Plastic recycling plants. How the only plastic processing plant in Russia works

Recycling PET bottles and other plastic products has become relevant immediately after the start of their mass production for household needs. AT vivo plastic decomposes for a very long time, so society sooner or later faces the question: what to do with waste from this material - to dispose of it or to process it into raw materials that are in demand for various production purposes. As statistics show, the profitability of enterprises involved in the processing of plastic is quite high. This is due to the low cost of setting up enterprises, the simplicity of processing technology and the almost inexhaustible sources of raw materials.

AT Russian Federation this business is much more promising than in European states. The figures speak eloquently about this: in Russia, only about 6% of plastic bottles and other types of packaging are recycled annually, while in Europe this figure is 80%. The recommended plastic recycling business plan with calculations is a project to organize a small plant that will be in demand in almost any region of the country, especially in small towns and near public places of recreation.

Market Review

Worldwide, more than 3 billion tons of waste is generated every year. various materials. Among this amount, at least 11-12% is accounted for by plastics. Most of the plastic waste is "supplied" by the United States - approximately 77 kg per person. In our country, this figure is 25 kg. Polyethylene and polypropylene are mainly recycled. Combined waste is practically not recycled. Secondary raw materials, which are obtained from plastic waste, are sent to enterprises engaged in the production of various constructs, composite building materials, packaging products, etc. An important advantage modern technologies recycling is that in the process of recycling, many of the original properties of plastic materials are lost and their scope reuse narrows, thereby reducing the re-formation of waste.

In Russia, the annual volume of plastic waste generation is estimated at about 40 million tons, of which only 35% are suitable for recycling. As noted above, only 6% of this amount is sent for processing. The rest is transported to numerous landfills, the size of which is growing from year to year.

The main obstacle to organizing a civilized approach to plastic recycling in our country is the lack of a separate collection system. Only such activity can become the main one for deep processing, because the sorting of mixed waste makes it possible to extract from them only 10-15% of recyclable raw materials.

Despite all the difficulties, the plastic waste recycling industry is developing in Russia. The number of factories for the production of flex from used plastic is gradually increasing in the country, their profitability is growing, the cost of primary raw materials is increasing, which, in turn, leads to an increase in the use of recycled materials.

It is gratifying that new laws are being adopted at the state level and attractive economic conditions are being developed for market participants. On it in given time the main players are:

• 11 thousand landfills and landfills.
• 4 waste incinerators (all located in the metropolitan area).
• 5 waste processing plants.
• 39 sorting bases.
• Over 1 thousand transport organizations involved in waste removal.

A feature of the domestic market for plastics processing is its predominantly local nature, which leads to a constant increase in the area occupied by landfills. According to the FAS Russia, the market is characterized by extremely low level competition, especially in the regional context. An example of this is the statistics for cities, which depend on the size of the population. In particular, 45% of cities with more than 100,000 inhabitants are served by one waste disposal company. Much more organizations are involved in recycling,

In general, according to Research.Techart, the domestic processing market is estimated at $1.5-2 billion. There are quite a few "clean" processors on it, most enterprises prefer to manufacture flex products.

In addition, the Russian plastic recycling market is technologically underdeveloped, as evidenced by the following statistics:

• There are 36-38 million tons of waste in the landfills of the country (i.e. 90-92% of their total).
• Only 1.8% of MSW is burned in the country.
• Industrial processing per year is 1.2-1.6 million tons (3-4%).

Thus, the opening of a small plastics processing plant is a socially significant and economically attractive line of business.

Organizational and legal form

A plastic recycling company is created under the legal form of a limited liability company (LLC). This choice is due to the advantages that the plant will have in production and commercial activities. Primarily:

• The possibility of concluding contracts for the supply of products abroad.
• Granting the right to conduct cooperation with legal entities.
• Wider prospects for the development of the enterprise.

In accordance with the chosen form of business organization, taxation is carried out according to the general system.

The main taxes paid and their amount are shown in the following table:

Description of the object

The plastic waste recycling plant being created will produce flex as the final product. This material is a granule, which can later be used for the manufacture of disposable plastic tableware, packaging containers, plastic films and tapes, and other products.

Implement milestones this project planned for the following dates:

Selection of industrial premises

For the normal functioning of a plastic processing enterprise, an unused premises of a factory or a large warehouse with a total area of ​​at least 120 square meters is selected. m. The object must have a connection to the networks of electricity, water supply and sewerage. The most preferable is the location of the plant near the landfills for the collection and storage of waste. This will reduce the cost of transport support for the project.

The facility is equipped with premises for:

• Enterprise office.
• Warehouses for raw materials and finished products.
• Factory workers.
• Shops with an established plastic processing line.
• Sanitary and hygienic needs of personnel.
• Storage of spare parts of equipment and tools.

A parking area for vehicles delivering raw materials for processing and exporting finished products is being equipped on the territory of the plant.

The best solution for choosing a room is to rent it out by the city administration within the framework of the regional environmental program.

Production and technological equipment

The preparatory stage for plastic recycling is the following operations:

• Collection of PET bottles and other types of plastic packaging.
• Sorting of raw materials by classes (colors).
• Rejection of products made of polyvinyl chloride (PVC).

After their completion, the raw materials are sent to the technological processing line, consisting of the following units:

• Band conveyer.
• Rotary machine.
• Screw conveyor with Archimedean screw.
• Machine for removing caps and labels from bottles.
• Crusher.
• Boiler.
• Screw.
• Washing machine.
• Rinsing machine.
• Dryer-water separator (centrifuge).
• Air drying equipment (pneumatic dryer).
• flotation baths.
• Bunker storage.

The capacity of the purchased equipment is 700 kg of flex per hour. The line is serviced by two workers.

Recruitment

18 employees are recruited to work at the plastic waste recycling plant at the initial stage of the project. staffing and labor costs are shown in the following table:

Accounting services for initial stage functioning of the enterprise are transferred to outsourcing.

Financial plan

The total investment in the project is distributed as follows:

It is planned that plastic bottles will be purchased mainly from the local population at a price of 15-18 rubles per 1 kg (the price of 18 rubles per 1 kg is used in the calculations). Considering that about 800 grams of flex is obtained from 1 kg of plastic waste, the technological losses of the line will amount to 20% of the total mass of waste. The average cost of flex-granules is 35 rubles/kg. Transport costs are accepted in the amount of 20% of the cost of raw materials.

Under these conditions, the plant's revenue from sales of products for the first year of its operation will amount to 17,248,000 rubles.

The total costs of the project for 1 year of operation of the enterprise are given in this table:

The projected volume of the plant's revenue for 1 year of operation will be 17,248,000 rubles with a production cost of 18,651,000 rubles. Taking into account the payment of taxes in the amount of 172,480 rubles, the net profit of the enterprise will be 1,575,480 rubles. Thus, with a 1-year planning horizon for the enterprise, projected costs and income, investments in the creation of a plastic processing plant will pay off no later than 8 months from the date of its opening. The profitability of the enterprise for this period will be 27%.

Business SWOT analysis

A SWOT analysis provides a clear idea of ​​the potential risks and benefits of this business.

Strengths:

• Availability of versatile international experience in the activities of enterprises in this industry.
• Availability of standard design and estimate documentation for the creation of plastic processing facilities.
• High social significance of the type of activity.
• The presence of public environmental organizations that support the creation of processing enterprises.
• Availability of environmental programs implemented by local government authorities.
• Simplicity of technologies for processing raw materials.
• Constant availability of raw materials for processing.

Weak sides:

• Insufficient development of a regional regulatory framework for the operation of plastic waste recycling plants.
• Possible limited raw material sources in some regions of the country.
• Insufficient level of organization of separate waste collection.
• Weak development of the industry in the country.
• Low social prestige of activity.

As a result, the business may face the following risks:

• Market fluctuations in the cost of final products.
• Decreased investment attractiveness.
• Changes in the sphere of state regulation of waste management rules.

Eventually

Establishing a plastic waste recycling facility is economically viable and profitable business. Profitability production process It is ensured by insignificant costs for the purchase of raw materials, low current production costs and a high level of profit after the company enters the break-even mode.

Few people think that polymers decompose for more than one hundred years. None Government program on environmental protection is not able to protect nature from plastic waste. But plastic recycling is currently carried out only by individual countries.

Not many people know that used plastic is easy to recycle and obtain feedstock for many industries. It turns out that collecting and processing plastic can not only save nature from harmful waste, but also earn a lot of money. From an ordinary plastic bottle that was in use, after processing, it is really possible to get PET containers or flex.

Flex is necessary for the production of the following products:

• paving slabs;
• packaging material.

general information

At this point, plastic bottle recycling as a business idea is one of the most profitable niches in the recycling industry. In many countries, production facilities for the processing of plastic bottles have been opened.

The processing of such raw materials as a business is very attractive, since the opening of a mini-factory is a relatively small investment (from 600 thousand rubles). And also, huge areas are not required to open production (an empty garage is suitable for a start). But it is interesting that this area is not very full at the moment, this allows you to immediately take a leading position.

Process steps

Disposal of plastic bottles is as follows:

• Waste collection (city dump, PET container collection points, waste disposal from industrial enterprises). In Russia, there is no separate storage of waste, so the collection plastic containers takes great amount time and human labor.
• Sorting (by color) is done only by hand, since machines have not yet been invented in the world that can automatically sort plastic containers from the rest of the garbage.
• Transportation - on average, one plastic bottle for one and a half liters weighs fifty grams. Therefore, in one ton of plastic containers there are twenty thousand bottles, which occupies approximately fifteen cubic meters of space.
• Compacting debris – Hydraulic presses are great.
• Shredding of plastic bottles - pressed containers are sent to the crusher. When choosing a crusher, the size of the receiving device should be taken into account. It is not cost-effective to buy a crusher that does not fit a five-liter bottle. The cost of a crusher item depends on the country of manufacture, performance.
• Washing - the process is carried out in hot water in the proportion of one hundred kilograms of crushed plastic per thousand liters of water. Soda is added to the resulting solution. Most plants use three-section washing baths.
• Cleaning PET containers from dirt, labels, various debris. The cleaning takes place automatically thanks to the paddle drums installed in the baths.
• The second stage of washing - in case of severe contamination, the washing process is repeated to increase the final cost of recyclables and facilitate the work of the granulator.
• Drying - the cleaned flakes must be thoroughly dried.
• Direct processing into secondary raw materials (Flex) - industrial extruders are used to process flakes into granules. An extruder is an electromechanical machine designed for the production of plastic parts from a semi-finished product.

More information about the extruder

The unit is a powerful plastic processing tool. Its popularity in the processing of raw materials is growing every year. The extruder consists of the following parts:

• housing with heating zones;
• boot node;
• auger (to move raw materials into working area extruder);
• spinneret (gives shape to the final product);
• the motor required to rotate the auger;
• automated process control system.

Already melted plastic, moving in the working area of ​​the extruder, enters the die. Then the granules of the required shape are cooled gradually or forcibly and packed for further delivery to the customer.

In most cases, the whole process takes place without human intervention, with the help of automated control. Today, the industry is able to provide a diverse range of devices needed for automatic control and monitoring, from primary sensors to multifunctional controllers.

Prices for extruders start from eighty thousand rubles. And also suitable for the installation, which was in use. When buying, you should carefully examine the heating units, temperature control.

Top 7 DIY Equipment for Plastic Bottle Recycling Business

Assembly of documents

It will not be difficult to assemble an extruder from improvised means, for this you just need the skill of a master and initial knowledge in the field of installation, adjustment and operation of automated systems.

To get started with plastic recycling, you need to:

• a license giving the right to process household waste;
• SES permission;
• fire department permit.

The license is issued for a period of five years, but after the expiration of the term it is possible to extend it. For registration you need:

• constituent and registration papers of the enterprise;
• papers on the ownership of industrial premises.

These documents are submitted to the Ministry natural resources. All documents are checked within three working days. If errors are found in the documents, the entrepreneur has thirty days to correct these controversial issues.

If the documents are correct, then the application is considered within thirty working days. In the process of considering the application, the necessary checks will be carried out on the territory of the entrepreneur.

To obtain a license, a process of inspections is carried out on the territory of the enterprise

Based on the documents and inspections, a decision is made on compliance with all the rules for the processing of plastic containers. This is followed by the process of preparing documents, usually this procedure takes no more than forty-five days. Within the same period, the entrepreneur is obliged to pay a state duty in the amount of 7.5 thousand rubles.

The Commission refuses to obtain a license in two cases:

• non-compliance with the requirements of the legislation of the Russian Federation;
• providing deliberately false information about the company.

In case of refusal, the applicant is provided with a detailed answer, which indicates all the reasons.

At a positive result, the license number is entered in the register.

The main criterion for choosing a site for the processing of containers is the distance from residential premises. Released during extrusion a large number of harmful components that have an extremely adverse effect on general health person.

And also, to allow work, a wastewater neutralization station is required, since industrial effluents contain a large percentage of pollution.

Price criteria

The price in Russia for plastic recyclables is from forty to seventy rubles per kilogram.

For the full operation of the mini-factory you will need:

• eight workers;
• accountant;
• manager;
• two movers.

For the full operation of the enterprise, it is necessary to have an accountant

Economic calculation:

• purchase, installation and installation of a finished line for the processing of PET waste with a capacity of 73 kW per hour - 9 million rubles;
• equipment productivity - one ton of raw materials per hour (as a result, specialists can receive 800 kg of flex at the output, this is only 80%, and the rest will go to waste);
• the cost of purchasing raw materials - 8.5 thousand rubles per ton;
• the cost of the finished flex is 26.5 thousand rubles per ton.

Working eight hours a day, craftsmen can use eight tons of PET containers.

The output will be 80% of the initial raw material load of 8 tons - 6.4 tons.

Purchase costs raw material base will amount to 68 thousand rubles. But at the cost of one ton of 8.5 thousand rubles.

The cost of selling the finished product is 169.6 thousand. This is taking into account the cost of one ton of 26.5 thousand rubles.

The amount of income per day, when deducting the purchase of raw materials from this amount, will amount to 101.6 thousand rubles. For 25 working days a month, experienced craftsmen earn 2.54 million rubles.

Deductions from the total amount

Monthly expenses:

• salary - four hundred thousand rubles;
• utilities and taxes - three hundred and thirty thousand rubles;
• transportation costs - three hundred thousand rubles.

Based on the indicators, the net profit per month will be one million five hundred and ten thousand rubles.

Thus, the processing of such raw materials is a profitable business with a minimum of competitors.

Rationale

Equipment for the processing of plastic bottles has a small cost in the calculation of its operation for at least 5 years.

Even a small plastic bottle recycling plant has been successfully fulfilling its duties for at least 10-15 years. There is little competition in this sector, so a plastic recycling plant easily recoups its initial costs and quickly adjusts to a bottom line.

The practice of such entrepreneurship already exists. Several mini plastic bottle recycling plants have already transitioned from lending to earning a mainstream income. The cost of the units is optimal: the machine for processing a plastic bottle has left the category of novelties for Russian market so its price is quite reasonable.

On the territory of a home mini-plant for plastic processing, the owners can locate all stages of production: from the sorting point to the final packaging of the product. It's easy to set up a line. It is completed in different rooms, even with a small area.

Video: Visiting Uralvtorpet

It takes about 300 years for a plastic bottle to completely decompose, and you can’t burn them, as this leads to pollution. environment. Therefore, they are usually simply buried in the ground. However, you can make good money out of this waste by recycling it. City administrations are interested in improving the environmental situation, so it is likely that you can expect to receive various preferences and discounts when organizing a workshop for recycling plastic bottles.

Sources of raw materials

If you want to open a mini plastic bottle recycling plant, the first step is to find out if you can find enough raw materials. It can be obtained in several ways:

• sign dump agreement;
• organize reception points bottles from the public for a small fee;
• spread around the city urns for separate waste collection, in which people will throw plastic bottles, including

At first glance, it might seem that getting bottles that people throw away is not a problem. However, in reality this is not the case. All recyclables that are in landfills have already been divided between interested companies, and it is usually very difficult to become the owner of this plastic.

By organizing collection points, you can expect to receive bottles directly from the public, but you will need advertising costs and a fee for the accepted container.

By placing bins for separate waste collection around the city, you can receive raw materials for free. To do this, you will have to first agree with the city administration - most likely, it will not mind. A cheaper option is to put bins just for plastic, but in this case you have to be prepared for the fact that people will just start throwing everything at them.

Mini-factory for the processing of plastic bottles: preparations for opening

If you are sure that you can get enough raw materials, you need to choose the legal form and taxation system. Suitable for PET bottle recycling business.

As a type of activity during registration, you must select the processing of non-metal waste and scrap, which takes place at number 37.20.

Plastic Bottle Recycling Equipment

In a PET bottle recycling shop, the following equipment may be needed:

• installation for removal of covers and removal of labels;
• crusher;
• steam boiler;
• polishing machine;
• rinsing machine;
• drying plant.

For the processing of plastic bottles, equipment can be purchased new or purchase installations, a plastic bottle recycling machine, already used, purchase the whole line entirely or cars separately.

Perhaps, the best option- acquisition of a new line for the processing of PET bottles of a full cycle - the likelihood of problems with the installations in this case will be minimal.

Most manufacturers provide installation supervision- the company's specialists install the line, adjust its operation and receive the first batch of processed raw materials at your enterprise.

How is plastic recycled?

Recycling of plastic bottles takes place in 5 main steps:

• first you need to sort the bottles by color, each color is processed separately;
• then they are cleaned of debris that could get on them - this operation, like the previous one, is done manually;
• bottles are delivered to the recycling line, where labels and caps are removed first;
• after crushing PET containers in a crusher, which is like a large blender, using hot water in the steam boiler, everything superfluous is removed from the raw materials - the remnants of labels and garbage elements that were not removed at the previous stages of processing;
• this is followed by a washing, rinsing and drying process, after which the plastic can be considered completely recycled.

The result is recycled raw materials that look like white or colored plastic flakes - flex.

Recycling PET bottles as a business: the necessary start-up capital and the payback of the enterprise

Like any other successful business idea, organizing a plastic bottle recycling shop with the right approach will bring good income. Necessary start-up capital depends on the region in which you open a business (plastic recycling). Opportunities for obtaining raw materials, the price of renting a room and the salary of employees differ significantly from city to city.

AT average form The numbers for a plastic (PET) bottle recycling business plan might look like this:

• purchase of equipment of an average price category - 3 million rubles;
• purchase of raw materials - 30 thousand rubles;
• salary expenses for employees of the enterprise - 120 thousand rubles;
• contributions to the PFR, FSS, MHIF - 40 thousand rubles;
• utility bills - 10 thousand rubles.

Net profit such a workshop will be about 150 thousand rubles, the term payback enterprises - about two years.

Thus, you can make good money on recycling bottles. The main thing is to find sources for obtaining raw materials and establish sales channels for products. By solving the first problem, you will ensure half the success of the entire enterprise. By finding buyers for your recyclables, you can expect to receive a stable income.

Perhaps, having started with the recycling of bottles and having achieved success in this business, in the future you will want to open own production using this raw material instead of selling it. This will allow you to bring your business to perfection. new level. Recycled plastic bottles are an excellent source material for a wide range of household and industrial products.

Man produces a huge amount of garbage every year.

Harsh statistics give a figure of 200 kg per year, and a good third of this is plastic bottles.

Some people know that such a bottle - valuable source of recyclables, others do not, others simply do not think about it.

And colorful bottles together they fly into ordinary ballot boxes.

AT recent times the organization of lines for PET bottles is moving from the field of non-standard ideas to a very real and very profitable business area. People took care of providing raw materials for decades to come.

Moving away from cheap plastic packaging in favor of more environmentally friendly (and more expensive) materials is unlikely to happen in the near future. Under natural conditions, polymers take hundreds of years to decompose, so why not combine profits from own business with concern for the home planet?

In Russia, no more than 6% of plastic bottles are recycled, while in the world this figure reaches 70-90%.

The pioneer in this type of business on Russian soil was the Plarus processing plant, near the city of Solnechnogorsk. The company operates on unique scheme "bottle to bottle" since 2007. AT this moment Plarus produces raw materials only for technical needs, but in the near future it is planned to launch the production of pellets that meet the quality standards of the food industry.

At first glance, there should be no problems finding raw materials for processing. Landfills and bins are overflowing with abandoned PET bottles. However, in reality, the main problem that one has to face is the underloading of the production line. Monitoring advertisements for the purchase and sale of plastic waste will give an initial understanding of market conditions and prices.

It makes sense to consider installing one or more plastic bottle collection points. The conclusion of an agreement with city dumps for the supply of raw materials will significantly expand business opportunities.

Dump city with a population of 100 thousand people. can produce up to 20 tons of PET bottles monthly.

First steps

The specifics of business (we work for the benefit of society!) are conducive to support from the authorities. It can be:

• subsidies;
• grants;
• provision of premises on preferential terms.

It is possible that appropriate programs are operating in the region right now. Registration required legal entity , individual entrepreneurship is not suitable for this type of business. The optimal form of organization is LLC. To obtain a license, an environmental opinion from the relevant bureau of expertise, permits from the SES and the fire service, you will need to spend from 30 thousand rubles.

Room selection depends on the planned scale of production.

The full-cycle line for the processing of plastic bottles consists of several overall units, plus belt conveyors connecting them.

The total length of the installation is about 35 meters. In addition to the actual production premises, it is necessary to provide a place for storing raw materials and recyclables.

A plastic bottle is a voluminous and lightweight material that occupies a solid area. Such production will require a large hangar or plant workshop, preferably outside the city, in an industrial zone.

Mobile alternative to a stationary workshop: mini plant, which is entirely placed in a 6-meter container. This option is great if you plan to collect raw materials in several small towns. Loading the processing line with original PET raw materials is a top priority for successful business development.

In both cases, it is necessary to establish the necessary communications:

• supply of electricity;
• water pipes;
• sewer for waste disposal.

Technologically, the process does not belong to a number of complex ones. All works can be completed in 2-3 days.

Production Line

The full cycle of processing plastic bottles consists of three stages, and the line, ready for operation, consists of three main links.

Technology Development recent years is aimed at a general reduction in the stages of the production cycle of processing at all its stages.

Previously, the process was much more complex and multi-stage.

Crusher

This includes waste already sorted by color, freed from covers and labels. The device operates on the principle of a blender and cuts whole bottles into small pieces.

Agglomerator

Plastic mass - flex- subjected to finer crushing and subsequent sintering into small lumps.

Finished intermediate product - agglomerate- you can already sell, or you can move on to the next cycle to get better, and more expensive raw materials.

Granulator

The mixture is heated again and in this state is subjected to cutting. After cooling, the final product of processing is obtained - granules.

Process in numbers

Minimum budget for the purchase of a full cycle line for the processing of PET bottles - 5.5-6 million rubles(100 thousand dollars). It is desirable to add 10% to this amount for the installation and commissioning of equipment. The output of the finished product is about 80% of the feedstock (800 g of granules per 1 kg of waste).

The full cycle line is usually designed for round-the-clock operation. The mode of operation is fully automatic, except for the sorting of raw materials.

Optional equipment

High-quality multi-stage cleaning of feedstock and flex allows you to significantly increase the operating time of the extruder filter and improves the quality of the final product (agglomerate, granulate). PTF Tekhprom LLC (Russia) declares a quality that is not inferior to Western counterparts.

The price of the flex washing and drying line from this manufacturer is 5 million rubles. in the maximum configuration and 1 million in the minimum. Equipped with the following additional equipment production line will greatly improve the quality and purity of the final product:

• hot wash bath (high-quality cleaning of the flex from dirt, glue, label residues using water and chemicals);
• one or two centrifuges;
• flotation washing (effectively separates materials with different densities. Contaminants remain on the surface, while a flex having a different density settles at the bottom of the bath);
• pneumatic transport connecting the units;
• a single equipment control module.

When choosing models of processing lines, it will not be superfluous to take into account the possibility of a modular design that allows you to complement, change the order and arrangement of machines.

Each installation can be purchased separately to then assemble them into a production line. The Internet is full of ads for the sale of used components and equipment. Regular monitoring of prices will allow you to choose the right prices and technical specifications options.

Income, expenses, payback

The lines operate in automatic mode, however, raw materials need to be unloaded, sorted, loaded into units, and the finished product is transported to the warehouse. Labor productivity of one worker: 125 kg/h. Thus, 3-4 people will be required. Also needed:

• master to control the work of the line;
• accountant;
• manager-manager.

The functions of the latter can be taken over by the owner of the business, in whose direct interests is the search for sales markets. When transferring production to a round-the-clock mode of operation, much more employees will be required, but productivity will also increase significantly.

Let's calculate approximate expenses:

1. 6 million rubles for the purchase and installation of a production line;
2. 400 thousand rubles for rent and utility payments;
3. 100 thousand rubles - other expenses (obtaining a license, registering an enterprise, etc.);
4. 200 thousand rubles for the wages of employees.

Total: 6.7 million rubles
The line will allow processing up to 300 kg of raw materials per hour, with the production of PET flakes in the amount of 240 kg/hour.

Under the condition of an 8-hour working day and a 24-day working month, this is at least 1.5 tons of product per day or 36 tons per month. Let's round this figure up to 30. The sale price of the flex depends on the color of the plastic. Transparent is more expensive, painted - cheaper.

The cheapest plastic is brown, since it is not subject to subsequent staining.

In the world 1 ton of refined PET flakes sells for an average of $500. In Russia, prices are lower, of the order 18-25 thousand rubles per ton. Let's take the figure of 20 thousand rubles.

Calculate the approximate profitability of the processing plant:

• expenses: 6.7 million rubles;
• income before tax, per month: 600 thousand rubles.

Estimated business payback A: about 1.5 years.

Sales of finished products

Potential buyers of products will mainly be enterprises of the chemical industry.

Recycled PET is widely used in the textile industry.

Recycled polymers are significantly cheaper than virgin PET raw materials, which makes them attractive to manufacturers.

The scope of application depends mainly on the degree of contamination of the product.

Recycled PET containers can find a second life in the following areas:

• production of chemical fibers;
• production of nonwoven materials;
• production building materials and details;
• production of consumer plastic goods;
• as an additive to primary raw materials.

These types of production are represented in all regions of the country, therefore demand for recycled PET is growing steadily. A developed sales market will allow, with minimally established connections, to carry out profitable sales of products at attractive prices.

Recycling plastic waste makes it possible to participate in environmental programs and effectively solve the important issue of PET recycling with a product that brings significant profit.

All stages of the processing process plastic bottles are presented in the introductory video.

In contact with

A plastic recycling business, if properly organized, can bring a decent income. At the same time, such activities help save the environment by cleaning landfills from non-decomposable garbage and preventing the release of harmful substances into the atmosphere when it is burned.

Advantages and disadvantages of a business idea

Even a small home-based plastic waste recycling business from the same empty bottles is economically viable. This is facilitated by low costs for raw materials - you can get it for free if you agree with enterprises that dream of getting rid of unnecessary waste.

Buying plastic waste from the population will require about 9 thousand rubles. per ton. If you choose the production of pellets, then from 5 tons of garbage you can get 4 tons of product. With properly established sales, their cost will be about 200 thousand rubles.

For a month, taking into account weekends and one-shift work, an average enterprise is able to produce about 40 tons of processed product.

Profit excluding taxes and other expenses comes out to about 2 million rubles. For such an enterprise, the equipment will cost about 4 million rubles. If you subtract the costs of rent, wages, utilities, transport, it will pay off in about six months.

Plastic bottle - the most common type of container at present

It is necessary to take into account the scale of production and the chosen business technology. If you process a small amount of plastic at home and produce not granules, but plastic flakes - flex, then the income will be much less, but the equipment costs will also be reduced. Here, the average income is about 300 thousand rubles. per month, and reaching the break-even point takes about a year.

When organizing a plastic recycling business, it is necessary to take into account its possible disadvantages:

• a large number of permits, which will have to spend both time and money. In general, it will take 4 months and at least 50 thousand rubles to start a business. without taking into account the cost of equipment and rent;
• difficulties in finding sales and rather high competition;
• the need for manual labor, which expands the staff and the cost of wages, payments to insurance funds and tax.

But with a competent approach to the plastic recycling business, these shortcomings are offset by a good profit, which will become stable in a year, and a fairly quick return on the initial investment.

Types of plastic recycling

To properly organize a plastic recycling business, you need to decide which specific plastic waste will be sent for processing, and what end result is planned to be obtained. The choice of technology, the scale of production and the cost of equipment depend on this.

by the most in a simple way is the processing of single-grade scrap without serious pollution - the same PET bottles.

But with good financial investments, you can organize a mini-factory for the processing of various plastic materials or plastics with the inclusion of impurities. In this case, additional cleaning equipment will be required.

The processing process at enterprises is carried out mechanically or use chemical and thermal methods. To obtain secondary raw materials for sale, the first method is used. Chemical methods (hydrolysis, glycolysis, methanolysis), as well as thermal destruction (pyrolysis) require expensive equipment, special laboratory conditions, and it is extremely difficult to organize such production on your own.

Main types of recycled plastic:

• polymer granules;
• polymer-sand mixture;
• flexes.

The granulated form of polypropylene is the best suited for its combination with other components

The plastic recycling business does not only involve the production of pellets, which are used to create plastic bottles, polymer fibers and packaging.

If you purchase the appropriate equipment - melting and heating devices, you can organize the production of a polymer-sand composition.

It can be sold to enterprises engaged in the creation of flexible tiles, paving slabs and other similar products.

Processing technology includes five main stages:

1. Sorting plastic by type and level of contamination.
2. Initial grinding.
3. secondary sorting.
4. Washing and drying.
5. Melting plastic to a homogeneous state and molding in a pellet press.

From one bottle you can get from 35 to 40 g of flakes

When creating flexes, the last stage is skipped, so it turns out just crushed plastic of a small fraction of a different color. Granules have the same weight and size, they are of higher quality. It is more profitable to produce them, but the equipment is more expensive, since a special extruder is required.

The main difficulty of mechanical recycling is pre-sorting and cleaning. Contaminated plastic is brought in from landfills - removing labels, debris and impurities takes time and manual labor.

Where to begin

To implement this business idea, first of all, you need to analyze the market for the presence of competitors. If a city with a population of less than 100 thousand people already has a similar production, it is unprofitable to open a new one. Or you need to change the direction of sales - negotiate with buyers in the nearest large settlements, choose a different type of finished product. But in any case, the first step is to draw up a plastic recycling business plan to take into account the likely costs and risks.

Drawing up a business plan

Even if you are considering starting a home plastic recycling business, you need to start by putting together a business plan. Ideally, it is better to make three options: realistic, optimistic and pessimistic. This will allow you to vary the work of production depending on the situation. When drawing up a plan, consider the following:

• Availability of probable suppliers of raw materials and potential distribution channels for finished products. It may be more profitable to invest in equipment for the independent production of blanks for bottles or polymer fibers.
• Required permits to open production. First of all, this is official registration with the tax authority as an LLC or individual entrepreneur with the purchase of an online cash register and its settings.
• Choosing the right space. If you organize not a tiny production in a personal garage, but a mini-factory, it is economical to rent a non-residential workshop on the outskirts of the city. But all communications must be connected.
• Selection and purchase of equipment. The kit depends on the final product. At the initial stage, you can save money by buying devices from your hands.
• Calculation of the staff and expenses for salaries, transport.

Do not forget about the advertising campaign. If preliminary sales agreements have already been concluded, a small website with product prices is sufficient. But it will probably be necessary to spend money on flyers to attract potential suppliers of raw materials and organize containers in yards for separate waste disposal.

Recycling plastic bottles is a hazardous industry, so you will need to issue a license to conduct activities and obtain an environmental opinion

Search for plastic suppliers

In order for the processing line to function continuously, a continuous supply of raw materials is required. To do this, it is necessary to establish not one, but several channels for its receipt:

• purchase from the public;
• organization environmental activities on cleaning up territories;
• use of containers for separate waste collection;
• collection of waste plastic containers in cafes and restaurants.

With the right approach most of The raw material base will come free of charge, which will reduce the cost of production and increase the likelihood of its rapid sale.

Installing containers is not enough, you need to purchase at least a cargo GAZelle

Search for premises and equipment

A mini plastic recycling plant will require an industrial area of ​​at least 60 square meters. m with additional departments for warehousing raw materials and finished products. All communication lines must be connected to it.

You will need to obtain permits from the fire and environmental services of the locality.

The set of equipment depends on the types of processed raw materials, but you will definitely need:

• automatic devices for supplying raw materials;
• cleaning devices;
• shredders for pre-grinding;
• crushers for final grinding;
• bunkers;
• dispensers.

Both liquid and dry modules can be used to clean plastics. The latter type is more convenient, economical and environmentally friendly.

The line consists of several units connected by belt conveyors

For processing plastic bottles into flakes, a perforator and a specialized line, which already includes cleaning devices and shredders, are enough.

If it is intended to obtain granules, a granulator press is additionally required. It consists of an extruder equipped with one or two screws, a slide filter, as well as an electric heater and an air or water cooler. Twin-screw extruders produce better products, but they are more expensive. Budget extrusion machines are manufactured in China, Russia and Ukraine, while more expensive and high-quality ones are brought from Western Europe.

Modern models suggest remote control work. If you do not skimp on an expensive automated line that carries out a full cycle of washing, separation from foreign inclusions, grinding and granulation, you can subsequently save a lot on the salaries of regular staff.

Homemade plastic recycling equipment on video

Personnel search

The staff of the processing complex depends on the scale of the enterprise and the automation of production. For a home business, two family members will be enough, but a small plant will require hiring four workers per line, as well as a truck driver.

Possible mistakes

An optimistic business plan assumes that the plant operates without interruption, there is always enough raw materials, and the finished product is not stale in the warehouse. In this case, it is possible to obtain consistently high profits. But the reality does not always coincide with the desired result. To set up the most profitable production, you need to consider possible problems:

• shortage of raw materials for full load lines;
• geographical proximity of a competing enterprise;
• lack of equipment capacity;
• the risk of breakage of equipment components, due to which production will stop;
• human factor - negligence or alcohol abuse of workers.

If you control these points, you can avoid production errors and achieve the stability of the enterprise.