Toilet paper is one of the most important household items of a civilized person. Millions of rolls of this indispensable product are produced and used every day around the world. Not every entrepreneur knows how toilet paper is made. Meanwhile, the production of such a necessary hygiene product is one of the most promising investments.

Types of toilet paper

Rolled toilet paper appeared in late XIX century and at first caused ridicule and embarrassment among the townsfolk. The demand for its production has increased significantly with the growth of population and the development of civilization. Modern toilet paper is significantly different from its progenitor and can be of several types:

Depending on the feedstock:

• gray - made from waste paper (grades МС1, МС3, МС3, МС7 - cardboard, МС10 - newspapers);
• white - made of cellulose.

By number of layers:

• single layer;
• two-layer;
• multilayer (three or more layers).

Regardless of the grade, toilet paper must be strong, soft, highly hygroscopic and break into fibers when it enters the water. For its decoration, you can use only eco-friendly and neutral dyes that do not cause allergic reactions.

Production stages

The paper production process consists of several stages:

1. Preparation of raw materials. Waste paper is cleaned of impurities, crushed in special crushers, mixed with water and filtered through a sieve that traps the remaining foreign objects.
2. Preparation of water-paper mixture. The paper pulp is washed in a large amount of water and ground in a mill to a fine fraction. Then poured into a concentration stabilizer and adjusted to 0.5%.
3. Drying. The resulting mixture is poured onto a conveyor mesh, along which it is directed to a drying drum. During the passage through the line, excess water drains and is sent to the flushing stage. In the drum, the paper mass dries, is cut into sheets and rolled into reels.
4. Formation of rolls. The bobbins are unwound, embossed and the required number of layers are applied to the paper, and then rolled into rolls of the required diameter.
5. Packing and calibration. Large rolls are labeled and cut into several small ones.

At the stage of formation, the paper can be dyed or applied on top with a decorative pattern with the manufacturer's logo.

Production equipment

It is impossible to complete the entire papermaking process with a single machine, so manufacturers install special lines or mini-factories. They consist of pulper, mixing tanks, paper machine, unwinder and cutter.

Pulper

A vertical cylindrical bath with blades, in which waste paper with a small amount of water is broken into fibers and passes through a sieve of a certain caliber. The device is intended for grinding and purification of raw materials from impurities. Its capacity depends on the size and can reach up to 500 tons per day.

Mixing tanks

For the production of paper, several tanks of different volumes are used, in which a water-paper mixture of a certain concentration is gradually prepared. In the first container, the slurry cleaned from impurities is washed with a large amount of running and reverse (flush from the grid line) water, and ground to a fine fraction. The quality and price of the final product depends on the degree of purity. The resulting mixture enters the pressure tank and passes into the concentration stabilizer, where it is brought to a consistency of 0.5% of the mixture with water.

paper machine

The main element of the entire production, where the process of turning paper pulp into an integral canvas takes place. It consists of a mesh table, a press, an inlet device, dryer drums and a reel. From the tanks, the water-paper mixture enters a moving screen table, from which the liquid flows down and is pumped out by vacuum pumps into a special tank for further use in washing.

The pressed mass is pressed to remove residual moisture, after which it becomes dense and transparent. The raw material enters a cylindrical drying drum, where it is dried with hot steam under pressure up to 40% humidity at 10 revolutions per minute. The finished canvas is cut with a scraper knife and rolled into reels.

Bobbin unwinder

A device for forming toilet paper of a given diameter. The bobbins are unwound, embossed and patterned on the surface, and the canvas is wound on a cardboard core or directly into a roll.

Slicing device

At the final stage of production, the wound paper web is cut into small rolls with a diameter of 80 to 200 mm. Thanks to specially sharpened band knives, the productivity of the machine can reach up to 1200 units/hour.

The production of toilet paper is an uncomplicated and cost-effective enterprise. It does not require a lot of resources and, with the right organization of sales, quickly pays off.

PURPOSE

The set of equipment that is part of the Mini-mill (this is a Paper Machine (PM) and a set of necessary machines. See Figures 1, 2, 3) is designed to process secondary raw materials from waste paper for the production of paper for sanitary and hygienic (household) purposes (toilet paper ).

(Fig. 1) Paper machine (PM)

(fig.2) Reel unwinding machine

(Fig. 3) Machine for cutting rolls

RATIONALE FOR DESIGN CHOICE

One of the main conditions of the technological process for the production of base paper for sanitary purposes is the dehydration of the paper pulp and its intensive drying. With relatively high speed movement of the newly formed canvas is necessary in the maximum a short time evaporate moisture from it by interacting with the heated surface of the Yankee cylinders.

Electric heating elements are used to heat the Yankee cylinders in this equipment configuration.

DEVICE AND PRINCIPLE OF OPERATION

The mini-factory for the recycling of waste paper and paper waste from printing enterprises is a set of technological equipment that allows the production of toilet paper, consists of the following main parts.

1. Stock preparation equipment
2. Papermaking equipment
3. Equipment for further paper processing

Technological process

It is advisable to load the initial raw material into the waste paper preparation tank and fill it with water (not a mandatory step, it is possible to immediately immerse the dry raw material into the pulper).
Waste paper (or sagging paper) is reloaded into the Hydropulper (GDV), where it is diluted with water and ground, resulting in the formation of a mass of coarse fraction.
The resulting mass is discharged by gravity into Tank No. 1 (paper pulp preparation tank), where it is enriched with water and brought to the required concentration.
The mill pump pumps the pulp into Tank No. 2 - the paper pulp compounding tank, in which it is in constant motion due to the operation of the Mill Pump, which pumps the pulp into the Tank-Receiver (Constant Flow Box).
The paper pulp in both tanks #1 and #2 is kept in suspension due to pumping and supplying compressed air to the tanks, discharged by the VVU-3 vacuum pump, which helps to accelerate the mass formation process.
Excess mass flows by gravity from the Receiver Tank back to Tank No. 2, and the prepared mass flows through one or more vortex traps from the Receiver Tank to the Headbox of the Paper Machine, from where to the Screen Table.
The mass supply to the Headbox is regulated by means of valves located on the nozzles of the Receiver Tank.
The grid table has a constant movement and the paper mass that has arrived on it, distributed evenly over the width of the table, enters the Couch-shaft zone, where pressing and preliminary calibration take place.
During the movement of the mass along the Grid table, excess liquid is separated into the Registered Water Collection (Pit). As it accumulates, the liquid is pumped by the Pump to Tank No. 1.
After being pre-crimped by the Couch Roll, the paper pulp sticks to the Felt Conveyor, which moves the paper web to the dewatering zone through the Vacuum Dewatering Nozzle and then to the Heating Drum for drying.
The released felt of the first Felt is cleaned by the Vacuum Cleaning Nozzle and the liquid rejected by the Vacuum Pump enters the Pulping Tank.
When moving the paper web along the Heating drum, the working surface of which has a uniform temperature heating, up to 65% of moisture is evaporated from it (the web). When it enters the creping zone, the web is separated from the Heating Drum by means of the Scraper Knife and fed to the Dryer Cloth.
Moving along the Drying cloth, the paper web covers up to 50% of the heated surface of the Finishing drum, through which it acquires output parameters.
The finished paper enters the receiving device area, where, depending on the configuration of the mini-mill, it is wound into logs or reels of a given diameter.
The bobbin received on the paper machine is transferred to the bobbin unwinder, where it is rewound into logs - these are rolls as wide as a bobbin, with a diameter as a roll of toilet paper.
Rewinding on a rewinding machine allows you to get a tighter winding in a roll, and to perform embossing on paper.
Next, the resulting log is glued with a label (which is usually ordered from a printing house), and then sawn into rolls on a roll cutting machine.
The received rolls are checked and packed in bags or boxes for sale.

The delivery set of all mini-mills includes equipment for further processing of paper, namely a machine for cutting rolls (logo cutting saw) and a reel-winding machine.

SPECIFICATIONS

RAW MATERIALS USED

White paper from bleached pulp without printing and line

White bleached pulp paper with lacquer and black and white or colored stripe

Newsprint from bleached wood pulp

Printed rejects and blank forms

Book and Archival

Book and magazine, Archival

Newsprint and newspapers

Unused newspapers

Used newspapers in black and white and color.

Cardboard

Carton boxes

Almost any mwaste paper can be used as a raw material for the manufacture of toilet paper from waste paper. It is categorically impossible to use only one type of paper - laminated paper. The sources of waste paper are usually: printing houses, printing houses, large offices and industries, banks, waste paper collection points, the local population, etc. etc. WASTE PAPER IS ALWAYS, YOU JUST START LOOKING FOR IT!

COMPLETENESS

ROOM REQUIREMENTS

APPENDIX TO THE CONTRACT - TECHNICAL CONDITIONS
necessary for the Buyer to perform at the stage of preparation for the installation of a mini-factory

1. Recommended room area - 150 m2;
2. The recommended length of the room is 15 m;
3. Recommended ceiling height - 4.0 m;
4. The need for water is not less than 3 m3 / day;
5. Availability of sewer communications;
6. The presence of exhaust ventilation;
8. Foundation preparation according to the technological scheme provided by the equipment manufacturer;
9. Manufacture of tanks according to the drawings of the equipment manufacturer;
10. The presence of ball valves (for those who do not know - these are ordinary water taps of the "American" type)":

• - 2 inch - 6 pcs.,
• - 1 ½ inch - 6 pcs.,
• - ¾ inch - 4 pcs.

11. The presence of fireclay (fire) bricks in the amount of 60 pieces;
12. The presence of a pipeline for the installation of equipment (the quantity is determined on site):

• - pipe 76 mm;
• - pipe 50 mm;
• - pipe 40 mm;
• - pipe 20 mm.

13. The presence of rubber corrugated hoses (the quantity is determined on site):

• - diameter 76 mm,
• - diameter 50 mm.

14. Electrical wiring according to circuit diagram power supply (the number of cable and wire is determined on site):
- bring a copper 4-core cable into the room (depending on the power consumption of the purchased mini-factory, the brand and cross section of the power cable is selected by the Buyer's electrician)

When ordering installation, the Buyer undertakes to provide the following specialists to the Seller's representative for the period of installation of the equipment:

• welder - 1 person;
• locksmith - 2 people;
• electrician - 1 person.

REPLACEABLE UNITS, PARTS, PRODUCTS

Data on Suppliers for the units, parts, products indicated in the table are received by the Buyer upon purchase of the equipment. Name

BOBBIN UNWINDING MACHINE

Purpose:
The machine is designed for rewinding bobbins with base paper for sanitary purposes into logs of a given diameter, for further production of toilet paper rolls or rolls of paper towels from them.

Principle of operation:
The reel with the base paper, fixed on the shaft, is installed on the machine, passes through the intermediate shafts and embossing shafts, and then is wound on a cardboard sleeve or immediately into a log without a sleeve. The resulting log is transferred to the log cutting machine, where it is cut into rolls of the required width. The machine is equipped with a counter of the footage of the rewound paper.

Specifications:

Attention! The free business plan provided for download below is an example. Business plan, the best way corresponding to the conditions of your business, you need to create with the help of specialists.

Says businessman Dmitry Dolmatov, owner of a factory for the production of toilet paper. Dmitry has a small production workshop, which employs 5 machine operators, 2 wholesale outlets. The business brings a small but stable income.

Making toilet paper as a business

In our city, it is very difficult to create your own business for the production of any consumer goods. We have a lot of different factories, factories, workshops. Almost any undertaking can lead to complete bankruptcy due to high competition.

But I always wanted to create my own business that brings a stable income, independent of the crisis and competition. What was always in demand, was in constant demand.

And then, I decided to engage in the production and marketing of toilet paper. It's no secret that toilet paper will always be a good buy, it is used by all segments of the population, at all times.

Where to begin?

To begin with, I studied the component of the production market and came to the conclusion that my business can exist quite well in the conditions of a developed infrastructure of the city.

Toilet paper production equipment

Then, I found out what equipment I need to purchase to start the production line:

• Machine for winding-rewinding rolls;
• Paper cutter;
• Table for packing rolls in a wrapper.

So, I got about 1,000,000 rubles.

Let's add to this the cost of rent for the workshop, repair and decoration - 2,000,000 rubles.

Further, we consider the purchase of raw materials - these are rolls of waste paper and, accordingly, labels - 400 thousand rubles (20 tons) + 20,000 rubles = 420,000 + 2,000,000 + 80 thousand (workers' wages) = 2,500,000 rubles. It was this amount, calculated approximately, that I needed to open a factory.

Where to get money for the production of toilet paper?

In order to find the required funds, I decided to sell everything I could from my property. So I sold an expensive tablet, a house in the village left after the death of my grandmother, a second car.

I still didn’t have enough money, so I went to the appropriate authorities. take a subsidy for business development. It is very difficult to take an increased one, but the usual one, at 50,000 rubles, suited me just fine.

To do this, you had to do the following:

• Get registered with the Central Health Center (not a problem);
• Register an individual entrepreneur (it takes 2 weeks, given that I was not registered with the tax office at all, as idle);
• Create and submit a working business plan.

What is the economic program for?

A business plan is essential for every aspiring businessman. This is the basis of any office work, a guarantee of the development of sales and demand.

It covers a wide range of details, including:

1. Calculation of the cost of initial purchases.
2. Expediency of business in the conditions of market competition.
3. Demand for the product.
4. Laws and sanitary norms.
5. Payback periods.

In addition, a well-written business plan is a guarantee of your stability, and, accordingly, an effective bait for profitable points of sale, suppliers of raw materials, and investors.

Most novice businessmen turn to special agencies and organizations of a consulting type, where analysts develop a working economic development program for them.

But this is not only an extra 50,000 costs, but also a waste of time to travel there, the lack of guarantees of the quality of the work performed.

On the Internet, there are ready-made business plan templates for any business. Their cost is low, about 300-500 rubles per template.

It contains all the up-to-date, relevant data.

It remains only to substitute your own values ​​of the estimated costs, bring the data together in the program, and you have a high-quality development plan ready.

Nothing complicated even for those who use a computer not at a professional level.

Using a business plan I made myself, I received a subsidy, found suppliers, outlets, and launched a toilet paper production line.

In a year, I produced approximately 450,000 - 500,000 rolls and after 2 years, I fully paid off the initial investment, starting to receive a clean, stable profit.

hd720 toilet paper machine

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

Toilet Paper Mini Factory

We present a two-year plan for the creation of a toilet paper production facility. There are three goals in creating such a production.

To implement your plans, you will need to take a loan of 6,000,000 rubles, which are fully paid off in 2 years and bring in earnings in the amount of 408,800 rubles.

The repayment of the loan starts from the first month of production operation. Start implementing your plans immediately after receiving credit funds.

Since the toilet paper business provides the market with personal care products, every individual is a consumer.

It will not be difficult for you to create an enterprise, especially since its products are always popular. The paper and board industry manufactures pulp, cardboard, photographic paper, printing paper, wallpaper paper, paper bags, napkins, toilet paper, and the like.

You need to register a company. Any building, even non-residential, is suitable for a legal address. For the production itself, you will have to rent a workshop with an area of ​​\u200b\u200babout one hundred square meters.

It is best if your business is registered as a Limited Liability Company.

Table number 1. Potential of toilet paper consumers in Russia

When you already have your own workshop, you can purchase the necessary machines and equipment. There are many hardware manufacturers out there, but it's best to choose the one closest to your facility.

This is done in order to timely service equipment, in the event of breakdowns. Only four machines are needed for the toilet paper production line.

Rewinding machine, so that finished products can be rewound into rolls of a certain size. In the manufacture of cardboard bushings for rollers, you need a bushing machine.

To divide into rolls, you need a cutting machine and a packaging machine for packaging finished products, as well as a table for sticking logs. To purchase them, you will spend at least 1 million 200 thousand rubles.

To this amount you need to add another 5% for the delivery and connection of equipment. From the manufacturer's company, specialists will come to you who will bring all the machines into working condition.

Table number 2. Growth of toilet paper market participants in Russia

Later, it will be necessary to increase the range of production, for example, to produce several varieties of toilet paper. This does not require new or special equipment, but your income will increase markedly.

Despite the fact that there are already many enterprises in the country paper production, do not be afraid of competition! After all, the products of such enterprises take first place in consumer lists.

Now we can sum up. Already after six months of work, production begins to generate income. The total amount of earnings for this period, the total turnover will be 152400000 rubles, and the net income will be 80965516 rubles.

Alexander Kaptsov

Reading time: 9 minutes

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The best business idea for a novice entrepreneur would be the production of essential goods. According to experts, this is a win-win option. Especially since the demand for hygiene items such as toilet paper and paper towels, which are on the list of priority items, is constantly growing. The business of manufacturing them is characterized by high profitability and minimal investment, which is of interest to many business people.

Organization of production for the manufacture of toilet paper: where to start?

When planning a business for the production of toilet paper, the first step is to register with the tax authorities. The enterprise is better because large suppliers and customers prefer to cooperate with legal entities. In the process of registering failures and difficulties with documents, there should not be any.

For the sale of finished products (GOST R 52354-2005) you will need:

• SES conclusion.
• A document on the conformity of products to the declared standards.

They are issued based on:

1. Certificates confirming the quality of raw materials.
2. Contracts for the lease of non-residential premises.
3. Certificate confirming the registration of the enterprise with the tax authorities.
4. The company's charter.

The approximate cost of registering an enterprise as an LLC is 11,000 rubles. Registration of licensing documents will cost 140,000 rubles.

Mini-factory or workshop for the production of toilet paper: choosing a business premises

It is best to rent a room for a mini-factory for the production of toilet paper in an industrial area, away from residential areas.

Today, many plants and factories rent out production areas that meet all business conditions:

• The height of the ceilings in them is over 4 meters.
• Floor area of ​​shops from 300 squares and more.

When renting a production facility, you can be sure that the toilet paper production line will easily fit on an area of ​​200 sq.m.

In addition, workshops are most often already equipped with ready-made engineering communications:

1. Electrical networks with a three-phase power supply of 380 volts.
2. Plumbing.
3. Water disposal system.

If necessary, repairs can be carried out in the premises, taking into account the requirements of the fire inspection and the sanitary service, since in case of violations of the rules and regulations of work, the enterprise will be fined. It should also be taken into account that for the normal functioning of the workshop, a place will be needed not only for the installation of an automated line, but also for the storage of raw materials and the storage of finished products.

Estimated rental industrial premises can range from 60,000 to 100,000 rubles. per month (at the rate of 300-500 rubles per 1m2).

What equipment is needed to produce toilet paper? Approximate cost of machines

Almost always, when organizing production, the largest costs fall on the purchase of equipment. But you can't do without it. The cost of an automatic line with high productivity can reach up to 1 million rubles or more.

In order for the toilet paper production workshop to start its work, it is necessary to purchase:

• paper production line . It includes: an electric generator, a vibrating screen, a washing tank, a multifunctional mill, cleaners and raw material mixers. Equipment costs vary. So, the ZS-E-1380 model costs 1,750,000 rubles, the OBM mini-factory costs 1,900,000 rubles. Although there are more expensive automated complexes. For example, ALPB-1 at a price of 8,000,000 rubles.
• Roll forming and cutting machine . Its price is 150,000 rubles.
• Bushing Machine . You can buy a machine at a price of 220,000 rubles. It is much more profitable to produce paper with cores.
• Finished Product Packing Machine . Its cost is approximately 185,000 rubles.
• sticker machine . Purchase costs - 190,000 rubles.

The productivity of the production line can reach 1000-3000 kg of paper per day.

Technology for the manufacture of toilet paper from recycled materials and cellulose

The technological process of manufacturing toilet paper directly depends on the completeness of the production cycle. With an incomplete cycle, the enterprise purchases raw materials that are already ready for production, and the workers immediately start making paper. However, the cost of manufactured products in this case will be higher than with a full cycle, when waste paper enters the workshop and is processed on site into finished paper material.

What the production process looks like:

1. Purification of secondary raw materials . At this stage, recyclables are crushed in a crusher, soaked in water and filtered through a sieve to remove unwanted impurities (pebbles, glass fragments, paper clips, etc.).
2. Raw material washing . In special tanks, the raw materials are thoroughly washed with running water. The whiteness of the finished product depends on the quality of the washing. For example, toilet paper white color costs much more than gray.
3. Fine grinding . After washing, the raw material is ground again with the addition of water in a fine grinding mill.
4. Mix consistency . In the pressure tank, the mixture acquires the required consistency, after which it enters the mesh surface of the machine, where the raw material is squeezed and dried, and the paper is wound into rolls.
5. The final stage . Toilet paper wound into rolls is sent for embossing, after which the finished product is weighed, packaged and shipped for sale.

Personnel needed to start a toilet paper business

If an incomplete technological cycle is used for the operation of the enterprise, then it is enough to maintain a staff of 3-6 people to service the production line. The mini-factory will need 9-11 employees. Special training is not needed for the staff, since the machines are automated and do all the work themselves.

• To look after the machines, you need 3 workers.
• Accounting will be handled by 1 specialist.
• For the shipment of finished products, you can hire 2-3 movers.
• For transportation - 1-2 drivers.
• You can put 1-2 people on the protection of the workshop.

The production line can work around the clock, but at the initial stage it is not rational, since large volumes of paper will have to be stored. Sales are not yet established. In the future, depending on the volume of production, the staffing can be changed.

Organization of the sale of toilet paper

When developing a business plan for an enterprise, it is important not to miss such Organizing time like selling toilet paper. This means that even before the production line is launched, it is necessary to establish contacts with wholesalers and shopping malls, to interest the retail buyer.

Stages of toilet paper promotion:

1. Conducting promotional presentations to advertise a new product and explain to the buyer its features and benefits.
2. Calling wholesale bases in order to conclude a contract for the supply of quality goods.
3. Conclusion of an agreement with shops and shopping centers for the sale of paper.
4. Placement of ads in specialized directories on the Internet.
5. Advertising products in wholesale markets.

Toilet paper belongs to the group of goods that are not taxed and are not excise, so its sale is not limited in any way. However, at first it is desirable to interest the buyer with an affordable price for the entire range of the company's products.

Toilet Paper Business Plan: Income and Expenses Calculation

The business plan of production should reflect the indicators of profitability and payback of the enterprise. The figures given depend on such indicators as prices for raw materials, equipment, goods sold.

Startup costs:

Monthly production maintenance costs:

Based on the fact that with monthly production costs, the company will produce up to 30 tons of toilet paper.