How to start a rubber toy business step by step guide by netlinehost

How to start a rubber toy business step by step guide


Starting capital - from 3.5 million rubles. or 49205.82$ (U.S)

How to start a rubber toy business step by step guide
How to start a rubber toy business step by step guide


Any business project focused on the manufacture and sale of children's toys has high profitability and profit. in this article, we will be talking about how to start a rubber toy business. Experts note a stable growth trend in the segment of products for children. The annual market sales of toys are about $ 850 million (equivalent to 48 billion rubles!). At the same time, this figure is growing every year, growth has been observed for the last 5 years - annually by 25-32%. The economic crisis, of course, did not pass without leaving a trace, but this area practically did not affect it. Despite such favorable conditions, the domestic toy market is still very far from being oversaturated. The segment of toys related to the market of children's products has a capacity of 13 billion dollars (which is equivalent to 740 billion rubles) and occupies less than a tenth of the total volume.


The main problems of enterprises for the production of children's rubber toys are market opacity, huge volumes of illegal imported products, as well as the import of counterfeit products from the countries of the Asian region (the volume share of the total capacity reaches more than 65%). At the same time, the percentage of domestic rubber toys on the market is relatively small - about 15-18%. In general, the structure of the domestic market for children's toys relative to the manufacturing countries is built as follows: 65% of products are manufactured in Asia (mainly in China), 25% in European countries (toys of German, Spanish and Polish production are very popular), the remaining 10% fall on Russian-made products.


But, according to experts, toys for children from large domestic manufacturing companies can compete well both in the domestic and global markets. Most of them have long been engaged in the export of manufactured products. The largest and most eminent Russian manufacturing companies include about 6-7 enterprises.


A characteristic feature of this segment of the domestic market is the presence of many ways for further development (for example, expanding the product range). Due to their high competitiveness, the inability to set low prices for manufactured products (relative to products made in China), as well as high prices for the necessary equipment, novice entrepreneurs begin to master one niche and only then think about expansion.


Basically, this applies to labor-intensive types of production. Small manufacturing companies produce toys from their own blanks (for example, from natural wood or textiles). Even the largest enterprises have at least one specialization: plastic toys, dolls, building constructors, and so on. It also includes the production of plastisol toys.


Children's toys, which are very often called rubber, belong to the low and medium price categories. At the same time, they are in high demand due to a wide range of different shades, low weight, high strength and, most importantly, attractiveness. Target audience - children aged 0-4.5 years. They are versatile (you can even wash with them), pleasant to the touch, made in the form of animals or various superheroes. They can also make various sounds or cues, if there is a special device.


In this market segment, the number of our manufacturing companies has prevailed over the past few years. Now, due to problems with design (domestic enterprises have been producing the same type of children's toys for the last couple of decades, even despite the loss of their relevance), foreign-made goods (mainly goods from China) are gradually beginning to conquer the market. Also, in parallel, there is a niche where there is not yet a single domestic competitor - collectible plastisol products targeted both for children and for an older audience. In any case, toy stores are always interested in new, beautiful and quality products.


Content

  • Technological process
  • Realization of rubber toys
  • Necessary equipment
  • Calculation of start-up capital and payback period


 

Technological process

The most costly laborious stage is the development of a model range. At this stage, several professionals are involved at once - artists, design engineers, sometimes even child psychologists are involved. To begin with, they draw up a sketch of the future product, after which they begin to create a layout in the format of an SVG drawing (in vector graphics). After that, a 3D model is created by design engineers. After painting and registration, it is approved, coordinated or sent for revision. Only after the approved 3D model is approved, the manufacture of specialized molds begins, only then the children's toy is launched into mass production.


In Russia, rubber products have been manufactured for several decades. Back in Soviet times, they were produced by 3 main methods:


Molding (using pre-made molds);

The dipping method (from rubber adhesive mixtures on porcelain models);

Blowing method (from rubber sheets by stamping method).

In the manufacture of children's toys by molding, the rubber composition is passed through a specialized calender, the emerging sheets are cut into plates. A "blowing" device is placed between 2 rubber plates, after which they are superimposed on each other, and then glued on a mechanical press.


After gluing, the workpiece is placed in metal molds with a heating system (operating temperature range - from 150 to 185 ° C) with compartments according to the shapes of the future product. Under the action of the "blowing" device, the rubber model begins to take the shape of a compartment, after which it begins the vulcanization process (transformation of rubber into rubber). Formed children's toys are grinded at the seams and then painted by hand using brushes or a special airbrush. In some cases, the bottom of the toy is equipped with a squeaker. They are made separately from plastic and metal raw materials, which are highly resistant to corrosion. Most modern toys are not "voiced" (that is, they do not have a squeaker).


Dipped products are created by the dummy method (using specialized equipment) of models from porcelain to a rubber compound (it includes rubber, which is dissolved in a gasoline base). After the product is removed from the porcelain blank. Now this production method fades into the background, many manufacturing companies are switching to more modern technologies.


Blown toys are extruded on a press machine from two rubber sheets (which were obtained after passing the calender) in a certain pattern. Parallel to this, the edges of the future toy are glued to each other. Then the product undergoes vulcanization and goes to the paint shop, most often by airbrushing.


The technological process of manufacturing monolithic (solid) rubber products can be divided into four stages:


Pressing and parallel vulcanization of the rubber base;

Grinding;

Washing;

Coloring.

These rubber toys are relatively small in size.


Over the past decade, the technological process for the production of rubber toys for children has changed dramatically, and has also been greatly modernized and automated. Modern manufacturing companies are using new types of raw materials. For example, rubber raw materials, which have a number of restrictions on their use, are replaced by plasticized polyvinyl chloride films (low and medium hardness), polyvinyl chloride pastes (the previously mentioned plastisol raw materials) and vinyl plastic in the form of sheets (unplasticized polyvinyl chloride).


The most common "ingredient" in modern rubber products - the so-called PVC - is referred to as thermally plastic synthetic raw materials. Produced in powder form, has a snow-white color, is absolutely tasteless, odorless.


Most of the toys of domestic production are made from plastisol raw materials - a polymeric compound cured at temperature exposure on a polyvinyl chloride basis, sometimes it is called PVC plastisol. Uncolored plastisol is similar in color and physical state to fatty sour cream. Dyes of organic origin are added to the mixture, which ensures uniform coloring of the future children's toy. Colors of various colors are used. To get a flesh-colored mixture, use ruby ​​color plus orange pigment in a ratio of one to two. Such a dye is almost impossible to erase, weakly fade, moisture resistant and, most importantly, environmentally friendly.


After the plastisol is poured into the mold, it polymerizes under the influence of high temperatures - this is how the necessary rubber properties are acquired. This manufacturing method is called rotary molding. A certain mass of plastisol raw materials is poured into a metal alloy mold, hermetically sealed and rotated at a certain speed (in parallel with the rotation, the mold is heated).


After the transformation of the plastisol into gelatin, the mold is transferred to a cooling unit. After cooling, the finished toy is removed and sent for painting with an airbrush or brush method. Then the products go for packaging (most often in polyethylene bags). Manufactured rubber toys are stored in clean and well-ventilated warehouses with low humidity levels (around 65%). The room is kept at a constant temperature range (15-18 ° C). Do not store rubber products in direct sunlight.


For toys made by blowing, use a gas-tight polyvinyl chloride film by welding (at ultra-high frequencies). A specialized valve is preliminarily placed in the film for subsequent blowing.


The key to successful development is the high quality of the manufactured products. The main criteria are high-quality raw materials, as well as compliance with the technological process. For example, in chemical reactions, sulfur-, fluoro- and phenol-containing compounds can act as a catalyst or component. The latter reagents are aromatic hydrocarbon compounds. In case of deviation from the technological process, vapors can enter the human respiratory system, which leads to internal burns and poisoning. In small doses, they are safe and do not appear in any way. But in Chinese toys, the dosage can exceed the limit by 10 or even 20 times, which can cause irreparable harm to young children.




Manufactured products must comply with all requirements and be confirmed by appropriate documentation. The surface of a rubber children's toy should be smooth, environmentally friendly, without sharp protrusions, resistant to deformation, and easy to clean.


Appropriate marking must be placed on the product and packaging: clearly written, must not be washed off. It should be marked:


Full name of the product and manufacturer;

Age qualification;

Enterprise address;

Release date;

A number of warnings;

Advice for safe use.

If a rubber toy is intended for children 0-4 years old (like most similar products), then a special UGO is indicated in the marking in accordance with GOST-R51556-99: a circle crossed out from the lower left to the upper right corner is red, inside it is indicated in black “0 -3 ”and the image of the baby's face is placed.


Realization of rubber toys

The main sales channels for rubber toys are wholesalers, specialized stores for children's goods, and pharmacies. When releasing collectible toys for an older audience, you don't have to buy hardware. Circulations of such issues are generally small, which means that it is quite problematic to recoup all costs. Models and its design are developed by staff members, and you can order production at another enterprise (for example, in one of the countries of the Asian region). In total, you only have to develop a model range and search for sales channels. Do not forget about kindergartens - government purchases for children's institutions are often found in any region of our large country.


Necessary equipment

The production line of the minimum configuration consists of:


Casting installations;

Forming equipment;

Production calenders;

Powerful mixers;

Press installations;

Furnace installations.

The approximate cost of such a set is about 5 million rubles (used ear installations can be found for 3 million rubles). Molds are generally ordered separately.


Calculation of start-up capital and payback period

About 1 million rubles will be spent on purchasing the first batch of foreign-made raw materials. To maintain the production line, it will be necessary to hire 10-15 employees who will work in shifts. You also need to enlist the help of highly qualified designers and design engineers. The monthly salary is over 20 thousand rubles. You will also have to spend money on registration of an individual entrepreneur, as well as on certification of products. The approximate payback period for such an enterprise is 2.5-3 years.

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