Technology for the production of plastic bags. Production of plastic bags: technology and equipment

The production of paper bags is a promising production with a payback period of initial costs ~ 1.5-2 years and a profitability of ~ 30%. The organization of the technological process does not require specific knowledge and large initial costs. Ease of entry into the data market segment has provoked the presence of many small companies and a high level of competition and struggle for large orders.

Advantages and Disadvantages of Paper Bag Making Business

Paper bags are made mainly from safe and inexpensive materials. The production of such products is rapidly gaining momentum. While plastic bags are practical and convenient to use, they are not intended for storing materials such as charcoal. Coffee, flour, spices, sugar, bakery products lose their original properties when stored in plastic bags. It is not recommended to use them for packaging building mixtures: alabaster, gypsum, cement, because. they contribute to the formation of condensate. Paper bags are also often used in marketing promotions because advertising or a logo can be easily applied to their surface. Consider the key advantages and disadvantages of starting a business.

Paper bag manufacturing business plan

Main consumers of paper packages

The main consumers of paper bags are companies, not individuals. The table below shows the main consumers of this product.

Production of paper bags: technological process

The production of paper bags consists of several technological stages.

The first stage is the manufacture of a multilayer paper glued tube (bag blank) with transverse or longitudinal sizing. For gluing, a special installation is used that stirs soluble glue. If the bottom of the bags is glued, the tube should have longitudinal cuts and, if necessary, an air outlet hole when filling the paper bag with cement, dry mortars, and other bulk materials.

The second stage is the application of information about the product, trademark, etc. on the front side of the package or bag. Logos and drawings are applied in the following ways:

• Offset printing - is performed on the development of the product, used for numerous runs.
• Silk-screen printing - used for small drawings and logos, applied to a scan or finished product, produced in small runs (up to 1000 pieces). It is not suitable for full-color printing, it does not convey halftones well.
• Flexography - printing with ink using flexible forms, it can be multi-color and monochrome, used for large runs.
• Embossing - is used only on paper printed sheets, when it is necessary to highlight any fragment of the drawing in a special way, there are no restrictions on the number of copies.

The third stage - the bottom of the paper bag is glued and stitched, the valve blank is prepared using a special semi-automatic machine for cutting paper tape. The valves themselves are made on a valve machine. For open bags and packages, this operation is not needed, the valve is made only for closed (valve) bags. Paper bags (open and closed) are divided into stitched and glued. Stitched ones are stronger, but more expensive, since a nylon thread is required in their production.

The fourth stage is different for stitched and glued paper bags and bags. For glued, final gluing by pressing is used. For stitched ones, the bottom is stitched with a “chain” stitch with two or one backing threads (depending on the required strength).

The fifth stage is pressing and packing into bales at the packaging plant. The bales are then labeled and stored, or sent directly to the buyer.

Bag making equipment

For the production of paper bags, special equipment is needed. For glued and stitched bags, you will need different machines. In the business plan for the production of paper bags, we include the cost of high-quality equipment.

The price of equipment is affected by the type of line and the power of the machine. The cost of a simple machine is about 190,000 rubles. A machine for producing a multilayer tube costs 430,000 rubles, a mixed-type machine costs 880,000 rubles.

Mixed-type machines, despite the considerable price, pay off quickly, since per hour of work they can produce 210 blanks in 2 layers. The automated line for the production of paper bags and bags has even more power.

Optional equipment:

• a device that performs multilayer stitching of the bottom of the paper product;
• special equipment for loading paper;
• punching machine;
• hydraulic press for boiling products;
• printing device for multi-color or monochrome printing.

The video below shows the operation of the Fidia Shopper paper bag making machine.

For the premises where the equipment is installed, there are no special requirements for compliance with building codes. We choose any room with access to electricity and water supply. The only requirement for the premises is compliance with fire safety standards.

Types of raw materials

For the production of thin bags, efalin, cardboard, coated paper, moisture-resistant artlibris and luxpack paper, special kraft wrapping paper are used. In the production of paper bags, thick paper is used from recycled materials, for example, from recycled waste paper (see ""). For reliability and durability of products, paper is glued together in several layers and additional transverse sizing is applied.

Staff

It will take 3-4 workers to work in 2 shifts. When selecting staff, it is necessary to take workers with work experience! Special education and qualifications are not required.

Company start-up costs

Renting a suitable room will cost 55,000-95,000 rubles. Special equipment for the production of paper bags for a small company costs about 600,000 rubles. Equipment for larger enterprises with several production workshops - at least 900,000 rubles.

The purchase of equipment is the main financial investment in our business, we will spend 600,000 - 900,000 rubles on this.

To purchase a fully equipped line, you will need 2-4 million rubles.

It will take 60,000-95,000 rubles per month to pay four workers. They work in shifts, no special qualifications are required. At the initial stage, 2 workers are enough with a monthly salary fund - 30,000-40,000 rubles. Additional expenses will amount to 10,000-15,000 rubles, payment of taxes - 95,000-120,000 rubles. per month.

Profitability

The production of paper bags and bags is a highly profitable business. At the initial stage, the proceeds from the sale of packages can amount to 250,000-400,000 rubles per month. The payback period is 1.5 years.

The cost of raw materials is 35,000 rubles per ton. For 1 package you will need 0.09 kg of paper (package size 120x150x50). The cost of paper for the release of 1 package is 35000x0.09 / 1000 = 3.15 rubles.

With salary costs for the release of 1 package in the amount of 0.05 rubles. and other expenses - 0.03 rubles. the cost of 1 package will be 3.23 rubles.

We set the selling price at least 10 rubles. We receive profit from the sale of 1 package - 6.77 rubles.

Having 2-3 machines in a small production facility, working in 2 shifts, it is possible to produce 6,000 paper bags per day, and at least 132,000 bags per month.

Net income from the sale of packages - 893,600 rubles. per month.

Business risks

The main problem affecting the profitability of the production of paper bags and bags is the search for cheap raw materials. It is recommended to use secondary raw materials. The production of bags consumes a lot of electricity. The solution to the problem is the acquisition of high-tech modern equipment.

The main problem is finding buyers. Before starting production, you must create agreements for future package deliveries. The packages may be of interest to grocery retail stores, agricultural and industrial enterprises that produce mineral fertilizers and building materials.

Evaluation of the attractiveness of a business by a magazine site

Business Profitability	(3.5 out of 5)	Business Attractiveness 3.2
Project payback	(3.8 out of 5)
Ease of starting a business	(2.0 out of 5)
The production of paper bags is a profitable ~30% and a fast payback business (~1.5-2 years) provided that a stable distribution network is created. To open production, an initial investment of 2-4 million rubles will be required. for the purchase of technological equipment. For a room with machines, no special permits are required, except for firefighters.

The production of plastic bags is a relatively simple and, at the same time, promising business. But how to start it? How big can the investment be?

What are the benefits of this type of business?

- a segment of the industry, which can be characterized by a constantly high demand for manufactured products. Polyethylene bags are in demand in everyday life, at industrial enterprises, in trade, in construction. In principle, it is rather difficult to name a business area in which polyethylene bags would not be regularly used.

The release of the packages in question is a relatively simple process from a technological point of view, which is quite feasible even at a small enterprise and with relatively small financial investments compared to investments in many other industries.

We will study in more detail how you can organize a business in the production of plastic bags.

The optimal premises for the organization of the production of plastic bags will be:

1. Be located in an area of ​​the city where harmful production is allowed (such as the production of goods made of plastic).
2. Have an area of ​​at least 100 sq. meters.
3. Have ceilings at least 6 meters high.
4. Equipped with the necessary communications, working smoothly.

The specific characteristics of the premises will depend on the structure of the production process, which in turn is determined by the quantity and capacity of the equipment for the production of plastic bags.

On average, in the largest Russian city, the cost of renting the corresponding premises can be about 100 thousand rubles per month (including utility bills) or 1.2 million rubles per year.

The main production asset of a company engaged in the production of plastic bags is an extrusion machine. It is an apparatus capable of manufacturing a finished product from polyethylene blanks (usually in the form of balls or granules) within the following main steps:

1. Melting of polyethylene blanks.
2. Transfer of molten material to extrusion elements.
3. Passing the molten mass through extrusion elements (which usually contain holes of one form or another) and forming a semi-finished product - a polymer film or a sleeve.

Of course, the sequence of these operations may be different based on the specific technology for the production of plastic bags. But in the general case, the extruder operation algorithm corresponds to the specified scheme.

The extrusion machine also allows you to add various dyes to the raw materials - if this is provided for by the production task.

The next stage in the production of bags is the processing of the corresponding types of semi-finished product into finished products. For these purposes, the following are involved:

1. Cutting machine. This type of equipment cuts the film or sleeve formed by the extruder into pieces of a certain length.
2. Packet making machine. Based on the blanks formed on the cutting machine, this device produces finished packages. In some cases, the functionality of the corresponding machine can be supplemented by packaging finished products in packs - usually 100 pieces.

Finished plastic bags are redirected to the company's warehouse.

In some cases, the enterprise may carry out additional processing of finished products - for example, represented by applying drawings to packages. For these purposes, a separate type of equipment is used - a flexographic machine.

At the same time, in many cases it is more profitable to outsource additional processing of packages to specialized printing companies. The fact is that the cost of maintaining flexographic equipment at the plant itself may be higher than in a company for which applying images to packages is one of the main activities.

The costs of acquiring these types of equipment can vary greatly depending on:

1. Device performance (the more powerful the equipment, the more expensive).
2. Country of origin (imported devices can be significantly more expensive).
3. Delivery region (the farther the supplier, the higher the cost of delivering fairly massive units, obviously).

It also matters whether the cost of delivery includes services for the installation of equipment in the production workshop. But the fact of their provision and the cost in many cases are predetermined, again, by the distance between the supplier and the customer of the equipment: if the counterparty is too far away, then the travel of the supplier’s setup specialists to him can be quite a costly prospect for the parties to the transaction.

Based on market average indicators, it would be legitimate to include in the business plan the costs of purchasing the equipment in question in the amount of about 2 million rubles.

In addition, there may be periodic maintenance costs for the machines. Their value can vary significantly, but if these costs are optimized at the proper level, it will amount to about 100 thousand rubles a year.

Raw material

The main type of raw material for the production of plastic bags, as we noted above, is polyethylene blanks in the form of balls (or granules). On the Russian market, the most common are its domestic and South Korean brands.

The blanks under consideration can be classified into 2 main types:

1. Made from high density polyethylene.
2. Made from low density polyethylene.

At the same time, blanks with mixed characteristics are also common on the market.

Raw materials of the first type are best suited for release:

• bags with reinforced cut-through handles;
• packages of more expensive price categories - for example, gift;
• reusable bags;
• packages to accommodate heavy enough - about 7-8 kg, items.

Raw materials of the second type are optimal for production:

• T-shirt bags;
• single use packages;
• bags to accommodate light items.

Mixed-type polyethylene raw materials can be used, in general, for the production of any product. At the same time, in some cases, its use makes it possible to establish a more economical production of packages, to expand the range of products with a low cost.

On average, the cost of 1 ton of plastic blanks of one type or another is about 30,000 rubles.

Another type of raw material in the production under consideration can be a dye. Substances of the corresponding type are presented on the Russian market in a fairly wide range of brands. But, in principle, even the most economical of them, as a rule, are quite capable of meeting the basic quality criteria when releasing packages. You can focus on the cost of 1 kg of dye in the amount of about 700 rubles.

At the same time, about 10-30 kg of dye falls on 1 ton of raw materials.

Staff

In a small workshop for the production of plastic bags, in which 1 production line will operate, the necessary work can be performed by:

1. Extrusion machine and cutting machine operator. On average, in the largest Russian city, his salary will be about 40 thousand rubles a month. It will also be supplemented by contributions to state funds in the amount of about 30% of the accrued amount of the specialist's earnings.
2. Bag making machine and flexographic machine operator (optional). In terms of complexity, his work will be comparable to that which the operator performs at the first stages of the production cycle, and the salary will be similar.
3. Specialist in receiving finished products and shipping to customers. As a rule, the work of this person is simpler than that related to the management of rather technological equipment. His salary can be about 30 thousand rubles.

Absolutely any work that corresponds to the specified positions can be performed by the owner of the company. If he operates as an individual entrepreneur, then he does not need to register himself for a salary.

Thus, the monthly salary costs for employees (provided that the owner of the company himself performs work in one of the expensive positions) will amount to about 91,000 rubles per month (70,000 is the salary of an acceptance specialist and operator, increased by 30%, which is represented by contributions to state funds) or 1.1 million rubles per year.

Calculation of profitability and payback

What can be the profitability and profitability of the production of plastic bags as a business depends on:

1. The formats of the bags produced (bulk items such as T-shirt bags are usually less profitable but generate more revenue than gift bags).
2. Characteristics of the bags (for example, producing products with a thicker film is obviously more expensive than producing bags with a thin film).
3. Supplements with bags with reinforced handles, various folds - including designer ones (the more complex the package structure is, the higher its cost will be).

In the first year of business, the owner of the plastic pact shop will need to invest in the business:

• 2 million rubles - for equipment;
• 1.1 million rubles - for staff salaries;
• 1.2 million rubles - for renting premises and paying for utilities;
• 100 thousand rubles - for car maintenance.

In total - about 4.6 million rubles.

But it will also be necessary to add to the costs those that should be directed to the purchase of raw materials. Its volume will depend, in turn, on the intensity of sales of goods.

On average, about 200 thousand bags can be made from 1 ton of polyethylene granules in common formats with an average size and thickness. The cost of 1 package (with a dye added at a maximum value of about 3%) will thus be about 0.25 rubles: 30,000 rubles (a ton of plastic blanks) + 21,000 (30 kg of dye) divided by 200,000.

The selling price of a package on the market is on average about 1 ruble.

A typical production rate for a well-established enterprise in the relevant market segment is about 30,000 bags per day on a line using 1 extruder. Thus, when these lines are fully loaded, it will be necessary to purchase about 4 tons of plastic raw materials and 120 kg of dye per month - for about 200 thousand rubles (4 * 30,000 + 120 * 700). A year - 2.4 million rubles.

Thus, the total expenses in the first year of the business will amount to about 7 million rubles (to 4.6 million rubles for investments in equipment, salaries, maintenance, premises, we add 2.4 million rubles for raw materials costs).

At the specified rate of release of packages - 30,000 pieces daily, and the price of a package of 1 ruble, the monthly revenue of the business will be about 900,000 rubles, the annual one - about 10.8 million rubles.

Thus, the business will pay off already in the first year: the profit in the above calculations can amount to 3.8 million rubles, and the profitability of production can exceed 50%. Further — only to increase at the expense of the paid off equipment. Which, however, has a lifespan, as well as increasing maintenance costs in relation to obsolescence.

In addition, it is necessary to take into account other possible costs - for transport, for insurance. But even taking into account the corresponding costs, profitability will not decrease by a factor and will be presented in a value that is quite worthy compared to the profitability indicators of many other industries.

Attention! The free business plan provided for download below is an example. The business plan that best suits the conditions of your business must be created with the help of specialists.

Business plan for creating shopping bags and others

How it all began

I have always dreamed of starting my own business. However, it had to meet several requirements:

• do not require significant, initial investment;
• be competitive;
• do not depend on the crisis, default and other cataclysms in the foreign exchange market;
• be in demand.

Only one thing stopped me - I did not know which products are most suitable for this. And so, somehow walking along the streets of the city, I noticed that passers-by were running, hurrying about their business and everyone was holding packages with a wide variety of things - food, books, clothes.

Thus, the idea was born to create a private business for the production of plastic bags, at minimal cost.

Why did I carefully calculate everything?

Initially, I made a list of the necessary equipment:

• Extruder for making film from raw materials;
• Machine for cutting and soldering polyethylene;
• Punching press for the manufacture of handles;
• Flexographic machine to print attractive logos, designs.

Roughly calculated the cost of buying machine tools by looking at their prices on the Internet. I needed about 600,000 rubles, which, in our time, would not be a problem to get.

Not much, given that I planned to find companies that would be willing to pay good money for advertising - their logo on my packages.

It would seem that, in general, everything is ready, but I understood that without a well-written business plan, my production could fail at the initial stage.

• competitiveness;
• gradation of demand for goods;
• raw material costs;
• payback of the project;
• regulations, laws and many more details.

Where can I get a business plan template?

Realizing the inexpediency of spending on the services of a consulting agency (as I roughly calculated, in order to recoup them, my factory would need three days of work), I decided to create an economic program on my own.

To do this, I downloaded an inexpensive business plan template on the Internet. It should be noted here that the network is full of free ones. Of course, I tried to download them, but the data there is so outdated that even if I substituted my derivatives, it would be impossible to achieve a clearly calibrated program.

But the template bought for 500 rubles pleasantly pleased me with a real analysis of the modern sales and consumption market. I substituted my values ​​​​into it and brought the data together in a special program, of which there are also a lot on the Internet, and I received a ready-made business plan.

Having carefully studied it, without a drop of doubt, I decided to establish my own derivative line, since the results of the payback were 100% satisfactory to me.

The next month, I spent in endless running around - I registered an IP, registered a company, looked for premises and workers, agreed on the placement of advertising logos and points of sale, and purchased equipment.

Soon, my workshop was opened and it works clearly, fully complying with the parameters of the business plan. Daily revenue is about 30,000 rubles, respectively, monthly - 900,000 rubles.

Within a year, taking into account all the costs of rent, salaries, raw materials, paying taxes and bills, I fully paid off my investment and began to receive quite stable profits.

Production of plastic bags

Some useful information and a brief presentation of the business plan for the production of bags:

Business plan for the production of plastic bags

We propose to consider a business project with low financial costs - the production of packages. Many who are already in the manufacturing business today say that this niche is the most promising.

This is a field of activity with great potential, because these products are in demand in all spheres of life. Polyethylene products are in high demand in trade, industry and everyday life.

Business bag making equipment

Modern extruders are in several price ranges. The equipment is characterized by product performance, the presence of advanced functions.

Inexpensive equipment segment within $10,000–12,000. The average price range of cars reaches $15,000. To organize a full-fledged production in a mini-factory for the manufacture of various polyethylene products, such equipment will cost $ 30,000.

The range of imported and domestic equipment representatives is diverse.

According to expert estimates, such a business has a rapid payback period of 2-3 years on average. Given the high demand for plastic packaging, the reported payback figures are realistic.

According to experts in the field of production, it is desirable to purchase several types of equipment. The fact is that by expanding the range of production resources, you will provide large quantities of goods to any customer. It is more profitable to form a loyal price against the background of large-scale production.

Types of production of polyethylene products:

• production of bags - T-shirts, different density, sizes, colors. The choice will attract potential customers;
• production of plastic bags of all standard sizes, colors, shapes;
• production of paper bags;
• production of garbage bags;
• production of packages with a logo. Shops, supermarkets, shopping centers use packaging bags with their logo as promotional products - they are your potential customers.

The more directions you choose, the more functional devices will be required.

You will be able to reach a large audience of customers, and deliver your products consistently.

Modern equipment for the production of bags is automated, so one person per shift can manage and control the process.

The production equipment is easy to operate and maintain.

As a rule, companies that sell equipment perform commissioning and start-up of production.

financial calculation

Any entrepreneur is interested in the financial benefits of the future enterprise. Let's predict the financial costs of the future project.

You buy simple equipment that costs 300,000 rubles. Its capacity is 50 bags per minute. Material costs for the production of one package costs 10 kopecks.

Table number 1. Potential of package consumers in Russia

Our wholesale customers buy for 40 kopecks. In total, the profit from one package will be 30 kopecks. We calculate the average daily operation of the machine (10-12 hours) - we get the production of 30,000 units.

In monetary terms, products worth 9,000 rubles are produced in one day.

For one working week from simple equipment, the income will be 198,000 rubles. We will have to take into account that the costs of wages, transport, consumables for machines should be deducted from this amount.

The salary of one worker on production equipment per month is about 18,000 rubles.

In addition to organizing production activities, it is necessary to design a sales plan. In large industries, this is done by marketers and sales specialists.

Table number 2. Growth of participants in the bag manufacturing market in Russia

If your plans include launching a large-scale production line, then, of course, professionals should be involved in sales. In a small business, this function is performed by business partners and entrepreneurs.

From developing a strategic marketing plan to submitting a commercial proposal to potential customers. Activities in this area of ​​production, with the right calculation, pay off from six months to several years.

We are confident that the organization of the production of bags on the shoulder of purposeful entrepreneurs will become a profitable enterprise for you.

Capital investments: 3,975,000 rubles.

Payback period: 1 year 9 months.

It is worth noting the fact that production of plastic bags can not be called a new or original type of entrepreneurial activity. These products have long been entrenched in the market as a necessary product in use.

Just think of the variety of packages used:

• with custom design (for sale in supermarkets and shops);
• transparent bags (in the CIS countries - an integral element of everyday life);
• garbage;
• gift polyethylene packages.

That is why we can come to the conclusion that no matter how many manufacturers enter this market, there will always be demand for such a product.

1. Production of plastic bags: pros and cons

What can be attributed to the positive aspects of such a business?

1. Ease and automation of the manufacturing process.
2. High demand - both among private entrepreneurs and large industrial facilities.
3. Low cost of raw materials.
4. Possibility of recycling raw materials.
5. The versatility of polyethylene.

Why PET production might be a bad idea?

All the main disadvantages of production can be combined in one word - ecology. Many people try to switch to paper bags, as they are considered environmentally friendly. After all, plastic bags have a very long decay period, this material is considered less acceptable for the ecosystem.

In the CIS countries, this minus is still poorly felt for entrepreneurs. But in Europe, the demand for polyethylene products is falling before our eyes.

2. How to register a business: a list of required documents

Before organizing the production of plastic bags, you need to collect a package of certain documents, as well as draw up the necessary acts.

List of documents for the production of plastic bags:

The charter of the company should indicate such points as: authorized capital, property, list of founders, subject of activity, location, principle of distribution of profits between the founders (if there are several), etc.

Registration with local authorities.

This means that the enterprise must be registered with legal entities + OKVED activity codes must be selected. The most suitable would be 25.22 and 51.47 (manufacture of plastic products for packaging; wholesale of non-food products).

Payment for the registration procedure.

You must have a certificate of payment of the state fee.

Certificates for raw materials.

Permits of ecological, as well as sanitary and epidemiological services.

Production certificates.

Permission from the local administration of the city, for production, as well as compliance with GOST (which requires quarterly confirmation).

3. What kind of raw materials will be required for production?

The first step in studying the manufacturing process is to determine what the product will be made from. In the case of plastic bags, there are two options: plastic film or sleeve.

A sleeve is something like a semi-finished product in the manufacture of bags. It can be ordered from other manufacturers. The advantage of this manufacturing method is that not much equipment is needed.

In the event that a further expansion of production formats is planned, it is better to start manufacturing polyethylene film on your own, since it can be used to make various goods in addition to bags.

For example:

• packing tape;
• raw materials for construction (waterproofing);
• materials for the arrangement of greenhouses, as well as other agricultural facilities.

The main and only raw material used for the production of polymer film is granular polymer. These may be pellets that are recyclable for the first time, or they may be pellets that have been recycled.

The raw materials that are used must comply with two GOSTs:

Granules for the production of polyethylene film on an industrial scale can be purchased, both domestic and foreign analogues. The choice depends entirely on the future destination.

For some types of goods (for example, garbage bags), even recycled granules are suitable.

Industrial dyes will be needed if a color film is to be produced at the factory.

4. Equipment for the production of plastic bags

For more efficient production, you will need equipment not only for forming bags, but also for making films. Although purchasing film from suppliers will reduce the amount of capital investment in production, the amount of monthly expenses will increase significantly from this.

Accordingly, in the future, this will be a very disadvantageous solution.

	Equipment for the production of plastic bags
Name	purpose	Price
extruder	Formation of a film from granular raw materials
bag maker	An apparatus that produces bags of various shapes and types	Since this is all one production line, the cost of all components as a whole will be 3,000,000 rubles.
Clamping machine	Equipment for the manufacture of bag clips
Flexo printing	A machine that prints patterns on packages

Such a production line requires maintenance, adjustment, as well as training of personnel to work with the equipment. All this will cost another 850,000 rubles.

You will also need office equipment and various inventory for storing finished goods:

In general, in order to fully equip production, it will be necessary to spend at least 3,920,000 rubles.

5. Production staff

6. Premises for organizing the production of PET bags

Obviously, it would be more profitable and more correct to rent premises in the industrial areas of the city.

Firstly, the cost of rent in this part of the city is much cheaper than in the center. Secondly, then the workshop will be located far from residential areas, which means that there will be no objections to its organization.

Requirements for the premises under the workshop:

• availability of electricity
• heated room,
• availability of sewerage and water supply,
• area from 250 sq. m.,
• good ventilation
• surface finishing with fire-fighting materials.

7. How plastic bags are made: technology and main stages

Bag making- far from the most difficult process, given that the main work is performed by an automated line. It consists of 8 stages.

Raw materials are poured into the extruder, the temperature in which is from 180 to 240 degrees. Gradually, the granulate is remelted and becomes homogeneous. After that, this alloy is pressed through and a film in the form of a sleeve is obtained.

The sleeve obtained as a result of punching is cooled, after which it is rolled out with special rollers.

The finished sleeve is cut into uniform parts with a special automatic knife.

At this stage, a pattern is applied, for which special rollers are used in the apparatus. After that, the colored and cut film is rolled up.

The roll, which turned out, is loaded into the machine to form the blank of the package - the bottom fold is pressed.

The workpiece enters the stamping press, where holes for the handles are cut and a shape is made according to the selected template.

Soldering the edges of the workpiece. The temperature of the welding surface is about 180 degrees.

The final stage

Checking the quality of the main fasteners and the sides of the soldering, since the strength of the package depends on this.

8. Production cost and pricing policy

Since we are talking about the manufacture of goods to order, the cost can be completely different.

The final amount depends on the following factors:

• Design - as a different amount of dye may be required.
• Form - as it implies different sizes.
• Density - since it depends on how much raw material goes into the manufacture of one package.
• The presence of additional reinforcing elements (handles, bottom).
• The size and complexity of the print (or lack of it).

9. Business Costs: – Capital and Regular

If we take average statistical indicators for calculations, the following amount will be spent on launching such a production:

Calculation of monthly production costs

10. Estimating the profitability of a plastic bag business

You can take for an approximate calculation the cost of a standard opaque plain package without additional reinforcements on the handles.

Parameters: width / height - 40/60 centimeters.

Calculation of monthly profit:

60 min * 8 hours * 22 days * 70 pcs (70 kopecks - 13 kopecks) = 421,344 rubles / month

Calculation of the net profit of the production of plastic bags:

RUB 421,344 - 234,252 rubles. (monthly expenses) = 187,092 rubles.

In the case of the production of plastic bags, the approximate amount of profit is 187,092 rubles.

The profitability of production is equal to the amount of profit for the month, divided by the cost of production.

Profitability calculation according to the formula: 187,092 / 234,252 = 79%.

What payback period can be expected?

Given that the capital costs for the full organization of production will amount to 3,975,000 rubles, and the net profit is about 187,092 rubles, we can conclude that it will pay off in about 1 year and 9 months.

This is a fairly fast time, as for production. Moreover, in the future, the business will bring good profits to the entrepreneur.

11. How can you expand production?

If the business is gaining momentum over time, you can always think about expanding production in order to generate additional profit.

Since polyethylene is a fairly versatile material, it can be used not only in packaging, but also in a wide range of other applications.

For example:

• raincoat manufacturing,
• boot covers manufacturing,
• polyethylene food gloves, etc.

The implementation of this step, of course, will require additional equipment (and costs, respectively), but it will also increase profitability at times.

How to make money in the production of plastic bags?

About the features of the implementation of this business idea in this video:

Conclusion on the profitability of the production of plastic bags

79% is an excellent indicator. However, it should be understood that “laboratory” calculations and real indicators are not the same thing. Such amounts of profit and payback period are possible only in the case of ideally adjusted sales.

Since this product is in demand, regardless of the time of year and other factors, there is no reason to doubt that it will be in demand on such a huge scale. But before start the production of plastic bags in full swing, create an extensive customer base by offering them better conditions for especially large orders.

We will tell you why the business idea for the production of plastic bags will not burn out, how much money is needed to launch the project, and how justified it is to invest in such a production.

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

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

How much demand is there for 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 decreasing.

Plastic bags are used in trade, public catering, manufacturing, construction, and private households. PET is used to produce garbage bags, bread bags, clothes bags, freezer bags, sandwich bags, 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, one should not be surprised at the opening of the next production of PET products: the population and entrepreneurs choose budget goods.

Why is this business idea not going to work?

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

The second factor is a wide range. A full-cycle PET plant will satisfy the needs of cities and villages, trade, construction, 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, dense bags are needed for storing and transporting vegetables, etc.

What else does the PET mini-factory attract entrepreneurs, and where are the risks?

Consider the pros and cons of the project:

Strategy: mini-workshop or full cycle?

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

To answer this question, we will conduct a brief comparative analysis:

The table shows the average parameters. It will take 10 times more money and effort to set up a full-cycle workshop than to launch 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 was concluded.
2. A contract was signed for high-quality raw materials at a low price.
3. Shipping and handling costs are minimal.

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

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

Watch the shop in action in video format:

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

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

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

Let's take a look at the parameters that you should definitely study.

Consumers. Think about who will become your buyer, what products and on what scale will be purchased. Take into account seasonal demand (if you plan to cooperate with construction companies and agriculture). Evaluate the distance of buyers from your warehouse (price and delivery time matter!).

Advice: take advantage of personal connections and conduct research in the business environment, find out about the needs of different companies in 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 goods, cost, terms of delivery.

Raw material suppliers. Determine the conditions under which you will receive raw materials for your workshop. Estimate the cost, delivery time, payment procedure, manufacturer's guarantees, batch volumes and everything that you consider important for your particular 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 be served. Economical options are good as long as other processes don't suffer.

For example, choosing a cheap rental of premises 120 km from consumers and railway stations, you risk ruining your business. Transportation costs for the transportation of containers with PET granules and the delivery of finished products to the Rublevo-Figasevo highway will become the main cost item, there will be no money for other expenses.

The number of staff depends on the business model, its volume and strategy. Assess the labor market in your region, the level of average wages, predict the payroll of your enterprise.

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

Following this simple path, you need to draw up a business plan.

Step 1. We 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 equity should also not neglect planning. Make a simple forecast, taking into account the marketing research data and the features of the technological process.

1. Sales prospects. Focusing on the planned capacity of the equipment, evaluate the real prospects for sales. For example, with a line capacity of 5,000 plastic bags per hour, you can produce 880,000 units per month. How many of them will you sell in the first month of operation and beyond?
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 in advance. You can change the conditions and get discounts and deferrals by becoming a regular customer of a major supplier. In the business plan, take into account the cost of stocking raw materials, shipping and storage.
4. Business processes and production maintenance costs. Determine how all departments of your enterprise will work and how much it will cost to maintain it.

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

For beginners, an easy way: download a ready-made business plan for free and modify it taking into account your parameters, getting a realistic forecast.

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

Step 2. Registering a business

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

Important! When registering, you need to select OKVED activity codes. Suitable 25.22 and 51.47 (manufacture of plastic products for packaging; wholesale 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 a room, use the following options:

1. Ceiling area and height. For a mini-line, a room with a standard ceiling height, with an area of ​​​​10 m2 or more, is enough. A full cycle will require special conditions: the room must have high ceilings, have a certain temperature regime for the operation of automation and an extruder (the PET granules are melted in it).
2. The area of ​​the premises should be sufficient for the storage of raw materials and finished products, staff accommodation (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.
5. infrastructure and location. Ideally, your enterprise should be located in close proximity to consumers and suppliers of raw materials. But miracles do not 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. We select personnel

The number of employees depends on the scope 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 staff, a sales manager, a forwarding driver, a storekeeper may be required. Perhaps all these functions will be performed by the entrepreneur himself.

At this stage, it is necessary to fix relations with employees by concluding contracts, determining working conditions.

Step 5 We buy raw materials and equipment

When choosing equipment, get advice from sellers - dealers of large line manufacturers. Determine the required composition of your line (extruder, punching machine, bag line, flexo printing, etc.). It is not necessary to immediately purchase a complete set: drawings for packages can be ordered from the side, 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 buying raw materials, do not forget to get certificates for compliance with GOSTs:

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

Do not forget about furniture and production equipment - tables and chairs, cabinets for documents and clothes, a safe, office equipment.

Step 6. Launch the business and start selling

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

What you need to get your business right

In addition to registering an enterprise (LLC or individual entrepreneur), you need to obtain permission from the local administration. The opening of a PET shop will require permits from the SES, fire protection, energy supervision, and environmentalists.

You will be able to receive a certificate of conformity of finished products to the GOST standard after the start by providing samples for examination.

How much money will it take to start a business

Answering the question of how much money you need 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 start-up capital is determined taking into account specific circumstances. For example, the landlord will want to prepay for the premises for six months, and the supplier of raw materials will ship a year's supply of pellets.

How profitable is this business?

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

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

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

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