Cement production today is quite profitable business. And even despite the fact that there is high competition in this area, every beginning entrepreneur has the opportunity to create his own successful business. However, before purchasing equipment and starting production, you need to carefully consider all the details of the business plan, taking into account the specifics of your region, the current economic situation and the activity of direct competitors.

What is cement?

We all know that without this material construction is impossible. How to make cement? To create it, limestone, gypsum, clay, mineral additives and other components are combined. Exist different kinds of this material, as well as the technology of its production. We invite you to take a closer look at the main stages of the opening similar business.

Cement production technology

The manufacturing process of this material consists of two main stages. At the first of them, clinker is produced, which is a specific intermediate product in the form of lime and clay granules (or other materials of similar composition) mechanically mixed and heated to one and a half thousand degrees. The resulting clinker granules are the basis of any cement. The process of their production is very complex and most expensive. The next step is the production of Portland cement, which is obtained by grinding clinker with gypsum or other additives.

Important Factors

Cement production is complicated due to the fact that the mineralogical and chemical composition raw materials (uniformity, hardness, moisture content) varies quite widely. Enterprises that produce this material based on imported raw materials know this firsthand.

Also taken into account are the technical and natural varieties of raw materials, which may differ, for example, in moisture and purity. For each of them, cement production is carried out in a special way, ensuring uniform mixing and fine grinding of the components, while using the minimum possible amount of energy.

The conditions for the extraction of raw materials, their storage and transportation, as well as the human factor, play a very important role.

Cement production methods

There are three main options for creating this material:

1. Wet method: grinding of raw materials and production takes place in water, resulting in mixed ingredients (or batches) in the form of a suspension.

2. Dry method. The production technology does not require water, and the charge is a crushed powder, the components of which are dried before mixing.

3. Combined method, based on one of the first two options. This produces a mixture whose humidity reaches 20%.

Equipment

This item represents the main cost item when starting a business. Equipment for the production of cement, first of all, includes industrial crushers (if limestone is used as a raw material), or mixing mills, or, as they are also called, mashers (if the material is produced on the basis of clay). The cost of this equipment can reach 200 thousand rubles.

Also, for the production of cement, tubular ball mills are required, in which limestone or clay slurry with various additives are mixed and finely ground. This equipment will cost about 3.3 million rubles.

After the composition has been adjusted, the sludge is fired in a rotary kiln, where it turns into hot clinker, which is then cooled using an industrial refrigerator. The cost of this equipment is about 170 thousand rubles.

The cement production line includes additional equipment for packaging the finished product in bags and shipping it.

In general, the amount of equipment, as well as personnel, is directly dependent on the planned production volumes. The financial capabilities of a businessman also play an important role. Procurement costs necessary equipment will average 2 million rubles. The amount is considerable, but these investments will definitely pay off in the course of work.

Production room

To create a workshop for the production of cement, it is necessary to select a suitable premises. Its area must be at least 500 square meters. meters, and the ceiling height is not lower than four meters. Ideal option To organize a workshop, it is located in close proximity to a clay or limestone quarry. In this case, the cost of raw materials will be minimal, and all your costs will consist of the purchase of equipment, utilities And wages employees.

Payback period and demand for a cement production enterprise

Despite the fact that there is quite high competitive activity in this area, it is quite possible to build a profitable cement business today. Concerning financial side question, then to start such an enterprise you will need an amount of at least 30-50 thousand dollars. This is due to the high cost of equipment. However, you should not be afraid of quite significant investments, since the invested funds will pay off within 6-12 months of active work. After all, the modern construction market is developing rapidly, which, accordingly, leads to the consumption of more building materials, including cement.

Making cement at home

Despite the fact that the production process of this building material is very complex and requires special equipment, there are people who manage to produce it in artisanal conditions. However, the way home production cement is also quite expensive and energy-intensive. In addition, at first you will have to ruin more than tens of kilograms of raw materials until you learn how to produce high-quality construction material.

Keep in mind that to make cement in artisanal conditions, you also cannot do without special equipment. At a minimum, you will need a mill and a high-temperature oven. We present to your attention one of the recipes for making cement at home. This material is perfect for cementing slabs and stones. It can also be used on objects exposed to regular temperature changes and moisture.

So, to prepare cement, take one part of the resin and melt it in a stable iron container. At the same time, melt one part of the sulfur in another container. After both components are melted, combine them. It is necessary to add two parts of sifted sand and three parts of lead litharge to the liquid mixture. After prolonged stirring, the finished material should be allowed to settle. This homemade cement should never be used on a damp surface. It is also advisable to pre-treat it with drying oil.

Prospects for the cement business – production of concrete fences

If you have successfully mastered the production of cement, then as an expansion of your business you can move on to the production of concrete fences. These products are durable, beautiful, varied, and the blocks can be used to create a fence of any length. Similar fences enclose the territory of both houses and cottages, as well as offices and industrial facilities. They look much more presentable than chain-link fencing, and are cheaper than fences made of forged metal rods.

The main advantage of this business is relative freedom in the market, since today few enterprises are engaged in the manufacture of such fences. The main direction of your activity may be the production of fences based on individual orders. To ensure that the product matches the size, color and pattern of the façade of the house as closely as possible, paving slabs and the general appearance of the site, it is advisable to hire a professional designer.

To start such a business, you need to purchase special equipment for molding and the molds themselves of various variations. As raw materials you will need cement, crushed stone, river sand and additives that help improve the quality of the product. Moreover, be sure to keep in mind that the higher quality the raw materials and equipment, the more presentable fences you will produce. So you shouldn’t skimp on these components.

It is difficult today to find a person who could imagine modern construction without the use of such a well-known material as cement. In general, cement can be called any artificially obtained binder. It has been established that even several thousand years BC. people used something similar to cement, namely crushed and burned rock. Around the same time, people began to use clay, gypsum and lime in construction. However, these three materials have one big drawback - they harden only in air and lose their strength qualities when wet. Further development cement compositions followed the path of obtaining more durable compositions that are not subject to soaking. A cement recipe very close to modern compositions was obtained in the 18th century. The composition included burnt limestone and clay; the composition was later called “hydraulic lime” due to its curing in an aqueous environment. In Russia, industrial production of cement began in the 19th century, and by the beginning of the 20th century there were over fifty cement factories. Today there are many types and types of cement.

Let's look at the main ones.

1. Portland cement. One of the most common cements. It consists of finely ground clinker, gypsum and various modifying additives. It is a hydraulic binder. By appearance Portland cement is a gray powder; its slightly greenish tint is given by the content of iron and manganese oxides. Portland cement received this name thanks to the Portland Peninsula (England), rock on the banks of which the color is similar to the color of the cement of the same name.

1. White cement. It consists of finely ground clinker, practically devoid of iron oxides and other similar impurities, and is therefore characterized by a rapid initial rate of strength gain. The area of ​​application of white cement is largely decorative: finishing plaster, making sculptures, artificial stone products, etc.

1. Slag cement. It is obtained by grinding blast furnace slag and adding various activators - gypsum, lime, etc. Compared to ordinary Portland cement, slag cement has delayed hardening and increased strength. Slag cement is often used in load-bearing structures in underground and aquatic environments.

1. Expanding cement. This type of cement has the following property: the volume of the mixture freshly prepared for use is always less than the volume of the same cement after curing (cement expands during the curing process). A little later, waterproof expanding cement was obtained. This cement is successfully used for high-quality waterproofing reinforced concrete structures in conditions of constant water supply. In private low-rise construction, waterproof expanding cement is rarely used.

1. Non-shrink cement. Cement does not change volume during the curing process. Non-shrinkage waterproof cement is used when carrying out waterproofing work, when expansion of the cement mass during the curing process is undesirable or unacceptable.

1. Fast-hardening. A group of cements that have a reduced setting and complete curing time due to very fine grinding and the addition of special modifiers. Cement has found wide application in performing all kinds of repairs and other work that is critical to the time of strength gain.

1. Hydrophobic cement. Obtained from Portland cement by adding water repellents. Cement has reduced moisture absorption and water permeability and can be stored in high humidity conditions. Due to its low water saturation, hydrophobic cement is less susceptible to destruction due to freeze-thaw cycles.

1. Oil well cement. Used in the oil and gas industry to strengthen wells.

1. Aluminous cement. Hydraulic cement has several properties at once: fast-hardening, low-temperature curing, high-strength. Used when performing construction work in the cold winter season, as well as for the production of heat-resistant structures.

1. Pozzolanic cement. Produced from Portland cement by introducing additives of volcanic origin. The main feature of pozzolanic cement is its good hardening in aqueous environments. After hardening, pozzolanic cement has high moisture resistance, so it is often used in the construction or finishing of water tanks.

Looking at the above variety of types of cement, it is not difficult to conclude that cement has a wide range of applications not only in all areas of construction, carrying out the main binding and structural functions, but also in everyday life as decorative and applied elements of the interior (for example, artificial stone ). It is probably difficult to find another type of building material that would have the same constant high consumer demand as cement.

Practice shows that whatever the economic situation on the building materials market, constant demand for cement allows, even in the most difficult times, not just to stay afloat, but to confidently develop a cement-producing enterprise. Despite this, when organizing or expanding cement production, the question of reasonable spending is always acute. Money for the purchase of equipment and arrangement of production areas.

It seems most reasonable to invest money in equipment, production lines or cement plants from China. Modern industrial production cement production consists of many interacting machines and units. When purchasing a ready-made Chinese cement line, you save yourself from the need for painful selection of equipment for each stage of production separately and the subsequent establishment of technical and logistical connections between them. All units on the cement line have a well-functioning conveyor system of interaction, the line is ready for operation (production in full) immediately after its quick installation. The high quality of modern Chinese cement lines has been rated “excellent” all over the world, including in Russia. Increased mean time between failures, low price components, high maintainability of the entire equipment complex rightfully make Chinese production lines the most advantageous offer on the industrial equipment market today.

Having carefully prepared business plans for cement factories from China provides an additional advantage over competitors.

A mechanical engineering company that manufactures equipment as well as cement production lines, turnkey plants for production Portland cement with productivity from 40,000 tons/year to 2,500,000 tons/year.

The cement business, despite its labor intensity, is one of the most attractive and income types production, especially since demand for it is always present.

Cement production is quite energy-intensive and costly. technological production, as a result of which one of the most popular building materials is obtained - cement.

It is used in its pure form, and also as a supplement for the production of concrete and reinforced concrete.

So the cement production business brings high income. Such a business is especially profitable if the plant is located near the place of extraction of raw materials for cement.

Reasons for opening a mini-factory

Cement is always a relevant building material, it stands on a par with new fashionable products, the production of which everyone rushed to produce, resulting in huge competition.

Since cement is not only an independent material, but also the basis of many construction products, the demand for it will never dry up. Moreover, the pace of construction is gaining momentum every year.

This means that even the presence of congruence will not reduce the profitability of such production.

Relevance of cement production in Russia

Russia is a rich country in raw materials, with huge deposits of clay, marl, minerals, coal, as well as huge areas of black soil, which in some cases is a component of cement.

However, even with such a large volume of raw materials and fairly widespread cement production, there may be a shortage of this building material in the warehouses of large cities, as, for example, in St. Petersburg in 2016 - according to data, its shortage was 40%.

So it is not only possible, but also necessary to engage in this business, since it will always bring profit in the conditions of today’s development of the construction industry.

How cement is produced can be seen in this video:

Startup start

Business registration and documents

Initially, you need to register an enterprise; during this event you should receive:

• License;
• Technical conditions – TU.

Get permits for the extraction of limestone and clay from a quarry, for this you should select the necessary OKVED codes corresponding to the type of occupation.

Real estate

To produce cement, you need a plant or, in any case, it must have workshops and a place to install equipment.

In this case, the premises for cement production must have:

• Ceilings 4 meters;
• Minimum area – 450 sq. meters;
• Availability of excellent ventilation, since production is harmful;
• It is desirable that the building be located away from a residential area.

Equipment

• Crusher for crushing limestone – from 200,000 rubles;
• Mill-mixer for grinding clay - from 250,000 rubles;
• Pipe mill to mix all components - from 3.3 million rubles;
• A kiln and a refrigerator included will cost about 140,000 rubles;
• Ball tube mill for crushing clinker and additives;
• Silos are large tanks on huge supports; they can be manufactured at a factory or at the site of direct cement production; especially large silos are delivered in rolls and assembled at sites.
• Equipment for packaging cement;
• Forklifts.

What equipment is needed for production charcoal– read

Raw materials for cement production

To make the cost of the finished product cheaper, it is best to purchase or rent a quarry for the extraction of clay and limestone.

If you purchase raw materials, it will cost approximately 371.5 million rubles annually:

• Ash – 109 million rubles;
• Limestone – 106 million rubles;
• Gypsum stone – 6.5 million rubles;
• Hard coal – 150 million rubles.

Factory staff

Typically, such a plant employs about 96 workers - 86 personnel and 10 administration.

With a given number of employees, it is possible to make a schedule of 3 shifts.

Grinding of raw materials

Clinker, minerals and gypsum are crushed to required sizes, according to the following scheme:

• The clinker is crushed;
• Gypsum;
• Drying mineral supplements to obtain characteristics - frost resistance, rapid hardening, resistance to water;
• Grinding of components;
• Packing.

Depending on the components used, the appropriate cement production method is used:

• Wet - the raw materials will be crushed in water, the result will be a mixture in the form of a suspension - sludge with a humidity of around 40%;
• Dry - in this case, the charge will be crushed powder, previously dried;
• Combined - dry and wet methods are used simultaneously to obtain a product with a moisture content of 20%.

Cement production technology is discussed in detail in this video:

Price issue

IN this business, as in any other, there are capital investments and current ones that must be made monthly.

When opening a plant you must:

• Purchasing raw materials, if you don’t have your own quarry, will cost 371.5 million rubles;
• Purchase of equipment 500 million rubles, plus its installation 250 million rubles;
• Registration and package of permits;
• Other expenses;
• Depreciation deductions.

In total, the start of production will cost about 800 million rubles.

Ongoing costs include:

• Payment for electricity – 70,000 rubles;
• Labor costs are about 25.5 million rubles, including insurance premiums.
• Additional expenses 70 million rubles

In total, about 550 million rubles will have to be spent additionally per year.

The cost of products sold will be about 4 – 5,000 rubles per ton.

Important: when developing it is necessary to take into account:

• Inflation;
• Quality of raw materials;
• Where is the equipment delivered from?

Profitability of production

If we produce approximately 181,500 tons of cement per year:

• The cost will be 2983 per ton;
• Market price 4,900 rubles per ton;
• The profit will be 129,249,000 rubles;
• Production profitability will be quite high up to 24%;
• It follows that the payback will occur in 6.2 years.

Sales market

Since 2009, Russia has seen an increase in cement production by 10% annually; today the cement market is worth 180 billion rubles.

Russian cement is the most popular material within the country, as well as in:

• Kazakhstan;
• Belarus;
• Azerbaijan.

A business plan must be carefully developed, everything must be calculated down to the smallest detail. It must include all necessary expenses, target audience, an accurate portrait of competitors.

Without it, any beginning is due only to research.

Studying the sales market, you need to learn in detail about your audience, their habits, life, and affairs.

If you have a great idea and a business plan, you should take out a loan exclusively from a bank; you should not involve friends and family in your business, as the relationship may deteriorate.

Payback – you shouldn’t expect it today; that’s why you need a business plan to know the exact time of production payback. Profit will be guaranteed if the interests of consumers are a priority among the goals and objectives.

The marketing approach should be comprehensive, you should not focus on one advertising agency, you need to try all methods.

Important: it is mandatory to have a qualified lawyer and accountant on staff.

All agreements and agreements must be drawn up on paper so that later promises do not remain just that.

In any business, it is necessary to have people nearby whose abilities will impress the owner and will complement his ideas and thoughts.

Conclusion

The pace of development of the cement business in Russia indicates that the demand for this building material is quite high and the country needs it more and more every year.

So starting such a business with a well-structured plan of development stages will only lead to enrichment.

So, we offer you for your consideration another review (list) of the main suppliers (manufacturers) of equipment intended for the production of cement.
The equipment can be supplied both in the form of individual units or parts, and in the form automatic lines or ready-made solutions - turnkey cement plants, project development and initial work (raw material analyses, development of a production concept in relation to customer specifications, etc.)

We should not forget about trivial situations when it would not be out of place to demand from the equipment supplier, after its delivery and installation, to carry out a pilot production of products in which the quality of the manufactured product fully complies with the previously agreed upon requirements. Moreover, in this case, such cement must also meet the requirements of GOST of the Russian Federation.

As in previously published articles, we suggest how, using the information below, you can directly contact the appropriate supplier, or you can set the task of selecting the necessary equipment directly for your specific tasks our Company . Currently, we have sufficient information and accumulated materials to fulfill the instructions received from you in full.

Options for using both your own resources and ours information base a great multitude. It is not at all necessary to “pass by” if you do not need the entire complex as a whole, but only individual sections or even elements of specific equipment. For example, if a specific crushing unit is needed from AMIT INDUSTRIESYSTEME GMBH (Germany), then this does not at all negate the possibility of selecting individual elements. You can contact all the companies mentioned either yourself or use our services.

Of course, this list is not exhaustive. There is a very wide and diverse number of companies on the market at various levels capable of realizing customer wishes for organizing cement production.
However, the organizations presented below are among the few who can provide answers to requests sent to them regarding the relevant area.

Attachments: from 580,970,000 rubles

Payback: from 15 months

Construction today is considered the most profitable and highly profitable industry. It is not surprising that the production of building materials will always generate income. In this article we will analyze a business idea for the production of cement.

Business concept

Cement is a popular building material. Its production is considered high-tech and profitable. This material is used both independently and as one of the components of concrete, reinforced concrete products.

The cement manufacturing process is divided into two stages. The most expensive thing will be to obtain clinker (durable bricks). It takes approximately 70% of the cost of the building material itself. Clinker granules are the basis of any type of cement. Next, it is crushed with gypsum and Portland cement is made.

There are three main methods for producing cement.

The first (wet) involves grinding the raw materials in water and obtaining a suspension of mixed ingredients.

The second (dry) is carried out without water, and the charge (a mixture of materials) is a crushed powder. Its components are specially dried in advance.

The third option is combined and can be implemented on the basis of the first or second. The peculiarity of this type is that the moisture content of the resulting mixture will be up to 20%.

If you choose the dry method as the main method, then you need to granulate the prepared mixture in advance, adding 10% water. If the basis is a wet method, then the sludge (waste) is forced to dehydrate up to 16%.

The main buyers of cement are shops, construction companies, enterprises producing concrete or reinforced concrete, private individuals.

What will be required to implement the business?

To set up a mini-factory you will need:

• limestone crusher;
• clay mixing mill;
• a mill that helps grind products;
• rotary kiln required for firing;
• ball tube mill for grinding and mixing raw materials;
• an industrial refrigerator where the clinker will be cooled;
• sludge basins and tanks;
• electrostatic precipitators;
• waste gas bunker;
• equipment for packing bags.

To save on setting up a production workshop, you can order used equipment.

The prospects for the development of a business depend on the type of raw material extraction. To begin with, the development of a limestone deposit and clay is underway. The quarry can be bought or rented. The extracted material must be crushed to pieces with a diameter of 10 cm. If the plant is remote from the deposit, then the raw materials must be transported to the work shop. Limestone is dried and crushed using special mills. Then it is mixed with the rest of the raw materials. Extraction, transportation - all this entails serious financial costs. At the initial stage of a business, it is better to purchase raw materials. To do this, you should look for wholesale suppliers.

For production you will need (per month):

• ash – 6,508 tons;
• gypsum stone – 752 tons;
• limestone - 14,758 tons;
• hard coal – 3667 tons.

To produce cement, you will need a room of approximately 400 square meters. m. It should have ceilings more than 4 m high. It is best to look for a room outside the populated area. There must be good ventilation inside the building.

The production requires approximately 80 workers and 5 administrative and management personnel.

Step-by-step instruction

1. The business must be registered as an LLC.
2. Obtain a permit for the extraction of raw materials.
3. Find a room.
4. Purchase raw materials.
5. Hire working people.
6. Conduct advertising of building materials.
7. Find buyers.
8. Make cement.

Financial calculations

Starting investments

Monthly expenses

How much can you earn?

The cost of a ton of cement is 4,900 rubles. In a month, 15,125 tons can be produced, which approximately corresponds to 74,112,500 rubles. Net profit is 36,525,724 rubles.

Payback

The payback period is 15 months with a competent approach to organizing the business. Profitability reaches 9%.

Risks

The cement production business is considered popular and attractive in terms of profitability and profitability. Its main drawback is its impressive starting investments. Before starting your own business, you need to study your competitors’ market and evaluate opportunities.

conclusions

Manufacturing and selling cement is profitable, but expensive business with high competition. To attract a sufficient number of customers, it is necessary to offer affordable prices and high quality. The payback period can be reduced by increasing production. This can also be done by adjusting the operating mode.