Business idea: how to open a rubber boots production?
Where we do business: workshop, rented premises
Main costs: purchase of equipment for production, purchase of raw materials, electricity, wages
Required equipment: rubber products vulcanization lines
Consumables: rubber, glue, fabrics
Initial capital: from 950,000 rubles. up to 1,500,000 rubles
Payback period: from 6 to 24 months
Possible profit: from 60,000 rubles. up to 130,000 rubles.
Before the Great Patriotic War, rubber boots and galoshes were very popular footwear among the inhabitants of the Soviet Union. For women, it was possible to purchase galoshes that had a hollow heel so that they could be worn over shoes. After the war, these shoes lost their former popularity and turned into work shoes for production and agriculture, only children's rubber boots continued to produce bright and very beautiful.
At the end of the last century, there were attempts to revive the business of producing fashionable and stylish rubber shoes, but they were not successful. The population, paying attention to Western countries, refused to accept rubber boots as a fashion item, but now, at the beginning of the twenty-first century, the inhabitants of the country again turned their attention to these products.
When drawing up a business plan, you need to think through everything, get acquainted in detail with the equipment and production technology, with the needs of the market and the market price.
What is the product of these factories? What are modern rubber boots?
Such shoes are made of synthetic rubber, on a knitted basis and have a fairly high quality.
The industry produces such shoes many models and varieties for consumers of different age groups.
Now you can find high-soled rural off-road boots and very elegant imitations of sneakers with high lacing, there are even leather imitations and stylish boots.
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Production technology.
To date, one of the most progressive methods for the production of rubber shoes is the shaping method. It is based on the simultaneous formation of the rubber frame of the shoe and its vulcanization. This method can be used to make boots, boots and shoes.
For the manufacture of boots using the forming method, rigid metal cores or cores with an elastic chamber are used. This technology is very simple. First, rubber and textile elements of shoes are prepared. Textile elements are cut out of fabric, which is lined with a thin layer of rubber compound, after which they are connected into a frame. It has the shape of a stocking. The rubber parts of the shoes are cut in the same way. Then the frame is put on a special metal block and lined with rubber elements. This core is placed in a special mold of the vulcanizing press. There is a heating formation and vulcanization of the boot. After the end of the process, the finished boot goes to the trimming of the top edge. After that, control and sorting is carried out. Then the boots are packed in plastic bags. Unlike cardboard boxes, this reduces the cost of shoes.
Cost of equipment.
The cost of a used production line is approximately 30-40 thousand dollars. The quality of shoes produced directly depends on the state of the production line. And the quality of products greatly affects both the price of the product and the demand for this product. When choosing a production line, give preference to Italian equipment and it is best if the raw materials are imported. Add to these costs also the cost of renting premises for the installation of the line and warehouses, wages to employees. For normal work, you will need the following specialists: fashion designers, technologists, adjusters, repairmen, seamstresses, managers, accountants.
Profit.
The lowest wholesale price on the market for one pair of rubber boots is approximately 150-200 rubles. At retail, such shoes are priced at 500-600 rubles. The cost of one pair is about 70-100 rubles. The output of a large rubber shoe factory is approximately 2-4 million pairs of shoes per year. At the same time, the sales proceeds are approximately 8-12 million dollars.
Today, the production of rubber shoes is not just stamping models that workers use in production. Such models were not so long ago widely represented on fashion catwalks. Of course, the “boom” on them soon passed, but in countries where mud and slush are an obligatory component in the off-season, they will still be in demand. So there will definitely be buyers, especially if an aspiring entrepreneur can come up with an idea that will “shoot”. So some models are now becoming extremely popular.
Another feature of the production of rubber shoes remains high competition in this market. Eminent European manufacturers also present their lines, although the demand for their products is low, because the price of one pair can be high for a Russian buyer, and Chinese manufacturers, it is they who fill the market.
Therefore, it is not so easy to say unequivocally whether the production of rubber shoes will become a profitable business.
Shoe production technology
The first condition will be the very idea, that is, the shoes should be beautiful and interesting. It is this condition that domestic manufacturers often neglect. And in vain, because first of all, the buyer pays attention to the appearance. Therefore, it is impossible to save on a designer in the production of shoes. Sometimes it even makes sense to involve foreign experts as consultants.
It is equally important to make shoes not only beautiful, but also comfortable and of high quality. And at this stage, you need to take a responsible approach to the choice of production method and the selection of equipment.
Shoe production technology: methods used in the production of rubber shoes
Gluing or assembly.
Punching.
Formation.
The production possibilities largely depend on the method used in the production of rubber shoes, as well as on the materials used. In any case, the product consists of several parts that are connected to each other. Glued shoes can have from thirteen to seventeen parts. The most common methods for the production of shoes are stamping and forming. Here they (details) are three to four times less, which means that the process is less time consuming.
Shoe production technology: materials
The main materials include rubber and textile mixtures, various fabrics, organic solvents.
Various rubber compounds processed, then the mixture is turned into sheet rubber, with which it is subsequently used. For the production of soles, sole mixtures are used. Rubber mixtures are also coated and coated with textile materials.
Many large manufacturers in the production of rubber shoes today are switching to PVC (polyvinyl chloride), which allows you to save up to thirty percent on the purchase of materials.
The mixtures are also used for lining fabrics, which are used in the production of rubber shoes for internal parts, for the development of these parts and their cutting.
Textiles are used for lining or for the production of stocking pipes, if we are talking about molded boots, in the production of insoles and socks, various decorative elements.
The most progressive method in the production of rubber shoes is the shaping method. In this way, the formation of the frame and the vulcanization of shoes takes place simultaneously, and the method itself is used to make not only boots, but also boots and shoes.
The manufacturing method is also quite simple. First of all, textile parts are cut out, covered with a thin layer of rubber and sewn together. Rubber parts are made, which are also screwed up with a prepared textile stocking worn on a metal workpiece. Then the boot is placed in a volcanic press - in a special mold. When pressed and heated, boots are formed and rubber is converted into rubber. Then the top of the boot is cut off, and the products are sorted.
Rubber shoe production: start-up costs
The most expensive item will be the purchase of equipment, but you should not save on it. Equipment and raw materials affect the quality of products, so Italian machines and foreign raw materials are preferred.
Renting premises and wages also requires significant investments. For the production of shoes you need to hire the following personnel:
Fashion designer.
Chemist technologist.
Equipment adjuster.
Repairman.
Seamstresses.
Sales managers.
Accounting workers.
If you have an idea, but do not have such funds to open production, you can think about the possibility of cooperation with enterprises where the technological process is established. In addition, income can be increased if you sell not to wholesalers, but to the consumer, for example, by organizing a store where you can sell, among other things, your products. Those who organized own production of rubber shoes, most of the profits in the early stages are invested in the development and expansion of their business and the development of new models.
Production of rubber shoes - video
Methods for the production of rubber shoes. To obtain rubber (polymer) shoes, the adhesive method, stamping, molding, injection molding, liquid molding and molding from plastisol (thermoforming) are used. The adhesive method produces solid rubber and rubber-textile shoes, which are assembled (glued) on a block from separate parts.
The parts are connected with rubber glue.
The assembled shoes are varnished and vulcanized. In glued shoes, the sole and facing rubber have different thicknesses, the joints of the parts are clearly visible. The gluing method is used in the production of all types of rubber shoes, but in last years superseded by others due to significant labor intensity. All-rubber overshoes are produced by the stamping method. The outer parts and the sole of the shoe are molded from a rubber compound.
Finished shoes are varnished and vulcanized. Stamped galoshes have thick walls of lining rubber and are therefore rough and heavy, but they are highly wear resistant. The external distinguishing feature of stamped shoes is the presence of mold marks. By molding produce all-rubber boots and galoshes. In the production of uniform shoes, rigid or elastic cores are used, on which a lining is put on. The lined cores are lined with unvulcanized rubber and placed in a mold where the shoe is finished and vulcanized.
Molded shoes are produced unvarnished and are used for wearing in difficult conditions. The sole in rubber-textile shoes is also attached by the molding method. The injection method is used in the production of footwear from PVC compound (boots, galoshes). The method of liquid molding from microcellular polyurethanes (MPU) is used in the production of shoes with uppers made of fabrics, knitwear, leather, artificial shoe materials with polyurethane soles and vamps.
The formation of the sole and facing parts (toe) occurs in a mold into which a mixture consisting of diisocyanates (component A) and glycols (component B) is alternately poured. When these components interact, a solid porous mass is formed, which is then bonded to the textile parts of the shoe. The liquid molding method is used in the manufacture of boots, boots, as well as two-layer shoes.
Polyvinyl chloride plastisol casting (thermoforming) is used to produce polymer shoes that look like leather shoes. To obtain footwear by this method, polyvinyl chloride layers - plastisols are used. At elevated temperatures (180-200°C) plastisol particles stick together and form a film. A seamless shoe shell made of plastisol is obtained in sealed hollow molds into which the plastisol composition is poured. The molds are then placed in ovens, in which, when heated, a layer of polymer of the required thickness is deposited on the inner surface.
The heel is poured separately to the resulting shoe shell. Shells with a heel are cooled and connected to the lining with nairite glue. Thermoforming is one of the most promising methods for the production of polymer shoes, and shoes made of polyurethane and polyvinyl chloride are replacing rubber shoes. 4.
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Two years ago, traditional rubber boots and galoshes from work shoes, which were used only by summer residents, fishermen and hunters, turned into the latest fashion. The cost of one branded pair of rubber boots can reach up to 12-15 thousand rubles. And, despite the fact that model shoes for rainy weather are gradually disappearing from world podiums, in Russia, where in many regions heavy rains are a common occurrence at any time of the year, the forgotten and newly revived fashion for special shoes is unlikely to pass without a trace.
But, of course, this promising niche is not distinguished by a lack of proposals. In addition to foreign brands, whose shoes are in less demand due to the rather high price, domestic manufacturers have to compete with Chinese factories that supply our market with their cheap and diverse products.
At present, one of the largest domestic manufacturers, Pskov-Polymer, can be singled out on the Russian rubber footwear market. In addition, there are several dozen smaller factories that produce similar products: PK KhimProm (Rostov-on-Don), LLC Dailos (Moscow), LLC Tomsk Rubber Footwear Plant, LLC PKF Duna -Ast" and LLC "Sardoniks" (Astrakhan), etc.
When asked whether it is worth opening a new company for the production of rubber shoes in the face of relatively high competition and a gradual decrease in demand among consumers, experts cannot answer unambiguously.
As in any other industry, the originality of the idea that underpins your offer and its competitive advantages is crucial. For example, Rain Level rubber boots from the Italian company Regina Regis, which are available in nine colors and are sold at a price of 69 euros per pair, would hardly have been in such high demand among buyers if it were not for the scale applied over the entire height of the shaft, as in an ordinary school ruler, which allows you to literally measure the depth of puddles with your feet. A simple idea, the implementation of which did not require any significant investment, brought its author a big profit.
Before launching a shoe into production, of course, it must first be designed. This process includes the development of the shape of the future boot, the size of the lasts, or, depending on the manufacturing method, the creation of appropriate molds and the construction of shoe models.
The main requirements for rubber shoes: they must be comfortable, strong and, as many Russian manufacturers forget, beautiful. If you are unable to hire a good shoe designer, perhaps Western colleagues can help you. For example, the Pskov-Polymer plant, when developing a new model line of rubber boots, turned to Italian designers for help, who acted as consultants.
Nowadays, rubber shoes are produced in three ways: by assembly (gluing), stamping and forming. Such shoes, like any other, consist of separate parts connected to each other. The quantity, shape, dimensions and materials of these components depend on the model and method of production.
Glued shoes have the largest number of parts (mainly galoshes, which are assembled from 13-17 parts, and boots from 16-21 parts). In shoes, which are produced by stamping and forming (the most common production methods), the number of parts is 3-4 times less than in glued shoes. Details, as a rule, are divided into groups according to their location: external, intermediate and internal.
The main materials for the production of rubber shoes are components of rubber and textile mixtures, organic solvents, knitwear and other fabrics.
Rubber mixtures of rubber, filler, vulcanizing agents, vulcanization accelerators, pigments and reclaim are processed on calenders, after which the mixture is turned into sheet rubber. From this sheet, the outer parts of the shoe upper are cut out, and from the profiled sheet sole mixture, respectively, the details of the sole. The rubber mixture is smeared and overlaid with textile materials on calenders.
Rag mixtures prepared from a rubber compound with unvulcanized scraps of rubberized fabrics are used for lining fabrics used for interior and intermediate parts of shoes or for cutting out parts from textiles.
In addition, in the production of rubber shoes, cotton knitwear is used for lining, hosiery (for molded boots), cotton fabrics for various parts of shoes (for backs and insoles, for socks and as decorative elements).
Most large manufacturers have already switched to using polyvinyl chloride (PVC) for the manufacture of such shoes. The cost of this material is lower than the cost of the rubber base by 25-30%. However, it has similar properties.
And the most progressive way of producing rubber boots is the shaping method. It represents the simultaneous formation of a rubber carcass and vulcanization of the shoe. Boots, shoes and even shoes are made in this way.
For the production of boots by molding, rigid metal cores or cores with an elastic chamber are used. The technology itself is quite simple. First, textile and rubber parts are harvested. Textile elements are cut out from a fabric covered with a thin layer of rubber mixture, and then a stocking-shaped shoe frame is sewn from them. Rubber parts are also cut out from the corresponding rubber blanks.
The resulting stocking is put on a metal block and lined with rubber parts. This core with a blank for a boot is placed in a mold of a vulcanizing press. During subsequent pressing and heating, the actual formation of the boot and its vulcanization (the technological process of converting rubber into rubber) takes place.
After that, the boots are sent for trimming the upper edge of the shaft, burrs and pressing out. Then they pass the control, they are sorted and packed. The packaging is usually plastic bags rather than cartons, further reducing the cost per pair of finished shoes.
The production of rubber boots by the formation method has a number of undoubted advantages: it is a much less labor- and time-consuming method of producing shoes than others. Shoes made in this way are more durable. The disadvantages are the increased weight and relative rigidity of the boots, the increase in rubber costs due to the need to seal some parts of the shoe and the presence of a large amount of waste (pressures), the possibility of the lining moving away from the lining rubber, the complexity and laboriousness of manufacturing molds.
Therefore, manufacturers are constantly improving and refining this technology in order to get rid of these shortcomings. For example, the use of combined cores from a metal case and an elastic rubber chamber leads to a decrease in the laboriousness of manufacturing shoes, a decrease in the abrasion of the lining in the process of wearing boots, and allows you to securely attach the textile "sock" to the rubber. The elastic rubber chamber on the core helps to reduce the weight of the boot and increase its flexibility and softness, reduce rubber consumption and facilitate the mold making process.
The cost of a used production line is about 30-40 thousand dollars. However, the quality of shoes produced on it directly depends on the equipment. And the quality of products directly affects its demand and saleability. Therefore, if it is possible not to save on equipment and materials, then when choosing, give preference to Italian production lines and imported raw materials.
Add to this the cost of renting production and storage facilities, wages for employees (you will need, at a minimum, a fashion designer, a chemical technologist, an equipment adjuster, an equipment repairman, seamstresses, purchase and sales managers, an accountant, etc. .).
If you do not have several million rubles as initial capital, then it is worth considering the possibility of either cooperating with existing factories for the production of rubber shoes according to your design, or thinking about creating a retail store selling finished products.
The output of large factories producing rubber shoes is 2-4 million pairs per year. And the rubber shoe business has revenues of $8-12 million. The most forward-thinking manufacturers spend most of their profits on developing new shoe lines, updating existing ranges and equipment, positioning and promoting their products.
Both small and large producers sell their products to wholesalers. At the same time, the lowest wholesale cost of one pair is about 150-200 rubles (at a cost of 70-100 rubles). In retail, the same shoes are sold at a price of 500-600 rubles per pair. 20-30% of the total production of large factories is exported to European retail chains.
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