Description
The company Integrated Systems offers a ready-made business for the production of auto chemicals. This is: a package of documents - technical specifications, technological regulations, formulations of antifreeze, windshield washer fluid, car shampoos, household and auto chemicals and much more, a set of equipment for finished production. Basic equipment complexes of different capacities - "ChemComplex-1" and "ChemComplex-2".
Equipment
Materials and equipment: The main parts of "ChemComplex-3" are made of polymer materials. "ChemComplex-3" is equipped with polymer pipelines and fittings, and is equipped with a chemical pump and a thermoelectric heater.
Productivity: 0.65 tons of final product per hour.
Energy consumption: no more than 4.5 kW
Service staff: 1-2 people
Requirements for the premises: occupied area - 4.5 sq.m., ceiling height - at least 3.5 meters.
The cost of "ChemComplex-3" together with a package of documentation (specifications, technical regulations, recipe for the production of antifreeze concentrate, antifreeze 40M, antifreeze 65M): 90,000 rubles.
Contact the seller
Materials and equipment: The main parts of "ChemComplexes" are made of stainless steel. At the request of the customer, the reactor jacket can be equipped with heating elements, which allows maintaining a certain temperature inside the apparatus without foreign coolants (steam, hot water, etc.). "ChemComplex" is equipped with polymer pipelines and fittings, and is equipped with 2 special pumps.
Filling unit: allows you to pour the final product into any container.
Requirements for the room: area 50-120 m2, ceiling height - 3-5 meters, power supply 220 - 380 V, containers for starting products are not included in the package.
Service and guarantees: together with "ChemComplex" the customer is given a package of documentation and a basic recipe for the production of antifreeze. Warranty obligations for individual parts and the complex as a whole are stipulated in the supply contract and may vary depending on specific conditions and configuration. The Himstroy-Plus company is ready to provide warranty and post-warranty service. Supervised installation of equipment, commissioning and initial training of customer personnel are carried out for a fee by agreement of the parties.
Equipment delivery time: within 30 days from the date of receipt of money to the supplier’s bank account. Payment is made in installments as agreed by the parties. Transportation costs are not included in the price.
You can also purchase packages of technical documentation (specifications, technological regulations and recipes) separately from the equipment. .
The Integrated Systems company is also pleased to offer you its new development - an installation for the production of glass washer coolant "ChemKompleks-3". Using this installation, you can set up your own production of antifreeze glass washer fluid. The equipment has a modular structure and allows simultaneous production and bottling of the final product into any consumer container, as well as barrels and other containers
It is more profitable to produce and sell than to just sell - this is a general rule. Wholesale bases, chains of auto stores, gas stations and service stations, logistics companies and automotive enterprises create auxiliary production with different tasks - reducing internal costs, increasing sales or margins, consistency of product quality or independence from suppliers. As a rule, for such production, not just equipment is purchased, but a ready-made business solution.
Today we'll look at how to organize production of operating fluids- antifreeze, antifreeze, windshield washer fluid and car detergents. For advice, we contacted LLC "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 made extensive use of the data he provided in preparing the article.
What's important?
The most important task is to research the market and correctly estimate production volumes and its profitability. The Russian automotive market is growing and will continue to grow for at least several 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 instructions 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 in a reasonable time,” says Andrey Karavaev, director of Integrated Systems. - About 50 tons per month is the level from which to start. Equipment utilization can be increased by releasing line of auto chemicals- two or three options of antifreeze/antifreeze, windshield washer fluid, car shampoo.” The payback period for investments is highly individual and can vary from two weeks to six months.
It is best if the result of market monitoring is an agreement on sales 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. Don’t be afraid of the words “basement production”: the quality of the finished product will not be inferior even to leading manufacturers; it is enough to follow the technology exactly.
Registration and organization of a production site
Production of the auto chemicals in question does not require licensing, therefore, registration of a site for most managers will include only familiar procedures: obtaining permits from fire, sanitary and environmental inspections; registration of technical conditions with the sanitary inspection; trademark design.
Shop
Let's consider the requirements of regulatory authorities for production premises. It must satisfy third class fire safety, which requires the appointment of a person responsible for the premises. Equipment includes fire extinguishers, fire shield and sandbox. An alarm system is not included in the list of mandatory equipment. With environmental inspection it is even easier - 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 above the installation and a washbasin.
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 cans, concentrate and additives can be stored in an unheated room and even in the open air, and well-functioning transport flows allow for the territorial separation of warehouse and production areas. However, the director of Integrated Systems, Andrey Karavaev, 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 purchasing a ready-made business solution, as in the case of Integrated Systems LLC, the production technology is described in detail. Clear following instructions guarantees exceeding the minimum GOST indicators several times.
It has been noticed that women are better at bottling finished products - this should also be taken into account when selecting personnel.
If your productivity is high, then it is advisable to purchase from “Integrated Systems” an automatic or semi-automatic line for filling car 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 of mixing prepared water, concentrate and a package of additives in different proportions. It should only be noted that to produce car shampoo in the same installation with antifreeze and windshield washer, you will need additional reactor, since washing equipment after car shampoo is a time-consuming process. 
Desalinated water- a mandatory component for all three product groups, and the technology involves heating the mixture. Energy savings can be achieved by using steam condensate from a thermal power plant. If cold treated water (filtration system) is used, the reactor will have to be additionally equipped with heating elements and increased energy costs will have to be taken into account in the cost price.
Production does not create discharges contaminated water. For example, when switching from the production of antifreeze to antifreeze, the water used during flushing can be stored and used when switching back to antifreeze. Even the spills that are inevitable when a product is spilled are not particularly dangerous: by equipping the installation with a tray, the spilled liquid can be collected, filtered and returned to the technological cycle.
The secret is not in unique technology
It is impossible to take into account all the nuances within one article, just as it is impossible to start a business from scratch and never step on a rake. That is why it is not equipment that is in demand, but a turnkey business solution. If the quality of support is high, even people who are 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 “Integrated Systems” equipment turned into regular customers. The secret is not technology. It’s just that the company’s main product is not machines, but the knowledge of how to get around the above-mentioned rake.
There cannot and should not be compromises in the production of antifreeze. 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 antifreeze production is relevant because it should help the end buyer to correctly navigate the coolant market and be able to choose the right and high-quality product.
It is worth recognizing that in Russia it is quite difficult to find a manufacturer of high-quality antifreeze. The scope of the counterfeit antifreeze market in our country indicates that the majority of domestic coolant manufacturers do not strive to produce high-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 large amounts of money in the development of high-quality compounds, additives and their serious running and bench testing. After all, given the size of the country’s modern vehicle fleet, they simply will not be able to regularly sell a large volume of products sufficient to “recoup” such costly activities.
Therefore, there are no manufacturers in Russia of truly modern components for antifreeze that meet international standards, and therefore the current engine requirements. The only way out is to import such components from abroad, but few are willing to bear the additional costs.
Let us add that domestic manufacturers of antifreeze made from Russian components, unlike world leaders in this field, do not interact with automobile brands at the development stage, which means they cannot guarantee complete and long-term protection of all engine elements and other automotive components. Taking into account the peculiarities of the Russian car market, the only real scheme for organizing the production of high-quality, world-class coolant in our country looks like this: importing the best foreign additive packages, blending and packaging of products at production facilities in Russia. This is exactly how the business of Technoform, the largest manufacturer of antifreeze under the Coolstream brand, is organized. The company's strategic partner is the Belgian company Arteco, a joint venture of the Chevron and Total concerns. Arteco is known throughout the world as a developer and manufacturer of additives, antifreeze and coolants. The scale of the company’s work is evidenced by the fact that the share of Arteco antifreeze in factory fills in Europe reaches 40%. Arteco specialists create all products in collaboration with specialists from automakers, developing antifreezes to meet the technical requirements of the corresponding cooling systems for each engine and automaker. The company has the resources to invest in the development of effective technologies, create and test new antifreeze additives. Arteco spends millions of euros annually on testing its products alone, and the volume of these investments is growing steadily.
What is the significance of such a partnership for the Technoform company? This mainly gives access to advanced production technologies and high-quality antifreeze components. This allows the company to produce coolant, which is in high demand in the retail market, and is also used for conveyor filling 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 the Technoform company is localized in Russia; there are two blending enterprises here, in Nizhnekamsk and in 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 needed to produce high-quality antifreeze: high-quality additives and premium ethylene glycol, as well as blending equipment characterized by high mixing accuracy.
For the production of coolant, two technologies are mainly used, which differ in the types of additive packages.
Traditional is a technology in which a group of mineral corrosion inhibitors (borates, phosphates, nitrates, etc.) is added to a water-glycol solution. The notorious antifreeze is made using this technology. Inside the cooling system, mineral inhibitors form a film that protects system components from corrosion, but also reduces the efficiency of heat transfer several times. This negatively affects engine operation, fuel consumption increases, wear of rubbing elements increases, and the process of oil oxidation accelerates. Over time, the film that mineral inhibitors form on the metal components of the system begins to break down, exposing the metal, and corrosion occurs in these places.
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. A package of additives with carboxylic acids is “activated” on corrosive areas of the metal and stops this destructive process. Due to this selective action, in which almost the entire metal surface is open, the efficiency of heat transfer 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 a vehicle and save money on servicing the cooling system.
But in Russia, a third technology has also become widespread - the technology for the production of surrogate coolant. Unscrupulous coolant manufacturers, in order to reduce production costs as much as possible, do not produce antifreeze, but surrogate glycerol-methanol compounds that are dangerous for the car’s cooling system. They have a low boiling point and high freezing point, and have high viscosity and density. Methanol coolers boil quickly in the heat or when driving in traffic jams. Overheating in the cooling system and a decrease in heat removal efficiency 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 short, those who are informed are armed against counterfeit and surrogate products.
" This time I would like to bring to your attention the work of student Evgeniy V. “Business plan for selling antifreeze”. The initial investment is 1.5 million rubles, and the monthly profit is approximately 275,000 rubles, therefore, such an enterprise will pay off in 6 months.
So, to choose a profitable startup, you need to take into account what is currently in demand in the market. As you know, most of the Russian Federation is located in a zone of prolonged frosts, which is why local car enthusiasts simply need anti-freezing liquid. It can be concluded– a small workshop for the production of antifreeze will bring its owner a good income, if the business is properly organized. Read on.
- a substance consisting of water, alcohol, propylene glycol, glycerin, fragrances and anti-corrosion substances. A similar composition is used all over the world as an anti-freeze agent and a windshield cleaner.
The production of non-freezing liquids has the following advantages:
Raw materials are cheap and available for purchase,
The production technology is so simple that antifreeze can be produced even at home. This reduces the initial capital investment.
A large sales market guarantees consistently high incomes.
It is quite possible that some will find this business unprofitable, since anti-freeze products are usually used only in winter. Unfortunately, this is true, but even in the warm season the manufacturer will not be left without profit, because the variability of the technology allows the enterprise to be reoriented at any time. By slightly changing the composition of the final product, you can no longer make antifreeze, but windshield cleaning fluid. Such products are especially necessary for car enthusiasts in the warm season.
What is important to consider?
In fact, it doesn’t matter what exactly our small plant will produce, because when creating antifreeze and windshield wipers, almost the same raw materials are used, and the difference is only in the ratio of the ingredients used.
When starting production, we need to attract a qualified specialist who can work out the composition of a high-quality liquid. But since this is too expensive for us, we will have to independently study all the intricacies of the technical process. Fortunately, all the necessary information can be found on the Internet.
For our production we will need the following raw materials:
Distilled water,
Ethylene glycol,
Dyes,
Various fragrances,
Isopropyl alcohol,
Surfactants (surfactants).
It is important to understand that during the production process some ingredients can be used and vice versa - some components can be added to the recipe. But absolutely each of the substances will affect the final quality of the product.
It is also important to remember one important nuance: If our final product contains nine or more than 9% pure alcohol, we will have to pay excise duty (indirect tax). So for us it is necessary to keep the alcohol level to be less than 9%.
Moreover, there is another opportunity to save. It is quite obvious that antifreeze can consist of cheaper components. For example, most manufacturers use methyl alcohol instead of isopropyl alcohol. The problem is that methyl alcohol is an extremely poisonous and toxic substance; if its vapors are inhaled, very serious poisoning can occur in a person. This sad fact does not stop cottage industry, but we don’t want to poison people, because it’s bad, and we don’t really want to go to jail. Moreover, having bought anti-freeze with methyl alcohol once, the buyer is unlikely to buy it again, and we need a stable income while remaining a conscientious company.
Secondary raw materials include bottling containers and, of course, branded labels.
When building a production line, it is important to adhere to the following plan:
Water purification (but if we buy distilled water, it is not required),
Mixing ingredients
Heat treatment of liquid,
Bottling of the final product,
Sticker on packaging labels,
And finally, product storage.
To create a windshield wiper or anti-freeze, the release technology does not change. Moreover, with a slight modification of the chemical composition, you can obtain other substances that car enthusiasts need to care for their cars.
Even with our simplest production technology it is impossible to do without equipment, unless, of course, we intend to manufacture our product on a negligible scale for personal use. So, for the workshop it is necessary to purchase the following equipment (this refers to obvious variable costs):
Thermal reactor,
Filling machine,
Container with stirrer,
Machine for gluing brand labels,
Intermediate tanks.
The equipment listed above is already designed for prepared distilled water. If we do not want to purchase water separately, but purify it ourselves, then we will have to purchase a system for its purification, which will cost somewhere 200,000 rubles. But this system will be simply necessary in the long term.
Mathematical calculations
We have exactly two options: buy all the equipment separately or equip our workshop with an already equipped line. The only difference is that if you buy the machines separately, you will be able to save a little, but the downside is that you will probably have to do some operations manually (this will be a constant implicit cost, since this will reduce production capacity). In turn, assembled lines are more expensive, but have one very important advantage– they have excellent production capacity and full automation of the process, which will save on employees.
Equipment price for the production of antifreeze on a small scale (≈500 l/h) on average equal to 700,000 - 1,200,000 rubles. And already high-performance machines (≈1500 l/h) from European brands will cost up to 1,700,000 rubles and this does not take into account possible delivery to the assembly site, but this does not concern our startup in any way, since we take the average option for 950,000 rubles. Also, you need to add to the market value of the devices from 50000 rubles for its installation, commissioning and launch.
For such a workshop you will need workers at the rate of 3 people - 2 in the conveyor production and a mechanic on duty. Since they are not required to have high qualifications, the salary will be in the region 25,000 rubles per month . On average, repairs will cost at 150,000 rubles in year.
Now let's calculate the approximate profit from such an enterprise. As I said at the very beginning, the antifreeze production business can pay for itself in the shortest possible time (although it all depends on the purchased production line). This figure includes all capital investments and we get a pretty good profitability indicator. According to minimal estimates, the costs of organizing a mini-workshop with a productivity somewhere 500 l/h, where some operations will have to be performed manually, it will take approximately 1,500,000 rubles . This figure includes the purchase, setup, delivery and debugging of machines (approximately 1000000 rubles ), preparing the premises for operation and, of course, renting them (somewhere 200,000 rubles ) and, finally, the purchase of raw materials and packaging for half a year (approximately 300,000 rubles ).
It is very difficult to calculate specific profit figures, which is why we indicated profitability from half a year to one year. It all depends on the volume of output of the final product, the system for selling the finished product and the pricing policy in the selected region of the Russian Federation. But you can still calculate your approximate income. The “average” windshield washer fluid or antifreeze with a volume of 5 liters costs somewhere on the wholesale market 250-600 rubles . In other words, with a price of 350 rubles and a label that inspires confidence, the net income will come out per month 560,000 rubles (taking into account that the enterprise is at the initial stage and the productivity due to the small amount of raw materials is very far from the technical limit, and the operating mode 20 working days per month and 8 hour days ).
We remove VAT in the amount of 18% (depreciation), workers' wages, repairs, raw materials, delivery to points of sale, production losses and we receive approximately 275,000 rubles.
Due to high demand, cheap labor and relatively inexpensive basic raw materials, this enterprise will pay for itself, on average, in 6 months.
I don’t know anything about antifreeze, but the work seemed interesting to me. If you have any thoughts on the content, be sure to write in the comments. It will be interesting to read.
Sincerely, Marina Shirshikova
You may be interested in other business topics:
Almost every family has a car, and some even have several. Such expensive equipment requires regular maintenance. And many people make decent money from car care products.
A little earlier, just water was poured into the radiator, but now they use a special coolant, which is called antifreeze or antifreeze. Such a fluid requires periodic replacement, and if the radiator begins to leak, then a constant addition of coolant is necessary until the moment of repair of the latter. Although, more often than not, drivers begin to delay this process. Therefore, there is always a demand for antifreeze and antifreeze, and due to the growth of the automotive industry and the demand for transport, it will always remain consistently high.
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Premises and its rent.
It is best to choose a premises in an industrial area and away from a residential area. The size of the room will range from 300 to 500 m2. The entire area will be divided into warehouses and a production part.
Warehouse premises will be divided into zones where raw materials and finished products will be stored. It is also worth highlighting an area where simply empty plastic bottles will be stored; this area does not need to be heated, and the remaining areas will require maintaining a normal, stable temperature throughout the entire storage period: from 16 to 25 degrees.
Antifreeze and antifreeze will be produced in the production area. About 50 m2 of the area will be occupied by the production line itself (this is the norm for small installations).
When choosing a room, you should pay special attention to fire safety. It must be third degree. You should be prepared for the fact that representatives from local fire safety authorities will constantly visit you. But you shouldn’t expect visitors from the environmental side, because the production is absolutely waste-free. This type of space will cost around $500-$700 monthly rent.
Equipment.
To produce antifreeze and antifreeze, a special modern installation is purchased, the smallest size will be about 10 m2.
The main elements of the production line are:
1. Machine for demineralization of water - $1.2 thousand;
2. Mixing containers - $600-800;
3. Steam condenser - $3 thousand;
4. Reactor - about $5 thousand;
5. Line for blowing bottles - up to $2 thousand;
6. Packaging equipment - about $1 thousand.
The prices of such a production line will depend on the manufacturer. By purchasing a modern installation, you can minimize manual labor and make production uninterrupted. It is also worth considering that the installation will need to be washed regularly. It is impossible to do this manually, so you need to invest in a washing installation.
In total, you should allocate at least $15 thousand for the necessary equipment.
Raw materials.
Antifreeze and antifreeze are based on three main liquids - water, concentrate and additives. The water used is not ordinary water, but special, purified water containing no salt. In addition to water, additives, glycol and dyes are used. Most often, a special machine is purchased that demineralizes water. The rest of the raw materials are on free sale and it is quite easy to contact the seller. The cost of raw materials will be about $2 thousand.
Staff.
The number of people in the state will directly depend on production volumes. For minimal maintenance of a small installation, up to 10 people are needed. Workers in the workshop can only have a special technical education, this is quite enough, because the production process itself is accessible to everyone and quite easy.
It is a priority to hire women to replace operators bottling antifreeze and antifreeze in bottles, since, as has been proven in practice, they cope with this task much better than male workers. In addition to line operators, you need to invite general workers, an accountant and a workshop manager to work on the line. It costs about $4 thousand to pay workers.
It is most profitable to promote products through outdoor advertising, which must be placed in places where car drivers gather in large numbers. This place is near car parks, close to parking lots and busy intersections. You can also use printed products on automotive topics, both magazines and printed newspapers. Also, to attract buyers, you should create your own website.
In the first couples it can be quite simple. It’s also worth participating in automotive forums. If funds allow, you can create your own video on a TV channel. At the beginning of business development, it is necessary to organize a large-scale promotion, possibly a discount or a gift (car air freshener, keychain, car cup) for each canister purchased. In total, it costs about $200 for advertising.
Costs of starting a business.
To organize a business, you need to consider the following expenses:
1. Rent of premises - $500-700;
2. Equipment - $15 thousand;
3. Raw materials - $2 thousand;
To open your own production facility antifreeze and antifreeze, you need to prepare an amount of at least $22 thousand.
Profit and payback period.
The production equipment is capable of producing about 1 thousand liters per hour of operation. If your production operates in two shifts, then about 10 thousand liters will be produced per day. In a month of work, it is possible to produce about 300 thousand liters of antifreeze and antifreeze. One liter of product costs $0.5 - this is the market value of the product. If we talk about 600 thousand liters of coolant, then in a month you can make a profit of $150 thousand. But this is not pure profit, and the company’s share will be only 20%. This is $35 thousand in income. Working in this mode and with 100% sales of products, you can achieve full business return in 3-4 months.
Clients and direction development.
The clients of the business are shops, supermarkets, markets, as well as car repair shops, workshops and service stations. To develop your business, you can create a laboratory in your own production; the investment is completely justified, since there are quite enough people willing to check the products and quality. You can also open your own company store or even an entire chain.
