Tosol technology. Technologies in the production of antifreezes. Antifreeze filling line - video

I am looking for an investor to build a plant for the production of antifreeze, antifreeze and non-freezing liquid

Business idea

Antifreeze production

Initial investment: 1000 tr.
Monthly profit: 200 tr.
Payback period: 5 months.

When choosing a profitable idea for organizing your own manufacturing business, it is important to choose the area whose products are in demand on the market. There are not so many options here, and one of them is the manufacture of non-freezing liquid.

It would seem that it could be easier for many of the familiar non-freezing, and, nevertheless, not a single motorist can do without it. And as you know, there are more and more cars on the roads every year.

We conclude that a mini-plant for the production of non-freezing liquid, subject to a competent business organization, will eventually bring its owner a consistently high profit.

"Nezzayka" - a chemical composition consisting of water and organic substances (alcohol, glycol, anti-corrosion agents, glycerin, fragrances). It is commonly used as an antifreeze and as a windshield wiper.

In general, the antifreeze business has the following advantages:

• The raw materials used are available and inexpensive.
• The simplicity of the technology makes it possible to produce anti-freeze with your own hands, which significantly reduces investment in the business.
• A huge sales market promises high income.

Many may doubt the effectiveness of the business, because antifreezes, as a rule, are massively used only in the winter. This, of course, is true, but even in the off-season, the entrepreneur will not be left without profit, since the variability of technology makes it possible to “repurpose” the business at any time - by slightly changing the composition of the liquid, you can produce not antifreeze, but cleaning fluid for washing windows and headlights. And this product is required by drivers in the summer.

What points should be taken into account by an entrepreneur who is working on a business plan for the production of anti-freeze?

We work out the composition of products and purchase raw materials
It does not matter what exactly the production workshop will specialize in, in the production of a windshield wiper or antifreeze - the raw materials used are almost identical. The difference here is only in the ratio of the ingredients used.

When launching a plant for the production of antifreezes, it is advisable to involve a qualified specialist in the case who would work out the formulation of a high-quality liquid. If the entrepreneur cannot afford it, you should independently study all the intricacies of the process and choose the “ideal” ratio of components.

The manufacture of antifreeze liquid will require the following raw materials in the workshop:

• water,
• isopropyl alcohol,
• ethylene glycol,
• surfactants,
• dyes,
• fragrances.

In the process of work, some components may not be used or, conversely, some components may be added to the recipe. But each of the substances will affect the final quality of the product.

If the products produced contain less than 9% alcohol, the entrepreneur will have the opportunity to avoid paying excise duty.

Anti-freeze liquid for cars may also consist of other, cheaper components. For example, many enterprises use methyl alcohol instead of isopropyl alcohol. But the fact is that it is poisonous and, if inhaled, can cause poisoning.
This does not stop underground organizations. That's just, having bought such products once, the consumer is unlikely to come to the store for it again. In addition, at the first check by regulatory authorities, counterfeit products will be removed from production.

The secondary raw materials include containers where the final product will be poured, and branded labels.

We master the technology of production of non-freezing liquid
The technology for the production of antifreeze liquid will be clear even to those who have never encountered the manufacturing industry before. This is what makes this niche popular among those who decide to start a home business.

In general, the line carries out the following stages of production:

• Water purification.
• Mixing of raw materials.
• Thermal treatment of liquid.
• Bottling of the finished product.
• Sticker on a container of labels.
• Warehousing of products.

Regardless of what substance is planned to be obtained at the output, the release technology remains unchanged. It turns out that, knowing how to make anti-freeze, you can get other chemical compounds that motorists need to care for their car in the same way.

No matter how simple the technology is, you cannot do without a certain set of equipment.

The main machines and devices are presented in the following list:

• Container with stirrer.
• Thermal reactor.
• Filling machine.
• Labeling machine.
• intermediate tanks.

The indicated equipment implies the use of already prepared water (filtered and purified). If the technology involves the use of tap water, then you will additionally need to purchase a system for its purification. And this is at least 200 thousand rubles.

The entrepreneur has 2 options - either buy equipment for the production of antifreeze separately, or equip the workshop with an already completed line. Which option to choose will depend on the planned investments in the business. For example, buying machines separately, in some cases, you can save a little. But here, most likely, some operations will have to be carried out manually. But the assembled lines, although they are more expensive, are characterized by decent power and full automation of the process.

The price of equipment for the production of non-freezing liquids of low power (≈500 l/h) fluctuates around 700 thousand-12 million rubles. rub.
High-performance machines (≈1500 l/h) of European brands will cost more - up to 1.7 million rubles. You can safely add 50-200 thousand rubles to the market value of the equipment. rub. for its commissioning.

Estimating business profit

Business in the production of non-freezing liquid, according to experts, can pay off in the shortest possible time. Depending on the cost of the purchased line, it is possible to reach the break-even point in 0.5-1 year. And this, taking into account all capital investments, is an excellent indicator of profitability. How much will it take to start your own business in this area?

According to minimal estimates, the organization of a mini-workshop, where many operations will be carried out manually, will require ≈1 million rubles. This is taking into account the acquisition of machine tools, preparation of the premises for work, and the purchase of raw materials. A larger enterprise with powerful equipment can be opened by spending at least 1.7 million rubles.

As for the specific figures of profitability, it is rather difficult to designate them. Here everything will depend on the volume of production, the system for the sale of finished goods and the pricing policy in the region. Calculating the possible income, you can proceed from the following data. "Average" windshield washer fluid and antifreeze cost ≈50-90 rubles on the wholesale market. for a 5 liter canister. The cost of production, taking into account all variable costs, is at least 40% lower than the selling price.

I will consider various investment options.

The investor receives 40% of net proceeds with the right to sell his share

It is more profitable to produce and sell than just sell - this is a general rule. Wholesale depots, networks of auto shops, gas stations and service stations, logistics companies and auto enterprises create auxiliary production with different tasks - reducing internal costs, increasing sales or margins, constancy of product quality or independence from suppliers. As a rule, not just equipment is bought for such production, but a ready-made business solution.

Today we will look at how to organize production of operating fluids- antifreeze, antifreeze, windshield washer fluid and car washes. For advice, we contacted OOO Complex Systems- this company offers turnkey solutions, including equipment, recipes, accompanying documents, technical and raw material support. The experience of "Integrated Systems" consists of more than 1000 implementations of complexes for the production of liquid auto chemicals, not only in Russia, but also in the former republics of the USSR, and even in Mongolia, Nigeria and China. The director of the company willingly shares information, and we widely used the data provided by him in preparing the article.

What's important?

The most important task is to research the market and correctly assess the volume of production and its profitability. The Russian automotive market is growing and will grow for at least a few more years, and with it the need for operating fluids. However, the situation depends on the region and many other factors. It is impossible to give precise guidelines here: each enterprise must assess the risks itself.

“One thing is clear - ten tons of antifreeze per month is too little to get a return on investment within a reasonable time,” says Andrey Karavaev, director of Integrated Systems. - The order of 50 tons per month is the bar from which to start. You can increase the load of equipment by issuing auto chemical goods line- two or three options for antifreeze / antifreeze, windshield washer fluid, car shampoo. The payback period of investments is purely individual and can vary from two weeks to six months.

It is best if market monitoring results in an agreement on marketing of finished products. Finally, we note that an enterprise that opens such a production creates new jobs in its region, and therefore can receive support from government investment programs. Do not be afraid of the words "basement production": the quality of the finished product will not be inferior even to the leading manufacturers, it is quite accurate to follow the technology.

Registration and organization of the production site

Production of the car chemicals in question does not require licensing, therefore, the design of the site for most managers will include only familiar procedures: obtaining permits from the fire, sanitary and environmental inspections; registration of technical conditions in the sanitary inspection; trademark design.

Shop

Consider the requirements of regulatory authorities for the production premises. It must satisfy third class fire safety, which requires the appointment of a person responsible for the premises. Equipment includes fire extinguishers, a fire shield and a sand box. The alarm is not included in the list of mandatory equipment. It is even easier with environmental inspection - production can be completely waste-free, which will be discussed in more detail later. According to sanitary requirements, the room will have to be equipped with a hood over the installation and a washstand.

How big should the workshop be? Although the installation itself occupies an area of ​​​​about 10 square meters. m., the minimum recommended area is 50 sq. m. Empty canisters, concentrate and additives can be stored in an unheated room and even in the open air, and streamlined transport flows allow for the territorial separation of warehouse and production areas. However, Andrey Karavaev, director of Complex Systems, believes that optimal area- 300-500 sq. m.

Staff

Depending on the volume of production, the site will be serviced by 1-3 people or more. The level of training is secondary technical education, since when buying a ready-made business solution, as in the case of Complex Systems LLC, the production technology is described in detail. clear compliance with instructions guarantees exceeding the minimum GOST indicators by several times.

It has been noticed that women cope better with the spill of finished products - this should also be taken into account when recruiting personnel.

If your productivity is high, then it is advisable to purchase from Complex Systems an automatic or semi-automatic line for filling auto liquids into containers from 0.5 liters to 10 liters, with a capacity of 2000 liters per hour or more

Production technology

Why are all three groups of liquids - coolants, windshield washers, shampoos - made on the same equipment? The fact is that the production technology consists in mixing prepared water, a concentrate and an additive package in different proportions. It should only be noted that for the production of car shampoo at the same plant with antifreeze and a windshield washer, additional reactor, since washing equipment after car shampoo is a time-consuming process.

Demineralized water- a mandatory component for all three product groups, and the technology involves heating the mixture. Savings on electricity can be obtained by using the steam condensate of the CHP. If cold prepared water is used (filtration system), the reactor will have to be additionally equipped with heating elements and take into account the increased cost of electricity in the cost price.

Production does not create resets contaminated water. For example, when switching from the production of antifreeze to antifreeze, the water used for washing can be stored and used during the reverse transition to antifreeze. Even the spills that are inevitable when spilling products are not particularly terrible: by equipping the unit with a drip tray, the spilled liquid can be collected, filtered and returned to the technological cycle.

The secret is not in the unique technology

It is impossible to take into account all the nuances within the framework of one article, just as it is impossible to start a business from scratch and never step on a rake. That is why the demand is not for equipment, but for a turnkey business solution. If the quality of support is high, even people far from the automotive business can succeed on the first try.

Despite the simplicity of the technology, more than half of the contracts for the supply of equipment "Integrated Systems" have become regular customers. The secret is not technology. It's just that the main product of the company is not machine tools, but knowledge of how to get around the aforementioned rake.

In the production of antifreezes, there cannot and should not be compromises. The damage that a surrogate coolant can cause to a car and its owner's wallet is too great. The topic of technology in the context of the production of antifreezes is relevant already because it should help the end buyer to navigate the coolant market correctly and be able to choose the right and high-quality product.

It is worth recognizing that it is rather difficult to find a manufacturer of high-quality antifreezes in Russia. The scope of the counterfeit antifreeze market in our country indicates that most domestic manufacturers of coolants do not strive to produce quality products. Why would they spend extra money if what they produce at no extra cost sells well? In addition, our enterprises simply cannot afford to invest heavily in the development of high-quality compounds, additives and their serious running and bench tests. After all, with the volume of the country's modern car fleet, they simply will not be able to regularly sell a large volume of products sufficient to “beat off” such costly events.

Therefore, there are no manufacturers of truly modern components for antifreeze that meet international standards, and hence the current requirements of engines, in Russia. The only way out is to bring such components from abroad, but few people are willing to bear the additional costs.

We add that domestic manufacturers of antifreezes from Russian components, unlike world leaders in this field, do not interact with automotive brands at the development stage, which means they cannot guarantee full and long-term protection of all engine elements and other auto components. Taking into account the peculiarities of the Russian car market, the only real scheme for organizing the production of world-class high-quality coolant in our country looks like this: importing the best foreign additive packages, blending and packaging products at a production site in Russia. This is exactly how the business of Technoform, the largest manufacturer of antifreezes under the Coolstream brand, is organized. The company's strategic partner is the Belgian company Arteco, a joint venture between Chevron and Total. Arteco is known worldwide as a developer and manufacturer of additives, antifreezes and heat transfer fluids. The scale of the company's work is evidenced by the fact that the share of Arteco antifreezes in factory filling in Europe reaches 40%. Arteco specialists create all products in cooperation with specialists from automakers, developing antifreezes to the technical requirements of the respective cooling systems for each engine and automaker. The company has the resources to invest in the development of efficient technologies, to create and test new antifreeze additives. Arteco spends millions of euros annually on testing its products alone, and the volume of these investments is steadily growing.

What is the significance of such a partnership for Technoform? This mainly gives access to advanced manufacturing technologies and quality antifreeze components. This allows the company to produce a coolant that is in high demand in the retail market, and is also used for conveyor refueling in cars of foreign and domestic brands, including Ford, Renault, Nissan, Volkswagen, Skoda, Audi, KIA, Hyundai, Peugeot, Citroen, Mitsubishi, Volvo, LADA, KAMAZ, GAZ and others. The production of Technoform is localized in Russia, two blending enterprises operate here, in Nizhnekamsk and Klimovsk. In their functional and technological essence, these plants are the Russian part of a single international production structure of the joint venture between Chevron and Total.

So, in addition to modern production technologies, other components are also necessary for the production of high-quality antifreezes: high-quality additives and top-grade ethylene glycol, as well as blending equipment with high mixing accuracy.

For the production of coolant, two technologies are mainly used, which differ in the types of additive packages.

Traditional is the technology by which a group of mineral corrosion inhibitors (borates, phosphates, nitrates, etc.) is added to the water-glycol solution. The notorious antifreeze is just made using this technology. Inside the cooling system, mineral inhibitors form a film that protects the system components from corrosion, but also reduces the heat transfer efficiency by several times. This negatively affects the operation of the engine, fuel consumption increases, wear of rubbing elements increases, and the process of oil oxidation accelerates. Over time, the film formed by mineral inhibitors on the metal components of the system begins to break down, the metal is exposed, and corrosion occurs in these places.

The modern technology in coolant production is organic technology (OAT technology). It involves the use of salts of carboxylic acids, which are highly effective in combating corrosion. The package of additives with carboxylic acids "activates" on the corrosive areas of the metal and stops this destructive process. Due to this selective action, in which almost the entire metal surface is exposed, the heat transfer efficiency in the engine is not reduced, which means there is no risk of premature wear of its components, increased fuel consumption and premature oil production. Plus, such antifreeze works in the system for five to ten years. The use of carboxylate coolant allows you to reduce the overall cost of operating the car, save money on maintenance of the cooling system.

But in Russia, a third technology has also become widespread - the technology for the production of a surrogate coolant. Unscrupulous coolant manufacturers, in order to minimize production costs, do not produce antifreezes, but surrogate glycerin-methanol compounds that are dangerous for the car's cooling system. They have a low boiling point and a high freezing point, high viscosity and density. Methanol coolers in the heat or when driving in traffic jams quickly boil. Overheating in the cooling system and a decrease in the efficiency of heat dissipation provoke an increase in fuel consumption and reduce engine power. And ignoring such a problem threatens to reduce the life of the engine and can lead to its breakdown and costly repairs.

In a word, those who are informed are armed against counterfeit and surrogate products.

It is more profitable to produce and sell than just sell - this is a general rule. Wholesale depots, networks of auto shops, gas stations and service stations, logistics companies and auto enterprises create auxiliary production with different tasks - reducing internal costs, increasing sales or margins, constancy of product quality or independence from suppliers.

As a rule, not just equipment is bought for such production, but a ready-made business solution.

Today we will look at how to organize the production of operating fluids - antifreeze, antifreeze, windshield washer fluid and car washes. For advice, we turned to Integrated Systems LLC - this company offers turnkey solutions, including equipment, recipes, accompanying documents, technical and raw materials support. The experience of "Integrated Systems" consists of more than 1000 implementations of complexes for the production of liquid auto chemicals, not only in Russia, but also in the former republics of the USSR, and even in Mongolia, Nigeria and China. The director of the company willingly shares information, and we widely used the data provided by him in preparing the article.

What's important?

The most important task is to research the market and correctly assess the volume of production and its profitability. The Russian automotive market is growing and will continue to grow for at least a few more years, and with it the need for operating fluids. However, the situation depends on the region and many other factors. It is impossible to give precise guidelines here: each enterprise must assess the risks itself.

“One thing is clear - ten tons of antifreeze per month is too little to get a return on investment within a reasonable time,” says Andrey Karavaev, director of Integrated Systems. - The order of 50 tons per month is the bar from which to start. It is possible to increase the equipment load by releasing a line of auto chemical goods - two or three versions of antifreeze / antifreeze, windshield washer fluid, car shampoo. The payback period of investments is purely individual and can vary from two weeks to six months.

Best of all, if the result of monitoring the market will be an agreement on the sale of finished products. Finally, we note that an enterprise that opens such a production creates new jobs in its region, and therefore can receive support from government investment programs. Do not be afraid of the words "basement production": the quality of the finished product will not be inferior even to the leading manufacturers, it is quite accurate to follow the technology.

Registration and organization of the production site

The production of the auto chemicals in question does not require licensing, so the design of the site for most managers will include only familiar procedures: obtaining permits from the fire, sanitary and environmental inspections; registration of technical conditions in the sanitary inspection; trademark design.

Consider the requirements of regulatory authorities for the production premises. It must satisfy the third class of fire safety, which requires the appointment of a person responsible for the premises. Equipment includes fire extinguishers, a fire shield and a sand box. The alarm is not included in the list of mandatory equipment. It is even easier with environmental inspection - production can be completely waste-free, which will be discussed in more detail later. According to sanitary requirements, the room will have to be equipped with a hood over the installation and a washstand.

How big should the workshop be? Although the installation itself occupies an area of ​​​​about 10 square meters. m., the minimum recommended area is 50 sq. m. Empty canisters, concentrate and additives can be stored in an unheated room and even in the open air, and streamlined transport flows allow for the territorial separation of warehouse and production areas. However, Andrey Karavaev, director of Complex Systems, believes that the optimal area is 300-500 sq. m.

Staff

Depending on the volume of production, the site will be serviced by 1-3 people or more. The level of training is secondary technical education, because when buying a ready-made business solution, as in the case of Complex Systems LLC, the production technology is described in detail. Strict observance of the instructions guarantees exceeding the minimum GOST indicators by several times.

It has been observed that women are better at handling finished product spills - this should also be taken into account when recruiting staff.

If your productivity is high, then it is advisable to purchase from Complex Systems an automatic or semi-automatic line for filling auto liquids into containers from 0.5 liters to 10 liters, with a capacity of 2000 liters per hour or more

Production technology

Why are all three groups of liquids - coolants, windshield washers, shampoos - made on the same equipment? The fact is that the production technology consists in mixing prepared water, a concentrate and an additive package in different proportions. It should only be noted that for the production of car shampoo at the same plant with antifreeze and windshield washer, an additional reactor will be required, since washing equipment after car shampoo is a time-consuming process.

Demineralized water is a mandatory component for all three product groups, and the technology involves heating the mixture. Savings on electricity can be obtained by using the steam condensate of the CHP. If cold prepared water is used (filtration system), the reactor will have to be additionally equipped with heating elements and take into account the increased cost of electricity in the cost price.

The production does not create discharges of polluted water. For example, when switching from the production of antifreeze to antifreeze, the water used for washing can be stored and used during the reverse transition to antifreeze. Even the spills that are inevitable when spilling products are not particularly terrible: by equipping the unit with a drip tray, the spilled liquid can be collected, filtered and returned to the technological cycle.

The secret is not in the unique technology

It is impossible to take into account all the nuances within the framework of one article, just as it is impossible to start a business from scratch and never step on a rake. That is why the demand is not for equipment, but for a turnkey business solution. If the quality of support is high, even people far from the automotive business can succeed on the first try.

Despite the simplicity of the technology, more than half of the contracts for the supply of equipment "Integrated Systems" have become regular customers. The secret is not technology. It's just that the main product of the company is not machine tools, but knowledge of how to get around the aforementioned rake.

Before starting a business, it is important to determine the possible market for the product. It is advisable to open production near large cities and metropolitan areas. This ensures that there is a demand for your products. The main wholesale buyers of antifreeze and antifreeze are auto parts stores, car washes, service stations and small retailers selling during the season right on the road.

When opening your own auto chemical goods production, be prepared for serious competition. Moreover, your main competitor is underground workshops. Most of what is sold on the market today is produced there. In order to reduce costs, artisanal manufacturers add banned methanol to the composition of antifreeze. This makes the final price lower, which attracts many car owners who do not think about the consequences of using low-quality antifreeze.

Financial investments in the business amount to about 1.5 million rubles. The main costs include:

• Purchase of equipment - from 650 thousand rubles.
• Arrangement of the premises (racks, auxiliary tools) - from 150 thousand rubles.
• Deposit for renting premises - from 100 thousand rubles.
• Purchase of raw materials and materials - from 100 thousand rubles.
• Advertising - from 50 thousand rubles.
• Technology development, project launch costs - from 150 thousand rubles.
• Reserve fund - from 200 thousand rubles.

Premises and equipment

Among the necessary equipment for organizing the bottling of auto chemicals are a reactor (0.5 m3), a measuring tank, a pressure tank, pumps, pipelines and fittings. The estimated cost of the kit is 650 thousand rubles. Line capacity, depending on the volume of the reactor and the number of personnel, ranges from 0.7 to 1.5 tons/hour.

The floor area must be at least 50 sq. m, the minimum ceiling height is 2.5 meters. It is obligatory to have a ventilation system, water supply and electricity for 380 watts.

Personnel Requirements

One of the biggest difficulties of the case is to work out the production recipe and choose the right ingredients. To do this, you will need to hire or use the services of an experienced chemical technologist.

Directly on the production site requires 2-3 people. There are no serious requirements for employees. The main thing is the presence of secondary technical education. There is an opinion that women are better at bottling products.

Raw material issue

First of all, you need to decide on the suppliers of raw materials. Three components are required to produce antifreeze: distilled water, ethylene glycol and a package of anti-corrosion additives.

The most expensive component in the composition of raw materials is ethylene glycol. For a ton of this component, you will have to pay from 60 - 70 thousand rubles.

Antifreeze is a colorless liquid, but there is a misconception among car owners that the color of antifreeze indicates its quality. To give the color of the liquid, you will need to purchase dyes that in no way affect the quality of antifreeze.

Production technology

The technology for the production of most types of auto chemicals, including antifreeze, consists in mixing components such as water, a concentrate and an additive package in different proportions. The main production process involves heating the mixture in a special reactor equipped with heating elements. The production of antifreeze does not pollute the water, and in the event of a spill of liquid (which happens often), after a certain filtration, it is returned to the technological cycle again.

The cost of production of antifreeze is estimated at 23-25 ​​rubles/l, antifreeze at 30-35 rubles/l. The markup for the sale of goods ranges from 50 to 100%.

Antifreeze filling line - video