Equipment for the production of charcoal. Company location and premises

Consisting of almost 100% carbon - charcoal is also known as safe for environment and an efficient type of fuel that does not spoil the air with toxic fumes and is very convenient for instant cooking food. Along with the use in the economy, charcoal is also used in industry. It employs entire metallurgical and chemical complexes. It is also used in construction as a convenient insulating material. Farmers also use it as an additive to livestock feed.

We're talking about production here. charcoal, equipment for its manufacture, technology.

• Black - obtained by firing soft rocks wood (aspen, poplar, alder, etc.);
• White - obtained by firing hardwoods (hornbeam, birch, oak, etc.);
• Red - obtained by soft roasting, mainly from conifers trees.

In accordance with GOST 7657-84, coal is divided into three grades according to quality: A, B and C (see video below).

Major Buyers

Given the high demand, the production and sale of finished coal can turn into a respectable business with a very high percentage of profitability. Objects alone Catering more than four million tons of charcoal are consumed in one season. If we add to this the rest of the enterprises and objects of life (schools, kindergartens, universities, etc.), as well as private consumption (hunting, fishing, summer cottages), we get a completely gigantic figure. At the same time, it should be taken into account that this form of business does not require any high-tech and costly forms of production.

Equipment for the production of

The following are used as charcoal production equipment:

• Charcoal kiln (from 100 thousand rubles);
• Scales (from 5 thousand rubles);
• Electricity generator (20 thousand rubles);
• Chainsaws (from 5 thousand rubles);
• Hydraulic device for chopping firewood (from 55 rubles / piece).

Under the arrangement of the furnace for the manufacture of charcoal, an open and flat area is required. The area of ​​the complex, taking into account storage facilities will be about 200 sq.m.

Production technology

As raw material for coal production presentation you will need wood (price from 1000 to 1800 rubles / m3) and bags for packaging (price from 7 to 11 rubles / piece).

The basis for the production of charcoal is the pyrolysis process (a special process of burning wood without oxygen). For these purposes, mobile and stationary charcoal kilns, also called retort kilns, are used. Such furnaces consist of special chambers in which the operations of firing and drying of the feedstock are carried out. The basic principle of operation is that the vapors and gases released during the combustion of coal flow into the furnace, where they are burned, providing the process with additional heat.

Detailed video of charcoal manufacturing technology:

The action proceeds in the following order: the wood delivered for these purposes is placed in a special loading chamber. After receiving an appropriate signal from the sensors about the burning and drying of coal, it is unloaded and left to cool. Then the final product is crushed into small pieces, packaged in paper or plastic bags and bags. The degree of crushing depends on the purpose of this party. Coal intended for domestic use is crushed into smaller pieces. For industrial enterprises accordingly, the crushing is larger.

In the manufacture of coal, any wood waste- stumps, branches, waste paper and furniture industry. Often, contacts are established with local forestry workers who carry out annual logging. Peat and sawdust can also be used. Waste of raw materials per ton final product approximately as follows: birch wood - 7-8 cubic meters, softwood - 11-12 cubic meters. m.

Capacity for the production of charcoal is recommended to be located in suburban areas. The optimal number of employees is approximately 2-3 people. Highly qualified personnel is not required to service the equipment. In addition to the workers, you will also need a watchman, an accountant and a manager.

This business does not require serious investments, education or any special knowledge. His feature is a fast payback period.

 

As a raw material for the manufacture of coal, waste from enterprises engaged in wood processing and logging is usually used. It can be coniferous or hardwood trees (birch, oak, elm). Depending on the type of wood, the finished product is assigned category A, B or C.

Scope of charcoal

In everyday life, this product is used as an environmentally friendly fuel for barbecues, fireplaces and barbecues. In the municipal sector, it is used for filtering drinking water. Small fractions, which are screened out from raw coal, serve as a food additive that enriches the diet of animals.

In industry, charcoal is used in the production of galvanized wire, non-ferrous metals, steel products, and glass. Thus, the consumers of packaged charcoal are:

• Metallurgical and chemical industry
• Housing and communal industry
• Peasant farms
• Private individuals

Required Equipment

To organize a business for the production of charcoal, you will need the following equipment:

	Name
	Charcoal burning oven PTORS-7G (pyrolysis plant)
	Weight dispenser (packing finished products);
	Portable bag sewing machine NewLong NP-7A
	Hydraulic wood splitter "Gorynych 6T"
	Chainsaw and hand tools (axes, cleavers, hacksaws).

The main equipment for the production of charcoal is pyrolysis plant. Currently on the market are various options charcoal kilns, differing in productivity, degree of automation of the process, cost. The change in the price of equipment, based on the level of performance, can be estimated in the following table.

One of the largest suppliers of equipment for the production of charcoal is the production and commercial company BMP, which manufactures stoves under the brand name "Fire Dragon", this company offers more than 10 modifications of pyrolysis plants, costing from 59,000 rubles and ending with a price of 2.1 million rubles.

Table 1. Comparative analysis cost of charcoal kilns based on productivity

To select the optimal equipment in terms of price and performance ratio, we will analyze the furnaces manufactured by BMP (furnace Fantastika 2/3) and SpetsTopResurs (furnace PTORS7D).

Table 2. Analysis of furnace equipment

As can be seen from the presented table, the pyrolysis furnace "Fantastic 2/3" is optimal in terms of price / performance ratio. In this regard, this stove is very often bought by entrepreneurs starting a charcoal production business.

Feasibility study of the project

For organization small business for the production of charcoal, with a capacity of 12 tons per month, the following investments will be needed:

• Charcoal kiln - 199,000 rubles.
• Weight dispenser - 137,000 rubles
• Manual bag sewing machine - 16,500 rubles.
• Wood splitter - 98,000 rubles.
• Chainsaw - 38,000 rubles.
• Hand tool(axes, cleavers, hacksaws) - 10,000 rubles.
• Initial purchase of raw materials - 50,000 rubles.
• Registration in the INFS, ordering a print, other expenses - 10,000 rubles.
• Total 508 thousand rubles.

Profitability of activity

• Subject to 100% load of equipment and work 25 days a month,
• charcoal production will be 10 tons.,
• Average wholesale price for 1 kg. finished products is 20 rubles, so the monthly revenue will be 200,000 rubles.
• Serving staff 3 people (excluding the entrepreneur).
• Net profit activities is 25%.
• Return on investment 10-12 months.

Today, charcoal is quite in demand - it is bought by restaurants and cafes for cooking, chemical and metallurgical plants for production processes, people for cooking barbecue and grill. Charcoal production as a business - perfect solution if you live in wooded areas. The procedure does not require serious investments and quickly pays off with the right approach. In this article, we will analyze how to start your own charcoal business and give an example of the calculation.

Introduction

Charcoal is a high-carbon material that is obtained by pyrolysis of wood. different varieties with limited air intake. For its production, a special oven is required, which can be placed both in your own garage and under open sky or in a specially equipped workshop.

Charcoal is a profitable business

As of 2017, in Russia there is an average saturation of the market with these products, so any businessman can easily start production and find sales outlets for finished products. The main thing is to correctly calculate and think over everything, analyze the consumer market, think over where it is more profitable to sell products in bulk. Compose detailed business plan and stick to it when implementing your idea.

Types of coal

Many people think that all coal sold in supermarkets and gas stations is the same, but in reality there are many varieties. It can be divided into:

1. Red. It is made from conifers using a special technology by soft charcoal.
2. White. To create it, hardwood is used, such as oak, birch, elm, hornbeam, etc.
3. The black. To create it, soft wood is used: linden, aspen, poplar, alder, willow, etc.

Many entrepreneurs make only classic black coal, but if you want to capture the market, then the range should be expanded. You should be guided by what raw materials you can get: if oak forests grow in your area, then you will have to use this particular material, etc. You should also know that there are three varieties according to GOST 7657-84 A, B and C. The higher the grade , the better the quality of coal and the more willing it will be purchased, so try to make only a quality product.

Note: a large number of entrepreneurs uses as raw materials various waste products from woodworking and furniture companies, as well as rotten logs and bars. It is not recommended to do this, since the quality of coal from such raw materials will be extremely low.

Of course, you can earn more in this way. But customers will not like your products and in the end it will hit the image of a young business.

You should also consider in what packaging to sell the product. Usually it is packaged in paper bags and plastic bags with a capacity of 2 to 50 kg. The most popular among the population are bags weighing 5-10 kg, while restaurants and enterprises buy it in bags of 50 kg to reduce the cost of raw materials.

Raw Material Improvement Dryer

How is charcoal made

Next, we will analyze the technology for the production of charcoal. There is nothing complicated in it - the process is based on the principle of pyrolysis. The finished raw material is fired at a given temperature without air access and turns into coal. The production algorithm is as follows:

1. Raw materials are manually loaded into the furnace.
2. The furnace turns on, burning occurs.
3. Coal is unloaded, cooled, packaged and sent to the warehouse.

As you can see, there is nothing complicated in the procedure, but safety precautions should be strictly followed during production. Be sure to observe fire safety, set up an alarm and have several fire extinguishers on hand so that in the event of a fire it can be quickly eliminated.

The best raw material for making coal is wood in chocks, cut into pieces of 40-60 cm. If you plan to buy logs, you will have to hire a special person who will grind them to a predetermined size. The cheapest way to buy raw materials is from a supplier or at woodworking plants - they are available in almost all regions of Russia. Negotiate with them wholesale deliveries - the cheaper you can buy raw materials, the greater the profit.

Equipment

Let's consider whatmust be purchased. Today, the market offers entrepreneurs a wide range of specialized equipment, ranging from inexpensive manual-loading furnaces to automated lines capable of producing tens of cubic meters. finished product for a shift. The main equipment for manufacturing is a pyrolysis oven. We do not recommend starting a business with professional stoves - first, get a small one, master the process, find customers, and then calculate how much coal you can sell, and select a new device based on this. When choosing, consider the following factors:

1. Available area. Entry-to-mid range ovens are about 40 m2, so think about whether you can place it on your site or in the workshop.
2. How many raw materials can you load at one time. Keep in mind that to get 1 ton of coal you need 7-9 tons. The better the quality of the loaded wood, the better the product will be.
3. duration of pyrolysis. On average, one cycle lasts about 50 hours, but it all depends on the type of wood, the selected equipment and the volume of the furnace.
4. The power of the pyrolysis oven. Power is how much coal can be created in one cycle. On the market there are models with a capacity of 100 to 2000 kilograms of finished products.

Pyrolysis oven for manufacturing

What you need to get started

Next, consider charcoal production technology and equipment needed to start. The main thing in this business is the oven. The price depends on its power - in 2017, a small 100-kilogram furnace can be bought for 50,000, a full-fledged 2 tons - for 1,000,000 rubles. Thanks to this division, you can choose the option that suits you both in terms of price and performance. Many entrepreneurs start their journey with a 300-500 kg oven, after which, if necessary, they buy a second one or change it to a more powerful one. Note that not only pyrolysis, but also retort furnaces are presented on the market, but they are worse in quality, so they should not be considered as an alternative. To get started you will also need:

1. Scales electronic 5-7 000 rubles.
2. Packaging device - 100-150,000 rubles.
3. Chainsaw - 10,000 rubles.

This is the minimum set of equipment to get started - it is quite enough for beginners and for small workshops. In the future, you may need separators for grinding, dryers for improving the quality of raw materials, batchers for process automation, special lines feed, etc., but usually this equipment is used on large enterprises so you don't need to worry about it just yet. You can save even more by purchasing not a ready-made furnace, but by ordering a pyrolysis barrel from local craftsmen, but this is an option for those who have a seriously limited budget - it’s better to buy a high-quality and specialized furnace right away.

How profitable is it

Universal business plan for the production of charcoal no - it all depends on where exactly you will buy raw materials, what price it will be, how you will arrange sales, etc., but the average figures for the industry are known. We recommend that you do not contact retail sales, in last resort you can just sell bags in the workshop without organizing your own outlets.

Quality charcoal

Look for those who will buy products in bulk:

1. Supermarkets or local retail chains.
2. Filling stations.
3. Restaurants and cafes.
4. Wholesale stores and bases.
5. Various industrial enterprises that need coal for technical processes.

Practice shows that in almost any region of Russia there are places where coal from the manufacturer will be popular and can be sold in bulk. Therefore, before starting, think about where you can rent it, try to communicate with potential buyers to determine their expectations and the required volumes. It often happens that an entrepreneur works with one wholesaler, handing over to him all the products produced.

1. Registration with the tax authorities - 15,000 rubles.
2. Purchase of a set of equipment - 1,000,000 rubles.
3. Room rental, repair work- 400,000 rubles per year.
4. Purchase of wood for processing - 300,000 rubles.

In total, to open a business, you will need approximately 1,700,000 rubles. Note that in this case we are talking about professional equipment and a medium-sized workshop that produces about 20 tons of coal per month. If there is no such budget, then you can get by with a cheaper set of equipment and a garage - this will require investments of about 300,000 rubles with a capacity of 2 tons per month. It is also desirable to have a car for the transportation of finished products - even an inexpensive GAZelle capable of taking on board about a ton of cargo is suitable.

Next, let's calculate the profit. The selling wholesale price of birch charcoal in 2017 is 100 rubles per kilogram, while its cost is about 60, including all expenses. On 1 kilogram you earn 40 rubles, on 2 tons products sold(home workshop) - 80 thousand rubles, for a full-fledged enterprise producing 20 tons per month - 800,000 rubles. Thus, the investments made pay off in 2-4 months, although in practice a full payback is obtained in 4-6 months (additional costs inevitably arise).

In contact with

Charcoal is a universal environmentally friendly type of fuel that has found its application in many areas of industrial and household activities:

1. Acts as a stabilizer (reducing agent) in metallurgical production.
2. In chemical technological process is an important component during vacuum dehydration of air and water.
3. Activated charcoal is a well-known sorbent, indispensable for poisoning.
4. It is used for cleaning sewer systems and drains.
5. It is widely used in agricultural work and for the care of cattle, poultry.
6. In everyday life it is used for kindling a fireplace, cooking.

Business project summary table

Registration and organization of business

Legalization of production is a complex multi-stage process that includes a number of preliminary and main stages of legal preparation.

TO preliminary stages applies to:

• form definition economic activity– Sole Proprietorship or LLC;
• collection of documents for registration;
• filling out an application;
• setting deadlines tax reporting And interest rate(according to personal income tax 13%).

The main stages of organizational and legal activities include:

• overhaul of the production area;
• obtaining a sanitary certificate, permission from the fire service of the city;
• conclusion of a contract for the removal of garbage and production waste;
• purchase and installation of the necessary equipment;
• scheduling and staffing;
• launch of the production line.

Premises and equipment

To launch a production line, it is recommended to rent an industrial facility outside the city with total area from 180 to 200 m 2. This is necessary in order to reduce the cost of purchasing and transporting raw materials. In addition to all of the above, such a technique will attract an additional group of buyers (summer residents, gardeners).

Equipment for the plant is imported as soon as the premises are ready. Required list includes the following types of machines:

1. An oxygen-free kiln produces 400 kg of finished products per day.
2. Packing block.
3. Metal lattices.
4. Packing conveyor.

Production technology

To date, Russia uses several methods for the manufacture of charcoal. The choice of one of them is determined by the quality of the source material and its variety.

However, the basis of the entire technological process is reduced to the following steps:

1. Burning wood in an oxygen-free oven. This operation is called pyrolysis. As part of this process, the wood is placed in retorts (specially prepared chopped blocks) and subjected to heat treatment.
2. Drying. After firing, the material must be dried in a special chamber.
3. Laying out on a metal grate. At this stage, the coal finally cools down.
4. Packing.

Raw materials and their varieties

The main material for the manufacture of coal is wood slag or waste. You can buy them by establishing strong business relationships with:

• furniture factories;
• woodworking factories;
• paper and pulp shops and so on.

In the event that there are no such industrial enterprises nearby, then it is possible to conclude an agreement with government agencies on cutting down part of the forest. Usually, the forestry allows you to take out the "dump" or old diseased trees.

Since the initial quality of raw materials does not significantly affect the final result of production, it is not of fundamental importance how the wood will be acquired.

However, the final form of the product will directly depend on the type of raw material chosen. This is expressed in a change in the color index of coals:

1. Red - the basis of its production is the use of exclusively coniferous wood. The finished product is obtained by low-temperature processing.
2. White color - obtained by processing solid hardwoods: maple, elm, larch and others.
3. Black coal - obtained by long heat treatment more malleable wood species: chestnut, willow, alder, aspen, birch.

Supplier search

It is worth buying raw materials from trusted suppliers who sell quality goods. These include large furniture enterprises with many years of experience, forestry, factories for the manufacture of paper products and wooden toys, wood processing plants.

In addition, you can simply buy timber from dealerships that have current contract from government bodies authorities.

The choice of the most appropriate procurement method should be chosen based on: considerations of the cost of raw materials, the duration and complexity of transportation; other nuances that can significantly increase the price.

Staff

It is worth hiring personnel for production based on its volume, the features of doing business. In this case, it will be enough to include in the staffing table:

1. Several workers.
2. Sales manager.
3. Secretary for the weekend.
4. Accountant (or do this work on your own, which becomes possible thanks to specialized courses for individual entrepreneurs).
5. Cleaners in the shop and on the territory.

Sales market

Charcoal in our country is not hot commodity. Unless during the summer holidays, when most of the working population begins to go out into the countryside en masse. However, profitable contacts can be found. To do this, you need to create several sales methods:

• sell coal wholesale and retail;
• supply products to owners of cafes, barbecue, bars and restaurants;
• enter into profitable contracts with other manufacturers (we are talking about smelting, forging shops);
• opening of country shops and tents with garden utensils.

The financial component of the business

You can determine the validity of a business project by counting important economic indicators. These include: the amount of initial investment, the monthly level of profit, the full payback period of production.

Cost of opening and maintaining

The base cost of the project is determined by the amount of production start-up, which is at least 1,170,000 rubles. What is it made up of:

1. Rent and repair of premises - 300,000 rubles.
2. Purchase and installation of equipment - 500,000 rubles.
3. Raw materials (chipped firewood) - 1.5 - 2 thousand rubles per meter 3.
4. Packing bags - 15 rubles apiece.
5. Salary - 200,000 rubles.
6. Development of the company logo - 30,000 rubles.
7. Tax (land, personal income tax, regional) - 100,000 rubles.
8. Utility payments (electricity, water supply) - 10,000 rubles.
9. Payment for cleaning work sewer pipes and ventilation shafts - 30,000 rubles.

Size of future income

The expected level of profit from production is at least 200,000 rubles per month. However, this figure will fluctuate significantly, depending on the seasonality of demand and the availability of regular customers.

Payback period

Based on the first 2 indicators - “the cost of opening and maintaining” and “the amount of future profit”, we can conclude that the production of charcoal will pay off the owner of the company no earlier than 1.5 years from the date of opening.

Engaging in the production of any type of product is not always easy. High competition within the market segment and a small number of possible distribution channels become a serious obstacle to obtaining the desired level of profit. And yet, all difficulties can be overcome. To do this, it is enough to plan your activities correctly and try to minimize costs, especially at the initial stage.

It may seem surprising, but despite the fact that the history of human use of fire goes back thousands of years, the coal obtained by burning wood, long time considered waste. And only in the last century, the production of charcoal as a additional source energy used for industrial and domestic purposes, was, as they say, put on stream.

Brief business analysis:
Business setup costs:350-500 thousand rubles
Relevant for cities with a population: no limits
Situation in the industry:high competition
The complexity of organizing a business: 2/5
Payback: 3 – 6 months

Moreover, the demand for this product shows such increases every year, and the production of charcoal is such a simple process that it would be a gross mistake not to pay attention to this type of business for serious entrepreneurs.

The use of charcoal in industry and daily life

Some applications of charcoal are well known to everyone - heating private houses and use for cooking. What's a picnic trip without a sack or two of charcoal? But as it turns out, charcoal has found its way into other industries as well:

• in the metallurgical sphere as a reducing agent in the smelting of some rare and valuable metals;
• in glass business - in the manufacture of glass and crystal;
• in agriculture- as a fertilizer and additive in some types of animal feed;
• in the production of welding electrodes, semiconductors;
• in the construction industry - as an insulator in the construction of houses;

Some "by-products" obtained during the production of charcoal are also used, from which they receive:

• turpentine;
• some types of solvents for paints;
• acetic acid;
• methyl alcohol.

Having gained an idea of ​​where charcoal is used and used, it becomes clear where exactly you should look for distribution channels for finished products.

Making charcoal as a business has a number of advantages that are extremely attractive for start-up entrepreneurs:

• organizing your own business does not require significant investments and the presence of any special knowledge about the technological process of production - a business can be organized both on a large scale and at home;
• raw materials for production (as a rule, these are waste from woodworking industries) are available in sufficient quantities in almost any region of the country and cost “mere pennies”, or you can get it for nothing at all;
• charcoal as a type of fuel has a high degree of environmental reliability, the products withstand any environmental impact assessment;
• finished products have a huge demand (having a seasonal direction) and high profitability.

From 1 cubic meter of wood of the second and third grade, which will cost from 600 to 1400 rubles, you can get up to 350 kg of finished charcoal. Calculating the profit from the sale of the finished product is not difficult.

Varieties of charcoal

The types of charcoal obtained depend on the type of wood used in the production. This information is reflected in the table below:

Type of coal	Used wood	A comment
"White coal	Oak, birch, acacia, hornbeam, ash, elm, and other hard varieties of trees of group I	It is considered the highest quality coal.
"Black" coal	Poplar, linden, alder, willow, aspen - soft varieties of trees of group III	The production of coal from such varieties of trees is considered the cheapest.
"Red" coal	"Red" coal Spruce, pine, and other varieties of coniferous trees of group II	The most common type of coal

There are also GOSTs of charcoal:

• grade A - pyrolysis (in this context - the process of obtaining the finished product by combustion with limited oxygen access) of I wood group;
• grade B - pyrolysis of I and II groups of wood;
• grade B - charcoal ( natural way obtaining coal) wood I, II, III groups.

How to start your own coal business

As already mentioned, organizing a charcoal business is simple, and anyone can do it.

The charcoal production technology consists of 4 main stages:

After cooling, the finished coal, if necessary, is crushed into smaller fractions and packed in bags or packages.

The degree of wood burning and the temperature of the flame is regulated by special sensors installed in the equipment. At home, the best result is achieved empirically.

The production of charcoal in retort kilns by pyrolysis is shown in the video below.

Charcoal production at home

The production of charcoal at home is not much different from the industrial process. The differences lie in the equipment used and the requirements for the feedstock. To obtain coal in an artisanal way, it is necessary to use only whole wood - firewood, logs, large branches, etc.

As equipment, you can use the usual metal barrel with a capacity of 200 liters. In the upper part of the barrel, it is necessary to drill holes for the release of accumulated gases. The barrel is tightly closed with a lid, placed over the fire and heated to a temperature of 350-380 ° C. When the specified temperature is reached, the barrel should be above the flame for another 2-2.5 hours, after which it is removed from the fire. The lid opens only after complete cooling.

Instead of a barrel, you can also use an ordinary hole dug in the ground. The lid can be a simple a metal sheet. The process of obtaining coal can be viewed in the video:

Production room/site

As a rule, the production of charcoal takes place in an open area. Land plot must be at least 200 sq. meters, cleared of debris and vegetation. In addition to the installed furnaces, a warehouse for raw materials and finished coal, a staff room should be equipped on the site. In addition, the team of workers must have fire fighting equipment.

It would be expedient to place the production site next to or not far from timber processing enterprises, sawmills, etc., in order to reduce costs and time for the transportation of raw materials.

Equipment overview

Charcoal production equipment includes the following:

• retort charcoal kiln - stationary or mobile, depending on the format of the business organization. The purchase will cost from 200 thousand to 1 million rubles, depending on the daily output of the furnace. Used equipment can be purchased, for example, on the Avito website for 70-90 thousand rubles;
• an electric generator, a power plant (in the absence of the possibility of supplying an electric line to the production site). Cost - from 30 to 50 thousand rubles;
• hydraulic wood splitter (can be replaced manual labor) - from 15 to 30 thousand rubles. A used wood splitter can be bought for an amount of 2-3 thousand;
• chainsaw - 5-8 thousand rubles;
• packing machine - from 70 to 100 thousand.

An overview of charcoal making equipment is presented in the video below:

The dependence of the volume of finished products on the type of wood and the quantity consumable presented in the table below:

Using this information it is possible to regulate the costs of raw materials and the production of finished coal, the volume of which also depends on the type of equipment used.