting a business is 5/10.
Whatever it takes large investments to launch an enterprise, it is better to immediately abandon the organization of a large-scale plant. For aspiring entrepreneurs the best option will open a mini plant for the production of drywall profiles. What are the stages to go on the way to success and great profits?
What assortment to offer to consumers?
It would seem that there is nothing complicated and unusual in such a simple product as a fastening profile. But for certain purposes, builders may need a variety of sizes and types of drywall profiles. And in order to gain the trust of customers, it is important to provide them with a wide range of products that differ in scope and geometry.
It is worth thinking over the assortment even before purchasing everything necessary equipment because many machines can only produce one kind of profile. But for the production of a whole range of products, multifunctional equipment will be required. It costs much more.
There are the following types of profiles for fixing drywall:
- guiding,
- ceiling,
- rack-mount,
- beacon,
- angular.
Of all possible options Ceiling and guide profiles are in great demand on the market. They are widely used for the construction of partitions, installation of suspended ceilings, for wall insulation. The standard dimensions of the ceiling profile are 60 * 27 mm. The standard dimensions of the guide profile are 27 * 28.
Assortment development is only the first stage from which a business plan for the production of a profile for drywall begins. There is still a lot of work ahead on the selection of raw materials and equipment.
How is the fastening profile manufacturing process carried out?
The production of galvanized profiles is impossible without appropriate raw materials. And here, as a rule, galvanized steel of class 2 is used, supplied to enterprises in the form of strips - strips. And if the thickness of the sheet should be standardly 0.3-0.6 mm, then the required width of the tape will depend on the type and purpose of the product planned for release.
For the manufacture of the ceiling profile, strips with a width of 123 mm are taken. And the guide fasteners require a steel tape 81 mm wide.
In order for the business in the production of profiles for drywall to be more profitable and less costly, metal raw materials should be purchased from those suppliers that are geographically located closer to production. In addition, the price of the material will be significantly reduced if you buy everything you need at once from small wholesale lots.
As for the technology for the release of fastening profiles, it is extremely simple - everyone can master the process. The stages are as follows:
- Filling a steel roll into the machine.
- Forming a profile from a metal blank.
- Packaging and storage of finished products.
It turns out that manual labor is minimized in the production process. And this is another plus of this direction, since the cost of production is reduced due to the refusal to hire highly qualified personnel. The workshop will require the presence of personnel of only working specialties.
And since all processes are carried out by an automated line for the production of profiles for drywall, we pay special attention to the next stage of business planning - the technical equipment of the workshop.
What equipment to equip the workshop with?
In order to buy equipment for the production of profiles for drywall, no problems should arise - suppliers offer a lot of equipment options for sale, because this area is characterized by high demand for finished products.
When equipping a workshop, the following factors should be analyzed - its cost, power, equipment, functionality. If you study the market, you can choose the option of technical equipment that is suitable in terms of price / quality ratio.
The "middle" line for the production of gypsum plasterboard profiles is equipped with the following machines and devices:
- Uncoiler.
- Profile bending machine.
- Cut-off machine.
- Reception table.
We have indicated a list of the main machines required to obtain quality products. But to facilitate and speed up the process, you will also need some additional equipment - a crane beam, a loader.
The final price of the equipment varies in a wide range - 500,000 - 2,000,000 rubles. It is important to understand that with the help of cheaper semi-automatic devices, an entrepreneur will be able to receive only 1-2 types of a profile. But the higher price of the machine for the production of profiles for drywall will indicate that such equipment will allow the production of a much wider assortment, which, of course, will affect the final profit from sales.
Even if there is no minimum amount for equipping a workshop, it is worth buying a used machine. And then the cost of purchasing equipment can be reduced up to 250,000 rubles.
Domestic production lines are slightly lower than those made abroad. But as practice shows, such equipment is much better in quality, durability, and functionality.
Features of the sales market for finished products
Since the demand for products only increases, consumers can be found without problems. There are several ways for an entrepreneur to develop:
- Construction companies and contractors.
- Private buyers.
It's great if the metal profile for drywall will be sold in bulk. This will save the entrepreneur the headache of attracting interested customers. But even so, it is hardly worth "writing off" and small private traders. If it is possible to organize a small warehouse-pavilion on the basis of the workshop, where the manufactured products will be presented for sale, this should certainly be used. Then, everyone will be able to come here for the necessary material.
Concerning marketing development the opening enterprise, then it is unlikely that it will be necessary to deploy large-scale advertising campaigns... Subject to cooperation with wholesalers, it is much more important to have a profitable commercial proposal... And if we talk about our own point of sale, you still have to invest some money in advertising.
And what will happen to the enterprise in the autumn-winter period, when the entire construction market is "sinking"? Yes, at this time not many people need a frame made of gypsum plasterboard profiles, but with well-functioning distribution channels, even in winter, equipment downtime can be avoided. Sales will decrease significantly, but this, of course, will not lead to the ruin of the enterprise.
Let's talk about the financial side of the matter
It has already been proven in practice that even a small profile production company can bring a high income to its owner. But before moving on to specific indicators of profitability, it is important to assess the capital investment that will be required to start the business.
The production of profiles for drywall will require the following investments (taking into account new equipment):
- Registration of an enterprise - from 10,000 rubles.
- Purchase and commissioning of the line (without additional equipment) - from 600,000 rubles.
- Preparing the premises for operation - from 100,000 rubles.
- Providing a raw material base - from 200,000 rubles.
In the case of the purchase of supported equipment, capital costs will be reduced up to 600,000 rubles.
If we talk about a workshop of low capacity (200 running meters / h), then with an 8-hour shift 22 days a month, it is possible to produce up to 35,500 running meters of products per month. As for the cost of the finished material, then a lot depends on its type. For approximate calculations, we will take the average wholesale price of a profile - 30 rubles / rm. By selling the entire volume of manufactured products, you can have a revenue of ≈1,000,000 rubles. Part of it will go to the further organization of production, and about 100,000 rubles. the entrepreneur himself will earn.
Drywall without exaggeration can be called one of the most popular and demanded building materials that are used in the renovation of apartments, offices, workshops and storage facilities... It breathes and allows you to hide all existing surface imperfections, providing an ideal basis for applying the final layers of putty, paint, wallpapering, etc. appearance interior. When installing drywall, you cannot do without the use of a metal profile, which will become a reliable basis for future construction.
Making a metal profile at home is a costly business at first, but at the same time it is quite profitable. Moreover, the equipment for the production of roller profiles can be made by hand. More on this further ...
Profile making machine
The production of galvanized steel profiles does not require a lot of skills and knowledge. You will need a special profile bending machine that is selected (or converted) to the type of profile that you plan to produce.
To acquire a rolling machine for a profile, you can go in two ways:
- Do rolling machine with your own hands, which can be modernized and converted for any type of manufactured product from galvanized sheet.
- Buy finished equipment for the production of profiles for drywall.
The most popular machines among gypsum plasterboard manufacturers are those with a single strand production line. They produce a certain type of profile (for example, ceiling or rail) at an average speed of 10 running meters per minute. Therefore, in one working hour, the equipment for the production of gypsum board profiles can produce up to 500 running meters. This means that after a continuous 8-hour working day, about 4000 meters of products can be sent to the warehouse, completely ready for sale. For a month, the volume of finished products can reach up to 88,000 running meters!
The average market price of a rolling mill hovers around $ 4,000. At the same time, the supplier company often not only ensures the delivery of the order, but also conducts comprehensive training in the correct use of the machine, and also carries out a full adjustment of the equipment and its further repair (if necessary).
But if you do not yet have the opportunity to purchase equipment for $ 4000, you can make your own machine with your own hands. It may be slightly inferior in performance. For example, there will be no guillotine on it and the workpieces will need to be cut in a separate operation. But in general, it will be possible to organize profitable production at home.
How to make a rolling machine for a profile with your own hands
Consider a 3D model of a rolling mill for the production of a 29x27 C-shaped or U-shaped profile.
For the manufacture of the machine you will need: metal, bearings, lathe or a familiar turner with a lathe. Pay attention to the design and device of the rolling machine.
Looking at the picture, the first impression is alarming. And if you look into the details, then there is nothing complicated.
Diagram of the device model of the roll forming machine
The machine consists of a table on which a worm gear motor NMRVP-063 is fixed. 7 stands are also fixed on the table. The first receiving stand is already shown in this figure:
- Channel table.
- Worm gear motor NMRVP-063.
- First receiving stand.
- Chain drive to the first stand.
Each stand consists of a few simple parts:
- Cage body.
- Self-aligning bearing unit UCST 204.
- Self-aligning bearing unit UCFT 204.
- Lower and upper shafts.
- Lower and upper rolling rollers.
- Chain sprocket Z = 16.
- Guides.
- Spacers.
- Adjusting bolts M12X70.
As you can see in the picture above, all the stands are connected to each other by a chain drive.
It should be noted that the rollers are removable and mounted on shafts. This allows you to re-equip the machine for a different type of profile produced. If desired, new rollers can be used to upgrade equipment for the production of LSTC profiles. Construction of houses using LSTK technology is actively gaining popularity in the field of prefabricated buildings.
Technological process for the production of profiles for drywall
The principle of operation can be easily understood by looking at at the end of the article. A sheet of galvanized metal is rolled through a series of rollers, each of which has a different mold:
Thus, with the help of rolling rollers, the workpiece is gradually transformed into the shape of the finished product.
In order to get acquainted with the device of the equipment in detail, we recommend that you read all the dimensions and descriptions of the units. In this archive there is a 3D model of a metalworking device, which can be disassembled to the smallest bolt or washer and see. There you can also remove all the dimensions of the parts, and then actually make the machine according to the model no worse than according to the drawings. Perhaps this format is even better than blueprints. 3D Model File Formats:
- * .sldasm is the main format of the paid software "SolidWorks" (this format also supports free program for viewing 3D models - eDrawings, which is already included in the archive).
- * .step is a standard format for exchanging 3D models between different 3D editing programs. This file format is supported by almost every 3D editor (for example: free FreeCAD, AutoCAD, 3D-Max, Blender, etc.).
Varieties of metal profiles
Plasterboard profile is divided into the following types:
- Used to create racks (type CW. The most common varieties on the building material market are profiles CW-50, CW-75 and CW-100).
- Guide (UW type. UW-50, UW-75 and UW-100 brands).
- Wall-mounted (type UD. But often only UD-27 is used, made of 81 mm steel).
- Ceiling (type CD. Grade CD-60, which is made of galvanized steel 123 mm wide) is used in repairs most widely and often.
The profile differs in its thickness, width, weight and other parameters. Each of these profiles is made from coils of galvanized strip steel, also known as strip.
As you can see, the business of manufacturing gypsum plasterboard profiles at home has a fairly high profitability. In the presence of start-up capital, which will cover all start-up costs, while also having an established network for the sale of finished products, you will be able to reach self-sufficiency in 7-8 months.
This type of product is always in demand. If you master all the nuances of its production technology, you can provide yourself with a stable income for many years.
Get started own business for production and sale right now, and the final profit will be the best reward for all your efforts!
The metal profile serves to form a frame system for fastening drywall sheets and provides functionality, reliability in operation of the structure and ease of technological installation. The use of metal slats is mandatory when:
- Arrangement of complex communication outputs and wiring;
- Subsequent cladding of the surface of gypsum boards with heavy materials - tiles, natural or artificial stone;
- Large deviations of the curvature of walls, ceilings in case of their unsatisfactory structure for installation - high porosity, looseness, dampness, etc.
- Designing curly multi-level decorative structures.
As a material for the production of a metal profile for the device of a frame for sheets of drywall, strip is used - galvanized strip steel coil. The optimum thickness of the sheet is 0.4 - 0.6 mm.
During the manufacturing process, the end of the steel strip is fed into a rolling mill, where a profile of a certain section is formed under the pressure of rollers of various shapes and sizes (sizing stands). After that, the workpiece is cut into the required length and thrown to the side. Setting the given length and width of the profile and finishing the steel strip to the cutting place (guillotine) is done manually once (at the very beginning of work). The process then runs automatically.
Aluminum or plastic is used as a material for the production of profile strips, which depends on the manufacturer.
Equipment for the production of
For the manufacture of a profile, special equipment is used, which includes:
- Profile bending machine;
- Pneumatic guillotine;
- Automatic control system.
The machine is designed to produce shaped blanks by cold rolling or stamping. Types - one and two-strand, for the release of a profile of several formats at the same time. The productivity of the first type of machine is 15 - 20 rpm / min, the volume of equipment work on 2 lines is 9 - 10 rpm.
Rolling mill The guillotine (or scissors) is used to adjust the workpiece according to the size specified by the customer. The standard length of the bar is 3-4 m, but by special order it reaches less than 1 or more than 6 m. Types of guillotine - stationary or flying, with a complete hydraulic drive for cutting material without stopping the line.
The control system is semi-automatic or automatic with a remote control and a touch screen control. The digitally controlled roll forming equipment ensures the smooth production of metal blanks to form gypsum board structures with precise parameters.
To ensure an optimal and uninterrupted workflow, the mill is additionally equipped with a table for accepting finished workpieces, on which the material is packed and sent to the warehouse, as well as a device for unwinding and feeding roll material.
What format is produced
Each machine is designed for the production of a certain type of profile in several formats:
- CD or ceiling;
- CW, also called rack-mountable;
- UD or parietal;
- UW as the designation for the guide bar.
Types of produced profiles According to the adopted SNiP and GOST standards regarding the assembly of drywall structures, the geometric and physical parameters of the profiles must meet certain requirements. So the UD bar has a section of 27x28 mm, and the CD 60x27 mm, which is due to the peculiarities of their fitting and fixation with each other.
The wall profile is made with pre-drilled holes in the center of the backrest, designed for dowels with a diameter of 6 mm. Hole frequency - 260 mm. As a result of processing through the machine, the surface of the ceiling profile at the base is covered with notches, and convex grooves (stiffeners) are formed on the side parts, which increases the strength and rigidity of the workpiece.
The CW profile is made of 0.5 mm thick steel strip. At the exit through the machine, a "C" -shaped workpiece with parameters 50/75 / 100x50 mm is formed. This strip serves to secure the plasterboard boards during the assembly of the partitions. The UW profile is produced in the shape of the letter "P". Its dimensions are 40x50 / 75/100 mm.
CD and UD profiles make up about 90% of the domestic market, therefore, a machine for the production of these 2 types of strips (double-strand) is more common. A less common format is a reinforced door (UA), flexible (arched) and corner perforated profile, whose brands are often represented by manufacturers from Poland and Germany.
Machine with 2 lines for CD and UD profiles How is the production of profiles of various formats on rolling mill can be seen in the video below.
Equipment brands
An important point in the process of manufacturing a profile is the choice of a brand of equipment and a country of production, on the quality of which high technical indicators of a batch of finished material depend. They give preference to European or domestic brands. The most famous and proven manufacturers:
- LGS-26 (Russia);
- Zenitech PW 40 (Ukraine);
- Knauf (Germany).
They also buy machines from Chinese brands Dongfeng or Titan-machinery. The production of a profile on such equipment allows the production of large volumes of material (up to 2,000,000 m2 / year) with minimal energy consumption, which is reflected in the cost of production and in the costs of constructing plasterboard structures.
In contact with
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The production of galvanized profiles is promising direction, since this type of material is indispensable for creating reliable structures of any complexity for fixing gypsum cardboard and is in great demand on the market.
The product is a fastening base for mounting drywall sheets during finishing work. Depending on the purpose, several types of profile are distinguished: rack, guide, ceiling, beacon, corner.
Due to its versatility, the most popular are the ceiling profile PP 60 * 27 and ceiling guide PPN 27 * 28, which allow you to quickly and conveniently form frames for the installation of interior partitions, suspended ceilings and wall cladding.
As a raw material for the production of a profile, thin-sheet rolled galvanized steel of class 2 with a thickness of 0.3-0.6 mm, cut into strips (strips), is used. For PP 60 * 27 you need tape 123 mm wide, and for PPN 27 * 28 - tape 81 mm wide.
Consumers of galvanized profiles can be divided into 3 groups:
- Companies and contractors that provide construction services, as well as are involved in the construction of commercial and residential real estate;
- Legal entities who carry out finishing work in their own offices and production facilities;
- Individuals making repairs to their own homes.
The main distribution channel for products individuals are hardware stores. The largest sales volume will be provided by contracts with large construction hypermarkets.
Manufacturing process and required equipment
The production of galvanized profiles is carried out using a special roll forming machine from thin sheet galvanized steel coils with a thickness of 0.3-0.6 mm.
The production process consists of several stages:
- adjustment of the roll forming machine for the thickness of the used metal sheet from 0.3 to 0.6 mm;
- filling a special workpiece or strip of the required width into the device;
- forming a profile from a workpiece in the working area of the machine and cutting the finished product of the required length using a pneumatic knife;
To complete all of the above steps, it is optimal to purchase an automatic production line.
Consider two options for completing the workshop.
Option number 1
Option number 2
 | Profile bending machine for the production of profiles for drywall Mobiprof GK, manufacturer "Center-FK" This line allows the production of two types of products:
The main specifications:
|
The line described in the first version has a higher productivity and requires less investment, however, the equipment manufactured by Center-FK can produce two types of profiles, which will allow the production of a wider range of products, which in turn will have a favorable effect on the sales opportunities ... In this regard, the second option for completing the production site will be taken as the base one in calculating the feasibility study of the activity.
To start the activity, it is necessary to equip the workshop with a crane beam to install the coiled steel on the decoiler automatic line, as well as carrying out unloading operations. One of the options is the purchase of an electric overhead crane girder for 5 tons, manufactured by "Ramenskiy Crane Plant"
Feasibility study of the project
Capital investments
- Purchase of a line (option No. 2) - 770,000 rubles.
- Delivery, installation, commissioning - 150,000 rubles.
- Buying a crane beam - 159,500 rubles.
- Purchase of hand tools and equipment - 50,000 rubles.
- Purchase of galvanized metal - 500 thousand rubles.
- Preparation and repair of premises - 300 thousand rubles.
- Expenses for organizing and registering a business, other expenses - 50,000 rubles.
The total amount of investments for opening a business for the production of a profile: 2,029 thousand rubles.
Calculation of monthly revenue:
When calculating the monthly proceeds, the load of the production line for the production of PP 60 * 27 by 55% was taken into account. With such a load, 1 ton of coiled steel is processed daily.
* The calculation of profit and payback was made based on the expert opinion of the author of the article.
