Production of plastic bags. Production of paper bags from scratch: business plan

Planning to implement, many novice entrepreneurs decide to start production. They purchase bricks, plastic bags, etc. To set up workshops, they need to find premises that will meet established standards.

What equipment is needed to produce plastic bags?

To establish the production of plastic bags, business entities need to purchase machines:

1. Extruders. This equipment is designed for processing raw materials that enter production in the form of balls. The machine subsequently converts the granules into polyethylene film or sleeve.
2. Machines for cutting and sealing polyethylene blanks. Rolled polyethylene material is loaded into a special compartment of the machine. The operator sets certain parameters to the device, after which the workpieces are cut and sealed on the required sides. Using cutting and soldering equipment, garbage and disposable bags without handles are produced.
3. Punching presses. These machines are used to produce polyethylene bags with handles.
4. Flexographic device. Manufacturers use such equipment to apply images, logos, etc. to finished products.
5. Auxiliary equipment: agglomerators, corona machines, etc.

Advice: Entrepreneurs can purchase a bag making machine that performs all functions except processing granules. To operate it, you must use reels with polyethylene film. The cost of such a line starts at 1,500,000 rubles.

Use of additional equipment in the production process

If business entities decide to expand the range of polyethylene products, then standard equipment will not be enough for them. To produce bags of different sizes and shapes, they need to use additional machines. Many entrepreneurs purchase an installation with a ZIP-lock type lock (its cost can reach 80,000 US dollars). For its operation it is necessary to use HDPE as a raw material. Such equipment, which has an extruder and a bag-making unit as its main components, can be installed in rooms whose area exceeds 20 sq.m. Its operating principle is as follows:

1. Polyethylene film is loaded.
2. A sleeve is blown out, along the edge of which a lock is formed.

note: the length of the finished product will be limited by the diameter of the die head, and the required width can be set by the operator.

Business entities can purchase equipment from Chinese manufacturers, which is intended for the manufacture of polyethylene products of different densities. Such machines are equipped with special units:

• double servo motor;
• control system;
• monitor (liquid crystal).

Raw materials are quite simply loaded into such a machine, after which they go through the entire production cycle and are stamped, punched and trimmed. The advantage of such equipment is full automation, thanks to which entrepreneurs can save on wages for employees. The cost of such an installation can reach 20,000 US dollars.

If business entities decide to start producing T-shirt-shaped bags, they should purchase a special machine, the cost of which on the market reaches $80,000. Entrepreneurs will need to use HDPE or LDPE as raw materials for such equipment. During operation, the installation performs the following processes:

• blows out a polyethylene sleeve;
• cuts workpieces;
• cuts out special necks;
• seals the edges of the product.

note: the advantage of such equipment is the complete automation of work processes. The advantages of the installation include the finished product supply system.

To produce packaging bags, business entities must use Chinese-made machines. Their cost can reach $60,000 (depending on functionality and brand promotion). Such equipment is considered universal, as it is equipped with a computer control system. The operator can control the temperature conditions, as well as the quantity of manufactured products. Such machines are characterized by high productivity. Entrepreneurs can use LDPE or HDPE as raw materials.

How to start a business producing plastic bags?

Each business entity that has decided to set up a production line for the production of plastic bags can start with small capacities. First, you need to equip a workshop that has special requirements. To install a production line, entrepreneurs are recommended to rent a premises, the area of ​​which should not be less than 150 sq.m. Such production is considered harmful, so workshops should be located at a remote distance from residential areas. In accordance with state regulations, the room must have high ceilings - at least 8 m. All important utilities must be installed in it:

• water supply;
• heating;
• sewerage;
• electricity (three-phase).

Entrepreneurs should pay special attention to the ventilation system. In such workshops it is necessary to install supply and exhaust ventilation, as well as climate control, thanks to which it will be possible to regulate humidity and temperature. A fire safety system must be installed in the workshop. To minimize harmful emissions into the atmosphere and nearby water bodies, entrepreneurs must install treatment facilities. Businessmen will have to spend at least 500,000 rubles to set up a production line.

Advice: Entrepreneurs can install, thereby expanding their product range. Such products are in great demand, so businessmen will not have problems with sales.

Beginning entrepreneurs who have just decided on their business strategy need to collect permits from many authorities:

• environmental service;
• sanitary and epidemiological station;
• fire inspection;
• local administration.

After the entrepreneur launches the production line and receives the first samples of finished products, he needs to submit them for inspection and receive certificates. To simplify the process of cooperation with wholesale buyers, experts recommend choosing an LLC when choosing a legal form.

How to choose a production technology and what raw materials to use?

If a business entity decides to produce T-shirt-shaped plastic bags, he needs to decide on the technology:

1. Full production cycle. In this case, the entrepreneur will have to purchase equipment that will process raw materials and stamp finished products.
2. Partial production cycle. An entrepreneur can save on some machines, for example, an extruder, and purchase workpieces prepared for processing.

Advice: if entrepreneurs want to save money, they can use recycled granules as raw materials. Despite their cheapness, this will not affect the quality of the finished product.

On the territory of the Russian Federation, plastic bags are manufactured as follows:

1. Initially, the worker pours the granules into a special hopper installed in the extruder. Under the influence of high temperatures, the raw material begins to melt and turns into a thick mass.
2. Coming out of the extruder, the molten mass takes the form of a polyethylene sleeve, which has a certain diameter.
3. During the cooling process, the polyethylene blank is rolled out using special rollers, and the sleeve takes on a flat shape.
4. The workpiece is cut into separate fragments, the dimensions of which are set by the equipment operator.
5. If the technological process involves applying drawings or logos to polyethylene products, then each package passes through rollers that carry out coloring.
6. After applying the image, each bag is wound into a separate roll and transferred to the bag-making plant. This machine generates a template for the finished product. The installation performs a bottom fold.
7. Holes for the handles are cut out on a special machine (you get a “T-shirt” package).
8. The products are transferred to the line, where they are sealed, after which the bags are folded into separate piles (they can remain wound into rolls).

How is the cost of one plastic bag determined?

When determining the cost of one package, business entities must take into account the following indicators:

• product dimensions;
• circulation;
• coloring (amount of dye);
• cost of raw materials;
• payment to hired workers who are involved in the production process;
• material density;
• presence of bottom bookmark;
• presence of a handle;
• transport and other production costs.

Any projects in Russia and other post-Soviet countries must be implemented with a competent strategy. If entrepreneurs decide to start producing plastic bags, they should expect a return on their initial investment within 2-3 years. They will be able to speed up this process only if they master the wholesale market and begin to increase capacity in accordance with growing demand.

Just like, the production of plastic bags can generate a monthly income of 500,000 rubles. This calculation was made based on the average workshop productivity of 60-70 bags per minute. If you subtract all current costs from your monthly income, your net profit will be at least 100,000 rubles. When planning to start such a business in a region where there are already manufacturers of polyethylene products, beginning businessmen should not be afraid of competition, since the demand for such products is constantly increasing in the domestic market.

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Some people who are looking to make money prefer. Those entrepreneurs who plan to create a dynamically developing and promising business can start producing plastic bags. To open a workshop, they must purchase special equipment (in most cases made in China), the price of which can reach tens of thousands of dollars. They should treat the issue of arranging the premises with great responsibility and comply with all government regulations. Before launching a production line, entrepreneurs need to obtain a large package of permits.

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In the modern world, many people want to open their own business. There are many factors that contribute to this desire. However, organizing your own business is not that difficult. The main thing is to choose the optimal idea that you like.

And today there are a lot of ideas. This review will focus on one of the types of entrepreneurial activity.

The need to purchase a production line

When organizing your enterprise, in some individual situations you will have to make a choice of equipment. For the production of plastic bags, namely for organizing such an entrepreneurial idea, this rule undoubtedly applies. So, what equipment is popular today? In modern conditions, certain technological lines can be ordered from China and Taiwan. These countries are popular among entrepreneurs.

List of main types of installations

When choosing equipment for the production of plastic bags, it is necessary to discuss those basic devices that must be present.

1. Extruder. It is used to make it possible to process blanks that come into production in the form of balls. Subsequently, it is from these raw materials that a plastic sleeve or finished polyethylene film is created.
2. Cutting and soldering machine for the production of polyethylene bags. This type of equipment takes the film and cuts it. In this case, the device is guided by the parameters specified by the program. After this, the blanks are sealed from a certain side. Using this type of machine you can produce garbage bags or bags that do not have handles. In order to start producing products with handles, you will need to purchase machines for the production of plastic bags, such as die-cutting presses.
3. You need to purchase a flexographic device. It can provide the opportunity to apply any images to finished products. These could be logos or a brand name.

What can affect the cost?

When choosing equipment for the production of plastic bags, you need to understand that the cost of the line will depend on the manufacturer of a particular unit. Whether the device is new or used – this factor also plays a major role.

Need for additional equipment

Due to the fact that bags have different sizes and shapes, and are also used in a wide variety of areas of human activity, a variety of installations can be used. This may affect the choice of equipment for the production of plastic bags.

An example is a special machine that has a ZIP-lock type lock. HDPE is used as raw material. In order to place the installation indoors, an area of ​​at least 20 square meters must be available. The cost of such a system reaches 80 thousand dollars.

An extruder and a bag-making machine are used as the main components. When the sleeve is blown out, a lock is formed. The length of the finished product is limited only by the diameter of the die head. The width can be set programmatically.

You can buy equipment in China

It is also worth purchasing a device made in China. With it you can create products of very different densities. The cost of the equipment reaches 20 thousand dollars. Such equipment can be supplied to almost any city in the country.

The main components are a double servo motor, a control system, and a liquid crystal monitor. The raw materials for the production of plastic bags are loaded quite simply. This is facilitated by the thoughtful design of all equipment as a whole. The same can be said about stamping, punching and trimming. It should be noted that such a line is fully automated.

Production of "T-shirt" bags

In order to produce bags with a “T-shirt” shape, you should use a special unit, the cost of which reaches 80 thousand dollars. The equipment is manufactured in China. The composition of plastic bags in such a situation includes LDPE or HDPE.

The production process is divided into several separate stages. The first stage involves blowing the sleeve. At the final step, a special neck is cut out. The main advantages of such a device include full automation, as well as a finished product supply system.

Universal installations

Packaging bags are produced using Chinese equipment, the cost of which is 60 thousand dollars. The raw material is HDPE or LDPE. Such devices can be classified as universal. They are equipped with computer control. It is possible to control the temperature and quantity of finished products. All this happens automatically. Productivity is also very high.

Conclusion

This review examined the main types of equipment that are used for the production of plastic bags. Additional equipment that will be required when expanding business activities was also partially described. One big disadvantage of this idea is the very high cost of all the equipment. This can explain the rather low competitiveness that is observed in our country.

This may affect the desire of novice entrepreneurs to engage in such business. However, if you properly organize entrepreneurial activities of this nature, you can begin to receive fairly high profits. With the right approach and vigorous activity, a business will pay off quite quickly. And this factor should always be considered one of the advantages of an organized enterprise.

We wish you good luck in establishing your business activity based on the creation of packages!

We will tell you why a business idea for producing plastic bags will not fail, how much money is needed to start a project and how justified is investing in such production.

Most entrepreneurs prefer to start in already developed industries, building a business in the image and likeness of successful analogues. The production of plastic bags is one of these areas.

Do you want to know what investments a new business will require, why it is attractive and unique, and what profit it will bring? Read our article carefully.

How in demand is the production of plastic bags?

The production of packaging materials attracts entrepreneurs with constant demand. Polyethylene has become the most popular packaging method in recent decades, and this trend is not slowing down.

Plastic bags are used in trade, catering, manufacturing, construction, and private households. PET is used to produce bags for garbage, bread, clothing, freezing, sandwiches, cling film, etc. And bright plastic bags with logos are an excellent advertising medium, inexpensive and effective.

We often hear about the need to replace plastic with paper, etc. There is a trend towards this, but the market situation in Russia dictates its own laws. Therefore, you should not be surprised by the opening of another PET production facility: the population and entrepreneurs are choosing budget products.

Why won't such a business idea fail?

So, the first factor in the attractiveness of film packaging is the constant demand of consumers.

The second factor is the wide range. A full-cycle PET plant will satisfy the needs of cities and villages, trade, construction, and manufacturing companies, and respond to seasonal changes in demand.

For example, during the summer season, covering material (films for greenhouses) is in demand, and when harvesting, thick bags are needed for storing and transporting vegetables, etc.

How else does a PET mini-plant attract entrepreneurs, and where do the risks await them?

Let's consider the pros and cons of the project:

Strategy: mini-shop or full cycle?

Is it possible to build a profitable enterprise with minimal start-up capital?

To answer this question, let's conduct a brief comparative analysis:

The table shows the average parameters. Setting up a full-cycle workshop will require 10 times more money and effort than launching a mini-line. But these costs will pay off faster: the cost of production is twice as high, the range is wider.

The first option (for example, a mini-workshop for the production of garbage bags) will become a profitable business if three conditions are met:

1. A profitable contract for the sale of products has been concluded.
2. An agreement was signed for high-quality raw materials at a low price.
3. Costs for delivery and maintenance of the workshop are minimal.

At the same time, the second option, based on the complete processing of raw materials into film and then into bags, may not bring the expected income, but losses. The reason will be the refusal of the wholesaler to cooperate, an increase in prices for raw materials or other commercial risk.

Having invested a large sum in development, you need to be prepared for both high profits and large losses. The result of any undertaking depends on the specific conditions of doing business, agreements with partners, the market situation and the managerial competence of the owner.

Watch the workshop in action in video format:

Where to start making plastic bags - step-by-step instructions for a businessman

Before making any investment, conduct market research and create a business plan. These actions are necessary, regardless of the chosen production format.

Of course, you can spend money by ordering marketing research from specialists. But if your plans do not include setting up an international holding company for the production of T-shirt bags, and your interests are limited to selling packaging for the needs of the nearby Villa-Kukuevo farms and retail outlets on the Rublevo-Figasevo highway, conduct your own marketing.

Let's look at the parameters that are definitely worth studying.

Consumers. Think about who your customers will be, what products they will purchase and in what quantities. Take into account seasonal demand (if you plan to cooperate with construction companies and agriculture). Also evaluate the distance of customers from your warehouse (price and delivery times matter!).

Advice: Take advantage of personal connections and conduct research in the business environment, find out about the needs of different companies for film or bags, volumes, prices, competitors, etc.

Competitors. Analyze who supplies products to your region, whether there are local manufacturers. Evaluate the quality of their product, cost, delivery conditions.

Raw material suppliers. Determine the conditions under which you will receive raw materials for your workshop. Evaluate the cost, delivery time, payment procedure, manufacturer’s guarantees, batch sizes and everything that you consider important for your specific business.

Advice: compare several offers and identify two or three suppliers with the most favorable conditions for you.

Business infrastructure. At this stage, determine where your business will be located and who will serve it. Economical options are good if other processes are not affected.

For example, if you choose cheap rental premises 120 km from consumers and the railway station, you risk ruining your business. Transportation costs for transporting containers with PET granules and delivering finished products to the Rublevo-Figasevo highway will become the main cost item; there will be no money for other expenses.

The number of personnel depends on the business model, its volume and strategy. Assess the labor market in your region, the level of average salaries, predict the wage fund of your enterprise.

Study labor legislation, think about how you will formalize relations with employees, how much taxes to pay.

Having gone through this simple path, you need to draw up a business plan.

Step 1. Draw up a business plan

If you intend to apply to a bank for a loan for equipment, a business plan will be required. Those who rely on their own capital should also not neglect planning. Make a simple forecast, taking into account market research data and technological process features.

1. Sales prospects. Based on the planned capacity of the equipment, evaluate the real sales prospects. For example, with a line capacity of 5,000 plastic bags per hour, you can produce 880,000 units in a month. How many of them will you sell in the first month of work and subsequent months?
2. Prices and terms of settlements with clients. Large wholesalers will want individual conditions: low prices, deferred payment. Reflect this in your forecasts.
3. Terms of supply of raw materials. Get ready to buy raw materials on an advance payment basis. You can change the terms and get discounts and deferments by becoming a regular customer of a large supplier. In your business plan, take into account the costs of stocking raw materials, delivery and storage.
4. Business processes and production maintenance costs. Determine how all divisions of your enterprise will operate and how much expenses will be required to maintain it.

As a result of all the calculations, you will get a forecast of production income and expenses for the near future.

For beginners, there is a simple way: download a ready-made business plan for free and modify it taking into account your parameters, obtaining a realistic forecast.

An example of a business plan with calculations of income and expenses for two years.

Step 2. Register a business

At this stage, you need to determine the form of ownership: LLC or individual entrepreneur. The last option is preferred by most entrepreneurs working in the field of small and medium-sized businesses. This is explained by the simple registration and reporting process: the entrepreneur submits an annual income tax return.

Important! When registering, you need to select OKVED activity codes. 25.22 and 51.47 are suitable (production of plastic products for packaging; wholesale trade of non-food products).

It will take from one to three weeks to register your business, depending on the chosen form.

Step 3. Choose a room

When searching for premises, use the following parameters:

1. Ceiling area and height. For a mini-line, a room with a standard ceiling height and an area of ​​10 m2 is sufficient. The full cycle will require special conditions: the room must have high ceilings, have a certain temperature regime for the operation of the automation and extruder (PET granules are melted in it).
2. The area of ​​the premises must be sufficient for storing raw materials and finished products, accommodating personnel (locker room, office, pantry, etc.)
3. Ventilation and communications. PET production is an unsafe process for health, so the room must have a good ventilation system. Check the quality of other communications: electrical wiring, water supply and sewerage systems, heating.
4. Driveways. It is important to have a ramp or area for loading and unloading operations.
5. Infrastructure and location. Ideally, your enterprise should be located in close proximity to consumers and suppliers of raw materials. But miracles don’t happen, so look for a compromise, evaluating offers not only by the amount of rent, but also by the convenience for doing business.

Step 4. Selecting personnel

The number of personnel depends on the scale and specifics of the work. To service one line when working in one shift, two workers and a foreman with the functions of a service technician are enough. In addition to the main personnel, a sales department manager, a delivery driver, and a storekeeper may be required. Perhaps all these functions will be performed by the entrepreneur himself.

At this stage, it is necessary to establish relationships with employees by concluding contracts and defining working conditions.

Step 5. We purchase raw materials and equipment

When choosing equipment, get advice from salespeople - dealers of major line manufacturers. Determine the required composition of your line (extruder, die-cutting machine, bag line, flexo printing, etc.). It is not necessary to immediately purchase a complete set: designs for bags can be ordered externally, saving on the purchase of expensive flexo printing.

Plan the timing at this stage, taking into account the delivery, assembly and commissioning of equipment.

When purchasing raw materials, do not forget to obtain certificates of compliance with GOSTs:

• high pressure polyethylene film, for food products GOST 16337-77 (LDPE);
• low pressure film, for bulk dry products GOST 16338-85 (HDPE).

Don’t forget about furniture and production equipment - tables and chairs, cabinets for documents and clothes, a safe, office equipment.

Step 6. Launch the business and begin sales

After registering the enterprise, technical launch of the equipment and training of personnel, proceed to production. By the time you open, you should already have contracts for the supply of finished products.

What you need to properly register a business

In addition to registering an enterprise (LLC or individual entrepreneur), you must obtain permission from the local administration. Opening a PET workshop will require permits from the SES, fire department, energy supervision, and environmentalists.

You can receive a certificate of compliance of finished products with the GOST standard after the start by submitting samples for examination.

How much money will you need to start a business?

Answering the question of how much money is needed to start, here are some simple calculations:

This is an incomplete list of all costs; there are no taxes, marketing costs, transportation, etc.

The amount of starting capital is determined taking into account specific circumstances. For example, the landlord will want an advance payment for the premises for six months, and the supplier of raw materials will ship a year's supply of pellets.

How profitable is such a business?

The production of PET products is considered a highly profitable business. But how do mathematical calculations correspond to reality?

Using the data from the previous example, we will calculate the payback of the workshop, subject to the production of one product - packaging bags:

Calculations show that the investment will pay off in 18 months. In a real situation, profit will depend on many nuances. For example, assortment and sales price, prices for raw materials and rent, etc. It is impossible to foresee all moments, but it is necessary to plan for force majeure.

Therefore, when drawing up your business plan, take into account possible downtime due to equipment breakdown, dumping of competitors' prices, increased utility costs, etc. That is, plan your income to the minimum and expenses to the maximum - this approach will give a realistic picture.

The demand for plastic bags does not decrease over time; any store needs them. If there is a large production in a particular region, there is still enough space for small or medium-sized businesses. For example, mini-production of plastic T-shirt bags can be organized even in a garage or basement.

Business Features

To produce this packaging material, no special knowledge is required for either the business owner or the employees. But in any case, at least minimal marketing research is needed to determine what products competitors produce and at what price they sell them. This will allow you to choose a type of finished product that is produced in small quantities, but is in demand.

Although experts believe that “T-shirts” or “bananas” packages are best suited for mini-production, you can diversify them by accepting orders for printing information about the customer in the form of a logo and contact information. But we must take into account that large production requires a large amount of initial capital, which is unprofitable and even dangerous for a beginning entrepreneur.

The simplest option– make bags from ready-made film. But this approach can only be used at the initial stage, since it does not provide an opportunity to compete in the area of ​​finished product cost. If you produce polyethylene yourself, the cost of bags is reduced, and this makes it possible to set a lower selling price. The most profitable option is production to order. But to do this, you need to conclude appropriate agreements not only with stores, but also with other organizations.

Documentation

To produce plastic bags, you need to register an individual entrepreneur or LLC, indicating your preferred taxation system and OKVED codes (25.2, 25.22 and 51.47). In addition, the production of plastic bags requires permits from the SES, administration, energy supervision, environmental service, and fire department. Finished products must comply with the requirements of GOST 10354-82. But the corresponding certificate is issued only after production has started (product samples are required for examination).

Selecting a room

Special requirements are also imposed on the production premises. It cannot be located in a residential area, it must be equipped with water, heating, good ventilation, and a three-phase power connection. Walls, floors and ceilings must be finished with non-combustible materials, and the possibility of quick evacuation in case of fire must be ensured. The area of ​​production premises depends on production volumes. For full-cycle production, the area should not be less than 300 m2.

Raw materials and manufacturing technology

If you organize a full production cycle, it will consist of several stages:

• loading granules into the extruder, heating to 180-250°C and turning into a viscous mass, which is squeezed out of the device in the form of a film;
• the polyethylene is cooled, then rolled out using rollers and wound into rolls;
• a pattern is applied to the material (paint diluted with alcohol is used);
• the material is wound into rolls for the second time, which are moved to a bag-making device that forms templates of a certain size;

• The handles are cut using a stamping press and the edges are sealed.

In this business, you can use only two types of raw materials for production: low pressure polyethylene (HDPE) And high-density polyethylene (HDPE). Prices vary between 420-750 dollars (per ton). If you plan to produce color film, you will need a dye. When making garbage bags, it is allowed to use recycled granulate, which is sold at a lower cost.

Equipment

A fairly wide range of equipment is offered, the price of which varies from several tens of thousands to a million or more rubles. For full-cycle production, the best option is to buy a line for the production of plastic bags:

• extruder (converting granules into film);
• flexo printing machine (image creation);
• cutting device;
• cutting press (cutting out handles for T-shirt type bags).

Don’t forget about additional equipment for offices, warehouses, and workplaces.

You can save money if you refuse to make plastic bags with a logo. Flexo printing machine costs from 65 thousand dollars, so it is quite possible to postpone its purchase if there is a lack of funds.

If the production has an incomplete cycle, then you can buy a multifunctional machine for the production of plastic bags, which is capable of performing all operations except extrusion.

Business plan for the production of plastic bags

The business plan should include not only the cost of equipment ( from 1.5 to 3.8 million rubles), but also rent, costs for water, heating and electricity, wages, taxes, which will amount to approximately 230 thousand rubles per month.

The cost and selling price of the finished package depends on the type of raw materials, film density, size, absence or presence of handles and the features of their fastening, the presence or absence of color printing, and dimensions.

To calculate the payback, you can take an opaque bag with a die-cut handle 40x60 cm. Its cost is only 13-24 kopecks, and it sells for an average of 70 kopecks. In an eight-hour shift, 33,600 pieces of such bags can be produced, that is, you can earn approximately 18 thousand rubles. The initial costs in this business pay off in a year and a half.

In this article:

Plastic bags are used everywhere: in supermarkets and stores, for standard and gift packaging, for storing food and removing garbage.

It is impossible to list all the areas of application of plastic bags. Gone are the days when our compatriots preferred to use rag bags, and plastic bags were carefully folded and stored. Today, a plastic bag fulfills its main purpose - to be a disposable means for packaging and comfortable transportation of products. This means that the demand for them will be stable and not prone to decline.

In addition to the obvious functions, packages have become a means of effective mobile advertising– after all, almost every large company, boutique or supermarket has a branded package with the company logo, a list of services and contact information, which are given out as a gift. And the client is pleased, and there is never too much advertising.

Analysis of demand for products (plastic bags) and sales market

According to statistics, there are enough unfilled niches in the domestic production market, because 20% of polyethylene products continue to come from foreign manufacturers. At the same time, the main competitors of domestic entrepreneurs are Turkish and Chinese-made bags, characterized by extremely low prices and appropriate quality. Torn handles, not completely soldered seams, falling out bottoms are just a small list of the “delights” of purchasing such products. But for our consumers, price has always been the decisive factor, so such competition takes place, especially in border regions.

However, this applies only to direct wholesale sales of finished products. It is much more profitable to work to order, concluding agreements for the supply of packaging materials and ready-made bags for various trade, manufacturing, construction and agricultural enterprises.

This is where the “company image” rule comes into play: no self-respecting company will offer the buyer a product in low-quality packaging. Polyethylene products are in demand in any region.

Moreover, even if a large plant already operates in your city, medium and small businesses can freely find their niche by studying the offers of competitors. There are many types of plastic bags: banana bags, T-shirt bags, garbage bags, gift bags, promotional packaging with a logo, single-layer, multi-layer, various sizes, colors and shapes. The entrepreneur’s task is to find products with the highest demand, or to occupy a niche not covered by other manufacturers.

Choosing a strategy and legal registration of business

• When starting the production of plastic bags, you can go in two ways:
• full cycle production (from film production to production of bags of any configuration);

partial production (from purchasing finished film, applying images, cutting into shapes with subsequent soldering).

Let's consider the full cycle as a more promising type of business. Although such an enterprise will require more capital investments, sales opportunities, versatility of the products produced and, accordingly, profitability will be significantly higher. In addition, such an enterprise can become the same supplier of finished film for incomplete cycle production.

• Possibility of using the finished film:
• universal packaging material,
• construction waterproofing,
• material for greenhouses, greenhouses and other needs of the agricultural sector,

protection from pollution during construction or repair work.

The optimal organizational form for the production of polyethylene products is a legal entity on a simplified taxation system.

• When registering an enterprise, you must indicate the following OKVED codes:
• 25.2 — Production of plastic products
• 25.22 — Production of plastic products for packaging

To start a workshop, you will need a production certificate, permits obtained from the local administration, the sanitary-epidemiological and environmental service, energy supervision, and fire protection. The production of film for plastic bags must comply with GOST 10354-82 (certification of cling film is required to be confirmed every 3 months). But in order to obtain such a certificate, you must run technological line(of course, after receiving all production permits), and provide the resulting samples for an expert opinion.

Premises for the production of plastic bags

The production of polyethylene film is an environmentally harmful production, therefore there are a number of specific requirements for choosing a room:

• the production workshop or mini-factory must be located in an industrial or suburban non-residential area;
• availability of supply and exhaust ventilation, heating and humidity control in the workshop and warehouse;
• three-phase electrical connection, grounding of batteries; - ceiling height of at least 8 m (extrusion machine height ~6 m), interior decoration of walls, floor, ceiling - from non-combustible materials;
• placement of production equipment in the workshop premises must comply with GOST 12.3.002-74;
• the presence of a fire protection system, the possibility of safe evacuation in case of fire;
• the organization of workplaces must comply with the requirements of GOSTs 12.2.061-81 and 12.3.002-74, as well as ergonomic characteristics in accordance with GOSTs 12.2.033-78, 12.2.032-78.

To accommodate a complex of production equipment, you will need a room of 300 square meters, which will be divided into three parts: a production workshop (180 m2), a warehouse for raw materials and finished products (80 m2), an office and an exhibition hall (40 m2).

Equipment for the production of plastic bags

For the production of polyethylene film with subsequent formation of bags, it is planned to purchase a production line consisting of the following equipment:

1) Extruder– converter of raw material granules into film (width 300-550 mm, thickness - 0.009 - 0.10 mm), using the bottom-up blowing method. Productivity – 40 kg/hour;

2) Flexo printing machine– for printing drawings, logos and other images;

3) Plastic Packaging Clip Making Machine;

4)Multifunctional bag making machine, with a built-in punching press, equipped with a servo drive, photosensor, conveyor, thermal needles, and allowing the production of packages of various modifications, incl. T-shirt, banana, double bottom seal bags, garbage bags, food packaging with plastic clip, etc.

The cost of the production line with delivery, setup, personnel training and signal launch is RUB 3,840,000.

In addition to machines, it is planned to purchase office, exhibition and warehouse equipment (racks, boxes, boxes, tables, stands) for storing raw materials, finished products and equipping workplaces for personnel. The cost of additional equipment for the workshop is 60,000 rubles.

Raw materials for the production of polyethylene bags

Polyethylene film is made from first grade or recycled polymer granules.

Two types of raw materials are used:

• HDPE (low-density polyethylene, GOST 16338-85), for contact with bulk and dry products;
• LDPE (high-density polyethylene, GOST 16337-77), intended for food packaging).

The cheapest raw material is South Korean granulate (~ $380 per ton), but there are many other types of domestic or foreign production, with a price range from $420 to $750 per ton. To produce colored film, special dyes are added to the raw materials ($15-50 per 1 kg).

At production of garbage bags or other types of non-food film, you can also use recycled granulate, which is much cheaper because it is made from polyethylene waste, but the quality of such raw materials is correspondingly low.

Technology for the production of plastic bags

1. Polymer granules are loaded into extruder hopper, from where they are picked up by the feeding auger. Here the temperature is maintained from 180 0 C to 240 0 C and as they move, the granules heat up, melting into a homogeneous mass. As a result of extrusion, a polyethylene film is formed in the shape of a pipe (sleeve). One extruder allows the production of film of various thicknesses and widths through special settings.

2. The polyethylene “pipe” is gradually cooled, then rolled out with rollers.

3. The sleeve is cut with an automatic knife so that two identical strips of the required width are obtained.

4. The winder winds the film into rolls (cuts are packaged separately for recycling). When the roll width reaches the set size, the roll is moved away with the help of the operator and the next one begins to be wound. And so on until the end of the produced film.

5. Drawing. The paint is diluted with alcohol and constantly stirred so as not to lose viscosity.

6. Using a dispenser, the dye is supplied to special ink rollers, which print the design. After printing, the film is again wound into rolls.

7. The finished roll enters the bag-making machine, where a template for future bags is formed and the bottom fold is highlighted.

8. A stamping press makes holes for the handles (cuts out the “t-shirt”, cuts off the top for attaching a plastic fastener - it all depends on the template).

9. The welding surface connects the edges, sealing them by heating up to 180 0 C. The finished bags are formed into packs of 100 pieces.

10. Quality control. Checking the soldering of seams and fasteners.

Business plan for the production of plastic bags

The cost of manufacturing plastic bags is calculated individually for each order, since in addition to the price of the granulate used, it depends on a number of additional factors:

• size, shape, package design,
• film density,
• the presence of a reinforced handle and bottom fold,
• color printing (number of shades involved, pattern area, presence of complex registrations, one-sided, two-sided printing, etc.).

To calculate the payback of a business project, let’s take the production of white opaque bags with a die-cut handle, 40 cm wide, 60 cm high and a side fold thickness of 16 microns.

The cost of such a package made from HDPE granules is 0.13 kopecks, and the wholesale selling price is 0.70 kopecks. Considering that the production capacity allows the production of about 70 pieces/minute, then with one-shift work and 22 working days, the profit will be: 60 minutes * 8 hours * 22 rubles/day * 70 pieces (0.70 - 0.13 rubles) = 421,344 rubles/month.

Expenditure part:

• rent of a production workshop (300 m 2 *150 rub./m 2) = 45,000 rub./month,
• electricity – 8,000 rub./month,
• heating (for 6 months of the heating season, divided equally into all months of the year),
• water and other utilities – 12,000 rubles/month,
• staff salaries (6 people: director, accountant, technologist, 3 workers) – 128,000 rubles/month.,
• income tax (15% of profit minus expenses) – 34,252 rubles/month.

Total expenses: 227,252 rubles/month.

Net profit: 421 344 – 227 252 = RUB 194,092/month.

Profitability calculation:

Initial investment (RUB 3,930,000):

• purchase of equipment - RUB 3,840,000,
• additional equipment – ​​60,000 rubles,
• costs for documenting production (opening a law firm, obtaining the necessary permits and product certification) – 30,000 rubles.

With an estimated profit of RUB 194,092/month, the initial investment will pay off in 1 year and 9 months.

It should be borne in mind that the calculations were based on one of the simplest options for finished products, but everything depends on demand and sales opportunities in your region. For example, the selling price of color packages of the same parameters will be higher by 15%, with one central single-color image - by 34% (with an increase in cost of 5 and 10%, respectively). In addition, the company can accept orders for the production of LDPE or HDPE packages according to individual designs, and the profitability of such projects is much higher.