"Plastic" business - production of disposable tableware. How to start a production of disposable plastic tableware

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Disposable plastic tableware is no longer a new product. This is an affordable and convenient way to reduce cleaning time and the weight of luggage on vacation or during transportation. Despite the periodic noise in the press about the dangers of plastic containers, they are in wide and constant demand. Because this is comfort for little money, and the “danger” of plastic for food is easily neutralized by its correct use. This product will always have its buyer. But will its production be profitable? Let's look at it step by step.

Areas of application and possible sales

Plastic products presented on today's disposable tableware market: plates, cups, glasses, skewers, drink stirrers, spoons, knives, forks, trays and containers for storing food of various shapes and sizes. Dishes are made from plain and foamed polystyrene (for cold foods) or polypropylene (for high temperatures, microwave ovens).

Areas of application of plastic tableware:

• catering outlets operating on the principles of “fast food” (pancake houses, pizzerias, children’s cafes, canteens);
• enterprises that deliver ready-made meals to your home or office;
• grocery stores;
• food production enterprises;
• retail outlets with goods in bulk (confectionery, dairy products, ready-made salads).

A huge segment of the disposable tableware market is occupied by plastic cups - they are used almost everywhere: in offices, sanatoriums, children's and sports institutions (for coolers, in vending machines for hot and cold drinks, in the catering industry). Of course, the level of competition here is much higher than in the manufacture of other plastic tableware products.

To start production, you need to decide on the product range. To do this, you need to assess the presence of competing enterprises in the region, their range and pricing policy. Despite the large number of offers on the plastic products market, there may not be any worthy competitors, since a huge amount of plastic tableware is imported from China, and, as practice shows, the buyer is more loyal to the domestic manufacturer, even if the price of its products is higher.

Organizational issues of registering a business producing plastic utensils

The choice of organizational form for legal registration of a business depends on the size of the planned profit. This can be either an individual entrepreneur (for a small enterprise) or an LLC. For the latter, despite the greater amount of paperwork, it is much easier to agree on cooperation with large enterprises both when purchasing raw materials and when concluding supply contracts for finished products. Traditionally, there is more trust in a legal entity. And VAT reimbursement is important in the tax optimization procedure. Therefore, the optimal organizational form for starting production is an LLC on the general taxation system, including VAT.

The following code should be indicated as the main activity: 25.24.2 manufacture of plastic tableware, kitchenware and toiletries

Activities for the production of plastic utensils are not licensed, but certificates and technical specifications will be required to ensure that finished products comply with SanPiN standards and GOST requirements.

Please note the following regulatory documents:

• GOST R 50962-96 – “Dishes and household products made of plastic. General technical conditions";
• GOST 15820-82 - “Polystyrene and styrene copolymers”;
• GN 2.3.3.972-00 - instead of SanPiN No. 42-123-4240-86 “Permissible quantities of migration (AQM) of chemical substances released from polymers and other materials in contact with food products and methods for their determination”;
• SP 2.2.2.1327-03 – “Hygienic requirements for the organization of technological processes, production equipment and the workplace”;
• GN 2.2.4.1313-03 - “Maximum concentration of harmful substances in the air of the working area.”

Nuances of choosing a production facility

If you plan to produce a full cycle with the operation of an extruder, the following requirements must be met:

• the height of the room is not lower than 4.5 m;
• floor – concrete or tiles;
• walls - 1.5-2 m from the floor surface are finished with non-combustible material;
• good ventilation; - ability to connect to a water supply system;
• connection to a 3-phase power supply.

If finished film is used as a raw material (in fact, the work is carried out on a heat press and packaging), the ceiling height is permissible lower, but not less than 3.5 m.

According to its functional purpose, the production premises should be divided into the following zones:

• Workshop for the production of plastic utensils;
• Administrative and amenity premises;
• Warehouse for storing raw materials;
• Warehouse for storing finished products;
• Changing rooms for staff;
• Bathroom.

Raw materials - choose quality

Technological process for the production of plastic tableware

Depending on the type of product, there are two technologies for producing plastic tableware: molding and casting. The injection molding method produces thick-walled tableware (cutlery, premium goods: shot glasses, wine glasses, glasses in individually made molds). The casting process is quite slow, production costs are high, since here the weight determines the quality and strength of the finished product. For example, the weight of a standard cup with a capacity of 200 ml is 3 g, made by injection molding - up to 10 g.

Making tableware using the molding method is more promising for mass consumption. The automated molding line can produce up to 30 million cups (13-18 million plates) per month.

Let us consider step by step the technology for manufacturing plastic utensils using this method:

1. Raw materials in the form of polyester residues (recycling) or finished granules are fed into the extruder. If you plan to produce colored tableware, colored granules are added to the white ones.

2. In the extruder, the granules are heated to the melting point, the melt is constantly mixed using a screw press. Having reached the desired consistency, the mass passes through a press, forming a plastic sheet about 2 mm thick. Basic Requirement– uniform thickness of the resulting product.

3. Ready The film roll enters the thermoforming machine, where, depending on the type of product, molds of various configurations are used.

4. But before forming blanks for future dishes, the film needs to be heated. To do this, it is sent through a 3-meter furnace, which heats the material to a plastic state.

5. In a thermoforming machine, the web is sucked tightly into the molds.

Using a press, finished products (cups, plates, packages) are squeezed out row by row.

7. The resulting film scraps are disposed of for further use. Thus, the production process is waste-free.

8. The trimmer transfers the products to the machine, which stacks the products and transfers them to the conveyor belt.

9. The belt transfers the products to the packaging. Or for further modification (heating and rolling the top edge of the cups to form rounded rims; applying printed images and logos), and then onto the packaging.

We are drawing up a business plan for the production of plastic tableware

1. The enterprise LLC “X” plans to produce the following product

• cutlery (spoons, knives, forks);
• glasses (200 ml capacity);
• dishes.

2. Raw materials and supplies

• for the manufacture of cutlery and plates - polypropylene;
• for cups - polystyrene.

The products produced will be transparent (cups) and white (other products), since color additives contain harmful chemical dyes. The production is waste-free (remains of the film are melted in an extruder for further use).

3. Sales

• stationary catering outlets (50%);
• population and offices (20%) - seasonal outdoor retail outlets (20%);
• cafe (5%);
• enterprises for the delivery of lunches, production of baked goods and confectionery products (8%).

4. Room

Rented industrial premises - 500 m2 * 1400 rubles/m2. Rental cost - 700,000 rubles/month. (RUB 8,400,000/year)

5. Capital investments

A) Technological equipment (the price includes delivery of the line to the production workshop, installation, commissioning, personnel training):

• Extruder – RUB 1,048,950,
• Thermoforming machines – 2 pieces * 672,000 rubles = 1,344,000 rubles,
• Molds – 5 pieces * 241,710=RUB 1,208,550,
• Compressor – 600,600 rub.

B) Additional equipment:

• 2 computers and office equipment – ​​65,100 rubles,
• transport (Gazelle car) – 3 * 82,950 = 248,850 rubles.

Total – RUB 4,516,050.

6. Calculation of production capacity

M = production rate (according to technical data) * equipment operating time

It is planned to work in 2 shifts of 8 hours each with a lunch break (Saturday, Sunday, official holidays - weekends).

Predicted operating time of equipment = (calendar days - weekends - holidays) * number of working hours * number of shifts = 249 * 7 * 2 = 3486 hours / year

Minus 60 hours/year of downtime for maintenance and repair work – 3426 hours/year.
Production capacity = standard productivity * number of operating equipment * operating time of equipment

In accordance with the characteristics of the equipment, we will calculate the production capacity for each type of product:

M (glasses) = 20,000 pieces * 1 * 3426 h = 68,520,000 pieces/year

M (plates) = 18,000 pieces * 1 * 3426h = 61,668,000 pieces/year

M (knives) = 21,000 pieces * 1 * 3426h = 71,946,000 pieces/year

M (forks) = 21,000 pieces * 1 * 3426h = 71,946,000 pieces/year

M (spoons) = 21,000 pieces * 1* 3426h = 71,946,000 pieces/year

7. Calculation of material costs

Material costs for the production of 1 unit of product = quantity of consumables * purchase price of the material.

Plates (0.005 kg x 61,668,000 pieces) x 40 rubles = 12,333,600 rubles.

Cups (0.004 kg x 68,520,000 pieces) x 36 rubles = 9,866,880 rubles.

Cutlery - (0.002 kg x 71,946,000 pieces x 3) x 40 rubles = 17,267,040 rubles.

Other material costs (packaging, fuel, etc.) – RUB 9,866,880.

Total material costs – 49,334,400 rubles/year.

8. Personnel and payroll

Number and total wage fund for the year (taking into account vacation pay and seasonal bonuses) to ensure 2-shift operation of the enterprise:

• Director – 435,600 rubles,
• Accountant – 382,800 rubles,
• Technologists (2*211,200 rubles) – 422,400 rubles,
• Equipment adjusters (2*204,600 rubles) - 409,200 rubles,
• Workers (20*198,000) – 3,960,000 rubles,
• Loaders (4*184,800) – 739,200 rubles,
• Drivers (4*171600) – 686,400 rubles,
• Cleaners (2*165,000) – RUB 330,000.

Total total wage fund – 7,365,600 rubles/year

Salary taxes (UST) will amount to RUB 1,915,056/year

During the high season (April-September), it is planned to create additional places and flexible work schedules for general workers (students).

9. Calculation of product costs

The cost per unit of production is calculated as the sum of material costs, costs of wages and social needs (UST), depreciation and other costs (rent + advertising).

Plates – 14,309,976 (material costs) + 1,473,120 (salary) + 383,011.2 (Unified Social Tax) + 1,578,821 (depreciation) + 1,741,000 (rent + advertising) = 19,485,928.20 rubles

Cost of 1 plate - 19,485,928.20 rubles / 61,668,000 pieces = 0.32 rubles

By analogy, we calculate the cost of other products:

• cups – 0.25 rub/piece,
• cutlery – 0.18 rub/piece

10. Determination of the selling wholesale price

Product unit price = Cost of 1 piece + Profit rate (according to standards - 25%)

We calculate the minimum selling price threshold for wholesale:

• plates – 0.32 + (0.32*25%) = 0.40 rub.
• glasses – 0.25 + (0.25*25%) = 0.31 rub.
• cutlery – 0.18 + (0.18*25%) = 0.23 rub.

11. Calculation of the production program

Sales revenue = number of product pieces/year * price per piece

Glasses – 68,520,000 pieces/year*0.31 rubles = 21,241,200 rubles/year

Plates - 61,668,000 pieces/year*0.40 rubles = 24,667,200 rubles/year

Knives - 71,946,000 pieces/year * 0.23 rubles = 16,547,580 rubles/year

Forks - 71,946,000 pieces/year*0.23 rubles = 16,547,580 rubles/year

Spoons - 71,946,000 pieces/year*0.23 rubles = 16,547,580 rubles/year

Total revenue for the year: 95,551,140 rubles/year.

12. Calculation of balance sheet and net profit

Based on the calculated data, we draw up a financial plan for the production of plastic tableware in value terms:

• Sales revenue – 95,551,140 rubles/year,
• The cost of dishes is 75,217,160 rubles/year,
• Profit from sales (balance sheet) – 20,333,980 rubles/year, (Revenue - Cost)
• Income tax (20%) – 4,066,796 rubles/year, Net profit = Balance sheet profit – Income tax = 16,267,184 rubles/year.

13. Calculation of profitability

Product profitability is calculated using the formula: P = (Book profit: Cost) x 100%P = 20,333,980: 75,217,160 * 100% = 27%

Conclusion: the business of producing plastic tableware is profitable with large scale sales. Subject to the estimated capacity utilization, the initial investment in a business project can pay off within 2-3 months.

Our company produces a wide range of disposable cutlery and food packaging (plastic jars made of polypropylene with a lid). Products are manufactured using modern high-tech equipment in compliance with all environmental standards. Our production employs experienced and qualified employees. All products are certified.

The production base is located near major transport arteries and federal highways. It has good access roads and an equipped warehouse terminal. The production has passed full certification.

The cutlery we produce (disposable forks, spoons, knives, cocktail straws) and plastic jars with lids have a compact internal packaging, which allows the products to be packaged in economical transport packaging (cardboard boxes), which in turn is convenient for transport logistics (warehouse + transportation ).

The main advantages of rigid polypropylene packaging:

1. Operating temperature range: -40°C +120°C.
2. Chemically “passive” material, long-term contact with fatty and acid-containing products is allowed, ideal for long-term preservation.
3. Manufactured in any color.

Disadvantages of polypropylene packaging:

1. Lack of barrier properties to oxygen diffusion.
2. It is not allowed to heat on an open fire source or in ovens.
3. Cannot be sterilized in autoclaves

Technical and temperature characteristics of raw materials

Chemical resistance

*Low(s) - used for packaging a product with a recommended shelf life and storage conditions.

*Medium(s) - long-term (3 - 6 months) storage of the product is excluded in the packaging.

*High (s) - can be used for packaging products with a long shelf life without harm to health.

Advantages and disadvantages of materials used for the manufacture of disposable food packaging

Since 2000, there has been rapid development of the disposable tableware market. Every year it becomes more and more popular. It changes shape, color, inscriptions and drawings appear on it. This allows you to expand the boundaries of use of this product. Now disposable tableware is used not only at picnics and on trips, but also at corporate events and holidays. Gradually, it is gaining a place in home use. This can significantly save time for hostesses, heroes of the occasion and everyone who is somehow involved in cleaning the premises after events.

At the stage of market formation, plastic dishes made from various polymers were more popular. But gradually, paper tableware took its rightful place, thanks to its colorfulness, diversity and lack of chemical emissions during use, which cannot be said about plastic.

When using utensils made of polymers, it is recommended to observe conditions under which their use will be safe. As a result, according to experts, in the future the consumption of paper tableware may far exceed plastic. However, for now, polymer tableware occupies a leading position with a market share of 80% in volume terms. The remainder comes from paper dishes.

Drawing 1 . Market structure in physical terms in 2009

Most of the disposable tableware market belongs to Russian manufacturers. Imports account for 15%. But if we consider the market by segment, then the largest share of the plastic tableware market is occupied by domestic production, namely 80% in physical terms. Paper tableware is mainly imported, with a market share of about 90% of the Russian disposable paper tableware market in volume terms.

Drawing 2 . Market structure in 2009 in physical terms

The main suppliers of plastic tableware in 2009 were China and Poland. Their share of imports was 34% and 15% in volume terms, respectively. The remaining countries accounted for less than 7% of supplies each. At the beginning of 2010, Portugal also became a leader, sharing second place with Poland, each country accounting for 7% of imports. The main supplier country in the 1st quarter of 2010 China remains - 36% in tons.

If we talk about companies supplying tableware made from polymers to the Russian market, among them we can highlight “ Tupperware", Alena LLC and IKEA . It was these companies that became the leaders in the market of imported plastic disposable tableware in 2009. Their shares are respectively 9%, 5% and 4% in volume terms. In the first quarter of 2010, the company “ Huhtamaki "(3% in tons), and Alena LLC is not even among the top five importers.

The main suppliers of disposable paper tableware to Russia in 2009 were Italy, Germany and Finland. Also, these countries held leading positions at the beginning of 2010, both in physical and value terms. Companies Seda, "Italica" and Huhtamaki , belonging to these countries, in 2009 and at the beginning of 2010, occupied large shares in the import of disposable paper tableware. In kind the company Seda in 2009 it occupied 33%, Huhtamaki - 25%, and Italica accounted for 11%.

In addition to selling our own products on the Russian market, our country also exports disposable tableware. The main countries receiving Russian plastic tableware are Ukraine and Kazakhstan, accounting for 71% of exports in volume terms. In addition to these countries, Poland also receives disposable paper tableware.

As mentioned earlier, the market began to actively develop in 2000. The next five years showed very high growth rates in the consumption of disposable tableware. On average, the annual increase was 20-25% in value terms. By 2007, the established market felt saturated and the growth rate decreased, amounting to 115%-117% in money terms. Then came the difficult crisis years for Russia and for all areas of activity, but the disposable tableware market resisted, reducing its development rate to 105% per year . According to experts, public catering outlets in the low price segment, which continued to operate and purchase large quantities of tableware even during the crisis, supported the market and did not allow it to begin a downward trend.

Drawing 3 . Dynamics of the disposable tableware market volume in 2005-2016, million US dollars

Consumers of disposable tableware mainly come from three segments: food service, catering and retail segments. The smallest share belongs to retail sales. Namely 10% of the market. 60% of retail sales come from non-chain retail. The remaining 40% goes to souvenir shops and shops offering goods for holidays. A large share of disposable tableware - about 51% - is consumed in cities such as Moscow and St. Petersburg. In these cities, the consumption of disposable paper products is actively developing. In the rest of Russia, most consumers still prefer cheap plastic.

The public catering segment occupies 30%. There has been an upward trend in the public catering market since 2005, the growth rate was 135%-136%. A sharp drop in the market occurred in 2009. The market volume decreased by 23%. The reason was the deterioration in the well-being of the population due to the onset of the global financial crisis. However, experts say that an improvement in the situation can be expected in the next year or two. Already, every day there is an increase in attendance at public catering establishments.

The catering segment accounts for 60% of disposable tableware consumption. The main market participants believe that the catering market is only 20-20% developed and its capacity is enormous. The market is developing at a fairly high pace. According to experts, it increases by 15%-20% per year. Consumption in the catering market depends on seasonal factors. For example, parties, dinners and private events are popular from January to February. From February to June is the time for corporate parties and events, summer is the period of weddings, picnics and organizing outdoor recreation, autumn is famous for its events to build the team spirit of the company, namely “team building”. The highest demand for catering companies comes in December, closer for the New Year holidays.

Drawing 4 . Structure of consumption of disposable tableware by consuming segments in 2009

Seasonality is an important factor for the disposable tableware market as a whole. About 10 years ago, the peak of sales occurred during the holiday season - from May to September. But everything is changing and now experts note that this factor is gradually leveling out. For 3-4 years now, disposable tableware has firmly taken its place in human life, cafes and canteens have increased the volume of purchases of these products, many consumers use them in everyday life and at home. As a result, the market has ceased to be subject to noticeable seasonal fluctuations and sales volumes are gradually leveling out throughout the year.

Disposable goods have confidently entered our lives and the demand for them can be called stable. The main reason for the growing demand for disposable tableware is its practicality and convenience. And in the future, these factors will become more and more significant due to the acceleration of human life.

The production of disposable plastic tableware is a relevant and profitable business with a fairly quick payback period. Despite the fact that this category of goods has been on the market for a long time, it continues to enjoy stable demand among consumers. Every year, the world produces products worth over 40 million dollars, most of it is sold in large cities. It should be taken into account that there is high competition in this area; in order to attract potential clients, novice entrepreneurs need to competently approach the organization of a business project.

Advantages of plastic tableware

Plastic products have many advantages; they are practical, hygienic, easy to use, and have an affordable price. The range of such products is varied. These can be glasses, forks, spoons, plates, knives and many other products. Disposable tableware is often used in offices, country houses, and during outdoor recreation. It is indispensable in various bistros, summer cafes, pizzerias, canteens and other similar establishments.

These products can be made from polystyrene or polypropylene. Polystyrene utensils are intended for chilled drinks and foods. Polypropylene products have a high melting point; if necessary, they can be heated in a microwave oven.
Video - making polypropylene reusable tableware:

Stages of building a business

In order for commercial activities to quickly begin to generate high profits, it is necessary to draw up a detailed business plan. It includes the following steps:

• registration of a company in the form of an LLC or individual entrepreneur;
• choosing a form of taxation and obtaining permits;
• purchase of raw materials and equipment;
• workshop rental;
• personnel selection;
• production of products;
• conducting a marketing campaign;
• sales of goods.

Disposable tableware production technology

The product manufacturing technology consists of several stages:

• the raw material is heated in the extruder and mixed to the desired consistency;
• the hot mass is processed with a special press, resulting in a plastic film;
• the canvas is placed in a thermoforming unit, which allows you to shape future dishes;
• using a trimmer, individual blanks are cut out of the film;
• finished products are stacked and packaged.

Video - how plastic forks, spoons and cups are made:

Financial calculations

Organizing this business requires significant capital investments:

• purchase of a production line for the production of tableware - from 1,000,000 rubles;
• ordering the first batch of raw materials – from 70,000 rubles;
• documentation - from 30,000 rubles.

The cost of production of one unit of goods is from 0.25 rubles. It includes the costs of renting premises, salaries, utilities, advertising and the purchase of raw materials. If you produce about 8,000,000 products monthly and sell each product at a price of 0.31 rubles, the net profit will be from 480,000 rubles per month.

Total:

• starting capital: from 1,100,000 rubles;
• monthly profit: from 480,000 rubles;
• payback period: from 3 months.

Required documents

To open a business, you do not need to obtain a license. Businessmen must complete the following documentation:

• product certificates;
• permits from the fire service and SES;
• permits from Rospotrebnadzor.

Premises requirements

To organize the production process, it is recommended to choose a premises with an area of ​​500 m2, located away from the city, in an industrial zone. It should provide several functional areas:

• a workshop in which equipment for the production of disposable plastic tableware will be installed;
• warehouses for storing raw materials and finished products;
• bathroom;
• locker rooms for employees.

The premises must meet all the requirements of the State Standard, it must be renovated, and also be equipped with all the necessary communications.
Work process for manufacturing plastic packaging in a production workshop:

Equipment

Equipment for the production of plastic tableware includes:

• thermoplastic installation;
• extruder;
• thermoforming machine.

Staff

The efficiency of the production process largely depends on the level of qualifications of the personnel, so it is recommended to hire experienced employees. The company's staff must include:

• directors;
• technologists;
• equipment adjusters;
• loaders;
• general workers;
• accountant;
• drivers;
• cleaners

Advertising

A well-thought-out marketing strategy will help attract potential customers. Advertising on the Internet can have a good effect; it is recommended to place it on specialized resources, forums and social networks. Creating your own website, which contains photographs of products, will attract an additional flow of customers.

Sales of products

In order to successfully sell finished products, you must take care in advance of finding distribution channels. The product can be supplied to various catering establishments:

• cafe;
• bistro;
• pizzerias;
• pancakes;
• canteens;
• kiosks selling takeaway food and drinks.

You can also establish cooperation with catering companies and companies that deliver food to your home. Additional profit can be made by supplying plastic tableware to large stores and supermarkets. You can also offer products to individuals by organizing your own wholesale and retail sales points.