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Business plan for processing wood waste. Wood waste recycling as a business. Processing equipment

The woodworking industry in our country is not very competitive, because many people refuse to start in an area where there are high operating costs and a long payback cycle. At the same time, demand for environmentally friendly materials is spurring the formation of supply. If you draw up a high-quality business plan, you can get a highly profitable business.

It is best to choose LLC as the legal form. This will allow you to more successfully establish contacts with partners, as well as avoid liability to the founders with all your property.

The main types of taxes paid by woodworking enterprises:

  • For profit
  • For property
  • Income

In addition, social contributions are required.

Where to start

In order to create an enterprise, you first need to decide on the field of activity. Moreover, there must be an understanding of what the company will be doing in the next year and a half.

The most popular areas of woodworking:

  • Log rounding (according to statistics, 20% of enterprises are engaged in this type of activity);
  • Manufacturing of blanks for window blocks;
  • Production of furniture panels (this is a hazardous type of production because glue is used);
  • Pellet production (biofuel in the form of pellets is very popular abroad, almost all large supplies are exported)
  • Production of chipboard or OSB boards.

You also need to keep in mind that there is traditionally high demand for wooden furniture.

When creating a woodworking enterprise, you need to clearly understand who will supply the raw materials. Perhaps, it is not even worth creating production until partnerships for raw materials are established, because now in Russia there is a shortage of high-quality and affordable timber.

Selection of raw material suppliers

Large enterprises mainly supply raw materials. You should immediately discuss the delivery schedule with them, and not just the volume. In case of closure of federal highways, it is necessary to create large warehouse stocks of raw materials in spring and autumn.

Most often raw materials are sold high humidity, which is not suitable for woodworking needs. Drying chambers may be required. Or you need to look for suppliers who can supply boards with at least transport humidity.

Drying wood makes it durable and resistant to rotting and the appearance of bugs. So-called atmospheric drying, when raw materials dry in the open air or in a large room, requires a long time. In the chambers, raw materials can be prepared in 5–6 days.

Thus, in order to make a significant profit, you will most likely have to spend money on drying chambers.

For a woodworking company, it is important to choose enough large territory, because it is necessary to accept raw materials, produce and store finished products. The territory must have convenient access. Ideally for several modes of transport, for example, road, rail or sea. It is also required to place on the territory:

  • Checkpoint;
  • Administration building;
  • Boiler room;
  • Drying chambers;
  • Premises for recreation and other service needs.

Typically, the cost of renting land outside the city is lower. This should be taken into account when searching for the desired site. But there must be a good transport interchange.

Staff

When hiring personnel, focus on blue-collar jobs. In total, for an enterprise focused, for example, on the production of 24–30 thousand cubic meters of finished deep wood processing products, approximately 100–110 people will be required. The most valuable employees are operators of woodworking machines, inspectors, rejectors, engineers, etc. Correct inventory records are very important, since only a specialist can determine the difference between product types. Therefore, the storekeeper must have an understanding of wood products. The staff will also include:

  • Director
  • Chief accountant
  • Head of HR Department
  • Chief mechanic
  • Chief Engineer
  • Technologist
  • Head of Labor Safety Department
  • Chief power engineer and other services.

When drawing up a business plan, you should take the industry average wage levels to make the appropriate calculations.

Equipment

This expense item will become the main one for the initial investment in the business. To do woodworking you will need:

  1. Four-sided machines;
  2. Band sawmill;
  3. Cross-cutting machine;
  4. Drying equipment;
  5. Forklifts (at least two);
  6. Circular saw;
  7. Ventilation equipment with exhaust (to absorb dust and small particles wood waste).

The equipment can be of domestic or foreign production. It is not necessary to buy new equipment, since its service life is usually very long. Taking into account exchange rate fluctuations, most likely for an increase economic efficiency The project will have to choose domestic machines at the start.

Sales

Depending on the scale of activity, sales can be established in foreign countries(both near and far abroad), and by regions of Russia. Wood products are always in demand, but for some clients it is important to have guaranteed large volumes of one type or another. In addition, it should be noted that individuals privately also often purchase products directly from the workshop. After all, they understand that prices are higher in retail stores.

Financial justification for the project

In order to start such a business, you will need about 16 million rubles. This cost could increase significantly if the ruble weakens further and equipment costs rise. So far, this amount includes that the entrepreneur will spend 2.7 million rubles on the purchase of woodworking equipment.

Of this, it may take about 1.5 million rubles to develop the territory. Monthly expenses should include:

  • Business expenses – 125 thousand rubles.
  • Costs for purchasing raw materials – 36 thousand rubles;
  • Expenses on fuel and energy resources – 30 thousand rubles;
  • Payroll – 420 thousand rubles;
  • Taxes and social contributions – 130 thousand rubles.

The business plan should include about 2 million rubles for unplanned expenses. per year. With an optimistic forecast, the project pays for itself within two years of operation and can provide up to 6 million rubles in income annually.

Necessary equipment.

Rough plan income of mini carpentry business

Organization of a medium-scale wooden products manufacturing business.

Additional tools.


Decoration wood is one of the most ancient crafts known in the world. Special significance give to this craft here in Russia. Many wood products are decorated and designed using this particular craft.

The development of the art of artistic woodworking in Russia was influenced by the development of the state itself and the cultural development of the people. Therefore, the history of the promotion of wood crafts is divided into several main periods.

Very few original monuments of ancient Russian art from the 9th-16th centuries have reached us. But based on ancient manuscripts, paintings, information from guests who visited ancient Kyiv and Veliky Novgorod indicate that even then the artistic processing of wood occupied a definitely high position in the life of the state and the people.

Wood was used to build housing, make furniture, dishes, city fortifications, workshops, outbuildings, ships, sleighs, pavements, water pipelines, machines and machines, tools and tools, children's toys and the like. All this was decorated with geometric patterns carved on them. Particularly in demand was the manufacture of spoons made of ash, maple, and birch, on the tips of which various ornaments were carved; one of the most popular was wicker.

The 15th century brought the inhabitants of Rus' liberation from the oppression of the Tatar-Mongol yoke and the foundation of a centralized state, the center of which was Moscow. Subsequently, folk arts, including artistic woodworking, gained freedom. Creative people were given free rein in their craft. It was at this time that the greatest wood craft artists lived Ancient Rus': Theophanes the Greek, Andrei Rublev, Dionysius, who stood out for the integrity and harmony of their works.

Masterpieces of decorative and applied art of the 15th century became objects of imitation for a generation of many masters. An example is the iconostasis; if you pay attention, they have wicker patterns and gilding, which was inherent in the iconostasis of artists of the 15th century.
A special place worth noting is wooden interiors and wood products. Being in a room with a wooden interior feels like you are one step closer to harmony with nature. Your soul becomes calm and you feel more energetic. Wood not only brings you closer to nature, but also adds sophistication and sophistication to your home, especially the various hewn geometric patterns, in the details of which craftsmen leave a piece of their soul.

Implementation of a mini carpentry business.

First, you need to study the markets, visit exhibitions, wood industry fairs, in order to know what type of products are in demand by buyers. After collecting information, create a business plan for your carpentry workshop that can lead you to success.

To create a workshop you need: a dry, bright room measuring 50 square meters with ceilings up to 4 meters high. Electricity is also required. Then start collecting the documents necessary for the tax and services fire safety.

Necessary equipment.

The next step is to collect the necessary materials and purchase machines for production. According to your wishes, you can either buy all the necessary equipment in full, or 50/50. Make half yourself using online drawings, and buy the other half. There is no point in saving on materials and equipment, because half the quality of your products depends on this. In short, you will need tools such as a circular or miter saw, a jointer, a planer, power tools: a drill, a milling cutter, as well as sets of hand tools: chisels, mallets, hacksaws.

Before purchasing equipment, you should consider everything carefully. What exactly will you produce, what tools and machines are needed for this, in order to avoid unnecessary expenses on unnecessary equipment. It is also important not to forget about the people who will work with you, or for you. It is best to look not only for masters of their craft, but also creative people who will put their soul into your products. If your product is original, the demand for it will never fall and it will bring a stable income.

What kind of wood products should be made?


Wood products have their own character, which gives not only the apartment, but also the same office coziness and harmony. Therefore, the choice of products is very large, from door handles to furniture of different categories. An entrepreneur in a carpentry business has a wide range of choices, the main thing is not to make a mistake.


There is a sea of ​​wooden products, including souvenirs, talismans, toys, amulets - these are some of those that are popular among buyers. Especially the “Knock on Wood” charm. Its design is quite simple. Take a birch log with a diameter of 5 cm and a length of 10 cm, cut into two lengthwise, and stripped of the bark. A wooden figurine of the spirit is placed at the bottom of the log, or the image of the spirit itself is carved. People say that by knocking on such a talisman you can contact the spirits of the tree, who will give you protection from evil forces and wickedness.

Do not apply varnish to such a talisman; they decorate it with pieces of birch bark. The specialty of the manufacturer of such amulets is the so-called knocking on wood instruction. People believe in all sorts of superstitions, so by printing instructions for communicating with spirits on your amulet, you will attract the attention of buyers. This product costs about 300 rubles.

By using the cheapest slab material, you can make benches, tables, stools for cottages, and decorate them with various geometric patterns. On at the moment such things are in demand and are quite well valued in Moscow.


The most ordinary bench made of slab costs about 2,500 rubles, and adding some kind of ornament to it can be customized for 3,500 rubles. During the summer, you will be able to produce and sell 25 pieces per month. Coasters for hot food cost 25-40 rubles, and those made from polished sections cost up to 100 rubles, napkin holders from 150 rubles, but good original bread bins can cost up to 1000 rubles.

Expenses and income for a mini business.

Business plan expenses will include the following items:
. -rent the premises up to $200 if you don’t have your own;
. -room lighting up to $10-20;
. -materials up to 300 dollars. USA.
. -tools – $2500

To open a small mini carpentry workshop you will need about $3170. With a business efficiency of 23%, the net profit will be from $1000 per month, and the payback period will be up to 4 months. You should have your carpentry business up and running by the beginning of the construction season.

Approximate income plan for a mini carpentry business.


Subject to your premises:
Let's say your mini workshop produces the simplest carpentry product - doors. A master with no experience will be able to make 10-12 doors per month. To do this you need to purchase 1.5-2 cubic meters tree. The cost will be $270-360.
Price per door $120-130. $120*10 doors = $1200 income. Net income: $1200 - $270 = $930. Here the capabilities of a craftsman without experience are highlighted, since usually in a month a carpentry workshop with one employee manages to make large volumes.

Organization of a medium-scale wooden products manufacturing business.

The production system of window and door blocks can be divided into the following stages:
1. cutting lumber, checking its quality;
2. creation and processing of blanks;
3. assembly of the structure;
4. sanding the product and applying coatings.

For each above-mentioned stage, you can buy a separate machine or choose a woodworking center that can perform all the above-mentioned points. You can also kill two birds with one stone, that is, purchase a multifunctional unit that can combine several functions and work for 2-3 workshops at the same time.

When purchasing such installations, you also save space in your premises, because one installation takes up less space than two or three, but includes the same functions. An example of such an installation is the D 300 machine, which can perform the functions of several types, such as: thicknesser, milling, grinding, planing shops.


Additional tools.

For high-quality and consistent work of your carpentry shop, you need to buy the following tools:

Minimum plumbing tool kit;
. drill;
. screwdriver;
. jigsaw;
. grinding machine;
. moisture meter;
. roulette;
. calipers;
. electric plane;
. corded circular saws;
. tool for applying coloring and antiseptic substances;
. fan with bags for organizing sawdust removal.

A small carpentry workshop can be set up on an area of ​​60 m2. Space savings can be achieved by combining all equipment in a woodworking center. To achieve success in business, it is necessary to hire at least two professional carpenters, and also in the first stages of publishing, the director must be personally present at the manufacturing processes of the products.

Feasibility study.


Capital investments(in rubles):
. purchase necessary equipment- 184,000 rub.
. expenses for tools - 85,000 rubles.
. transportation costs - 50,000 rubles.
. purchase of raw materials - 400,000 rubles.
. registration of a business in the form of an individual entrepreneur - 21,000 rubles;
. other expenses (payment labor force) - 15,000 rub.
Total investment in business: RUB 755,000.
A sketch is created separately for each future product. First, this is done by hand, not on the scale of the future product. This is a sketch by eye, in which the author develops the idea for the product itself. After which he coordinates this with the director of the enterprise, if this development is liked, then another drawing is created, already to scale, directly according to which future products will be made.

The designed product is depicted in three views from above, front and side. If necessary, make a section of the part. If the part model is very complex, then it is divided into parts and each part is depicted separately. Each part receives its own number, under which it is included in its specification. All drawings are made on paper, in pencil, so that if necessary, it is easy to correct a mistake, or introduce some kind of amendment or modification.

Most use special paper - graph paper. This is paper that is divided into cells to make it easier to calculate the scale and draw to scale.

Together with the sketch, they think through the manufacturing system of this product. Exactly what materials will be needed, what machines will be needed for this development, what tools will be used in the process of creating this product, the costs are calculated. They calculate everything down to the last nail in order to avoid shortages of some materials in the future, and naturally so that production is organized.

Also during this period, the craftsmen are preparing the place of work. Choose a workshop that is more convenient in size and will correspond to the size of the product. They choose a convenient location for the drawings and placement of materials in the workshop from which future products will be made. Provide the master with free access to the machine, as well as tools. Provide him with comfortable working conditions. Then the manufacturing system and design of the future product are checked again in order to avoid damage to quality and various failures during the manufacturing process.

The country's reserves of wood waste are extremely large. To date, in Russia, taking into account all the known various methods of its processing, only about 50% is used, and in Siberia only about 35% of the total mass of wood raw materials. Mostly remain unprocessed: logging waste (tree greens), wood processing waste (bark), sawmill waste (sawdust and shavings), which indicates that there are opportunities for the development of this industry.

For today, there are various business ideas for processing wood raw materials, but many of them require large financial investments in qualified personnel and sophisticated equipment. We are interested promising business with affordable production organization and minor investments.

This type of production includes the processing of still remains into pine extract. Bottom residue is the condensate that, when boiling woody greens, cedar and pine bark, accumulates at the bottom of distillation tanks. It consists of biologically active substances that dissolve in water during prolonged cooking. This condensate is rich in vitamins, provitamins, carotenes, chlorophylls, organic acids and other substances that have a beneficial effect on a living organism (even humans). When concentrated, the condensate turns into pine extract, which has high consumer properties.

This extract can be used as a feed additive for animals and birds in agriculture and as a preparation for medicinal baths. In addition, pine extract is widely used in industrial production antibiotics (for animals).

After the process of cooking wood greens, cedar and pine bark, about 90% of the feedstock remains as waste solid waste. The idea of ​​processing this raw material into feed meal will also help increase the income of the wood processing business. Shredded waste solid waste They have bactericidal and other positive properties, and they are also endowed with anti-tuberculosis effects. In addition, feed meal can be used as an alternative to roughage.

Another technological solution for rational waste disposal is the preparation of fertilizer based on waste wood waste using composting. The main costs for implementing this process will be the equipment of trenches and their filling. The crushed waste mass accumulates nitrogen in the substrate and will help increase soil potential. It is especially advisable to use such composts to improve the fertility of loamy and highly mineralized soils.

Besides, waste wood waste can be used as fuel, it can be burned in a boiler room as an energy carrier. Although it is much more efficient and economical to prepare wood waste for further processing into fuel briquettes or pellets (environmentally friendly fuels). This processing will be able to solve the problem of providing the population with inexpensive energy resources, as well as reduce the volume of harmful emissions, which will reduce the negative impact of energy on the environment, improve the sanitary condition of the forest and create new jobs.


Ideas for Business from the section:

Wood processing makes it possible to obtain various products and materials that are widely used both in industry and in our everyday life. In addition, recycling wood waste contributes to order and rationalization of the use of natural resources. That's why this topic is of great importance and requires special attention.

Processing wood waste into new materials and products has many different directions. But before we begin to consider this issue, it is necessary to remember what waste from sawmilling and wood processing industries is.

Wood waste is generated in large quantities at enterprises involved in woodworking, sleepers, sawmills, plywood, furniture production, etc. Such waste can be presented in the form of sawdust, shavings, wood chips, twigs, greenery of trees, their roots and stumps.

Sawdust is most often used to make new products from waste. They are used to produce building materials (chip-gypsum sheets, sawdust concrete, etc.), fuel briquettes and pellets. Wood shavings is widely used in the production of chipboard, CBPB and other products used in construction.

Various wood processing wastes are used in pulp and paper mills, as well as in agriculture. A unique material for construction – wood concrete – is obtained from the chips of coniferous trees. In addition, wood waste is used in production cosmetics, medicines and feed additives for animals.

Obtaining fertilizers from wood and wood waste

Everyone knows that to improve soil fertility, fertilizers are used organic origin: manure, peat, etc. To eliminate the deficiency of organic components in infertile soils, fertilizers based on wood and wood waste can also be used.

For example, many people use sawdust to improve soil quality when growing raspberries. But using sawdust alone is ineffective.

To increase the fertility of agricultural lands, it is more correct to use composts. An excellent fertilizer is obtained by composting shredded wood waste with the addition of some nutrients and microelements.

Due to various chemicals and the good humus-forming ability of tree bark, composts are most often created on its basis. It contains large number carbon, potassium and calcium.

Composting bark consists of several stages:

  1. Raw materials are crushed using hammer mills, box grinders or feed grinders (for example, Volgar-5). The size of the resulting pieces should not exceed 1 cm.
  2. The crushed mass is mixed with inorganic nitrogen and phosphorus compounds.
  3. Clusters are formed in which the compostable mixture is stored for 1.5 - 4 months. The piles are periodically turned for better aeration.

The humus obtained after composting has the properties of humus; its use in agriculture helps to increase plant productivity.

In addition, the bark can be used in a non-compostable form. It is crushed to produce mulch, which, when applied to soil cover makes it difficult for weeds to grow, slows down the process of water evaporation, prevents the formation of a soil crust and reduces the difference in soil temperatures at night and during the day.

Wood-based fertilizers can be produced in various ways, only a few of them were discussed in the article.

Wood processing methods

Wood is a valuable raw material from which in the modern world the most different materials and products. However, in production purposes Not only tree trunks are used, but also wood waste, which significantly saves resources.

The main goal set for wood processing enterprises today is deep processing of wood, which implies the implementation of a full processing cycle wood material and making new products from it.

There are several ways to process wood:


Chemical processing includes several main areas:

  • paper production at pulp and paper mills;
  • hydrolysis;
  • pyrolysis;
  • production of rosin and turpentine.

Let's look at some processes chemical technology wood processing.

Hydrolysis. Dilute sulfuric acid is added to the crushed mass of waste, after which the mixture is heated in a boiler with steam to a temperature of 180 - 190 o C. During hydrolysis, monosaccharides, methanol, organic acids (acetic and formic), as well as a solid residue - the so-called hydrolytic lignin. The sugar-containing solution is poured out of the boiler, then the acid is neutralized with calcium hydroxide and the sediment is subsequently separated, and the resulting solution is sent to a special vat for fermentation. During the fermentation process, microorganisms transform sugars into alcohol. The result of fermentation is a 1.2 - 1.6% ethanol solution, which is sent for rectification in order to obtain pure alcohol. Ethanol is a raw material from which synthetic rubber, dyes, medicines, plastics, etc. are produced.

Pyrolysis. Wood raw materials decompose in pyrolysis plants in an airless environment at a temperature of 450 o C. As a result of pyrolysis, substances in liquid and gaseous states are obtained, as well as a solid residue - charcoal. The process begins with dividing the mass of wood (waste) into separate pieces, which are then dried. The next stage is the pyrolysis itself. Then the coal part is cooled and stabilized to prevent it from igniting. Next, the resulting vapors are condensed.

Interesting! Pyrolysis became popular already in the 19th century. Then, deciduous trees were used in the process to form the final products (acetic acid).

Nowadays, hardwood components are also mainly used for pyrolysis. For example, the result of the pyrolysis process of birch, the moisture content of which is 10-15%, is the formation of 25% coal, 50% liquid compounds (“liquid”) and approximately 23% gaseous substances.

The charcoal fraction can be sent either to direct customers or to a processing plant in order to obtain any products. The liquid residue of the process is subjected to settling, during which resin accumulates. Acetic acid, methyl alcohol, aldehydes and other valuable products are obtained from it.

The gas mixture formed during pyrolysis consists of carbon oxides, methane and some other hydrocarbons.

Thus, complex wood processing consists of obtaining high-quality solid wood, wood-based materials, wood products for different industries, chemical compounds.

Pay attention! The profession of working with wood is still relevant today. Therefore, in our country there are many educational institutions, which train technology specialists complex processing wood

Processing equipment

Equipment for different branches of production from sawdust and wood waste depends on the specific focus of the business. There are a number of the most common installations required for processing wood raw materials, consisting of:

  • low-speed shredders used to convert wood into chips with a size of 0.8-1 cm;
  • shredders that crush waste different sizes, equipped with special knives for cutting;
  • horizontal shredders;
  • briquetting presses used in the production of fuel briquettes;
  • silos designed for storing, transporting and unloading raw materials.

You can see what the installations included in the deep wood processing line look like in the following short video

Where to take wood waste for recycling

Reception of wood waste is carried out by specialized companies involved in the collection, removal and processing of wood and plant residues. It is most convenient to search for addresses of such organizations via the Internet. As a rule, large wood processing and other enterprises whose activities generate wood waste enter into an agreement with companies to process unnecessary wood residues. You can hand over such waste for money (companies buy raw materials for the purpose of their further processing).

Wood processing as a business

Wood can be used to produce a huge number of products for different areas our life activity. Therefore, processing wood waste as a business (OKVED code 16) is a promising area of ​​entrepreneurship. Let us point out some advantages of such an activity:

  1. The relevance of the business, the absence of fierce competition in the Russian market, the availability of cheap raw material base due to the fact that most of the wood waste in our country is not processed in any way, but simply rots.
  2. Ease of finding distribution channels for finished products, relatively quick payback, despite the high cost of the necessary equipment.

Thus, wood recycling is a great idea for profitable business which, with proper guidance, will be successfully implemented.

Russia is rich in forest resources. Therefore, the topic of wood processing is extremely relevant for our country. Developing business in in this direction Perhaps in the near future we will process almost the entire volume of wood waste into useful and high-quality products without causing damage to our environment.

Wood processing can be classified according to technological and instrumental characteristics as follows:

Sawing, planing, milling, cutting, peeling, debarking, chopping, drilling, gluing, hammering, tenoning, drying, protective impregnation, impregnation that improves properties, protective surface treatment.

The flammable environment in wood machining shops consists of wood, wood waste, oils and lubricants in woodworking machines. When mechanically processing wood, a significant amount of dust and small shavings are released, which are more fire hazardous than compact wood. Wood dust generated during the operation of grinding machines can form explosive and fire-hazardous mixtures with air.

The main sources of ignition in wood machining processes are:

Frictional heat during overheating of fan bearings, conveyors, electric motors of machine tools in case of violation of their lubrication regime, misalignment of shafts and saws, contamination of the surface with dust or wood waste, heating and ignition of drive belts when slipping. Frictional heat can also be a source of ignition when sawing hard wood, the presence of branches in it, overloading and distortion of saws;

Impact sparks, which are formed in the event of a violation of the relative position of moving and stationary parts of mechanisms, as well as in the presence of metal inclusions in the wood: nails, pieces of metal, etc.;

Sparks and electric arcs due to mechanical damage to the insulation of electrical cables connected to the electric motors of machine tools;

Thermal manifestations of faulty electrical equipment, lighting and power networks (short circuits, overloads, high transient resistances), overload of electric motors of machine tools;

Spark discharges of static electricity during the operation of pneumatic transport;

Lightning strikes and its secondary manifestations;

The heat of spontaneous combustion of wood waste impregnated with oil (when it accumulates under machines or is stored for a long time), as well as oil-soaked cleaning materials;

Use of open fire (smoking, hot repair work). The spread of fire in wood machining shops is facilitated by: flammable building structures; wood and wood processing waste; air ducts of ventilation systems; production waste disposal systems, conveyor lines and technological openings.



Specific requirements for ensuring fire safety during mechanical wood processing processes (regulate):

Premises and equipment must be regularly cleaned of dust, shavings, sawdust and oily cleaning materials. The frequency of cleaning dust from high-lying building structures, utilities and lighting fixtures in premises should be determined depending on the time of accumulation of dust in dangerous quantities and in accordance with the workshop instructions on fire safety measures;

Cleaning dust in production premises from building structures, equipment, utilities and lamps should be carried out using explosion-proof industrial vacuum cleaners or special system pneumatic cleaning, and in their absence - in a wet way that does not allow dust. Compressed air is not allowed for cleaning;

To remove waste, woodworking machines must be equipped with working local suction. Operation of machines with the ventilation and pneumatic transport systems turned off is not allowed;

To prevent sedimentation of waste in the air ducts of local suction and pneumatic transport, the speed of air movement during suction is taken to be at least 15 m/s;

In pneumatic transport and aspiration systems, in bunkers, stagnant zones leading to dust deposition must be excluded;

Chip and dust transportation systems must prevent spillage of materials;

The serviceability of electrical equipment and wiring must be monitored; overloading of the electrical equipment of machines is not allowed;

It is necessary to periodically monitor the bearing temperature;

For work, a sharp and properly sharpened one must be used. cutting tool;

Explosion-proof fans must be used in pneumatic transport systems;



To prevent metal objects from entering aspiration and ventilation units that remove flammable substances, air ducts behind local exhausts must be equipped with meshes with a mesh size of 10x10 mm or magnetic traps;

The transmission of motion from the electric motor to the mechanisms must be carried out using V-belts.

Technological processes and equipment of main production

Processes and equipment

To remove fire and explosion hazardous waste (dust, sawdust, shavings, vapors of flammable liquids and gases), local suction must be provided in the process equipment.

Job technological equipment not allowed:

when the ventilation, aspiration and pneumatic transport systems are turned off, to which local suction is connected;

in case of violation of the established operating parameters of these systems;

in the event of a malfunction of ventilation, aspiration and pneumatic transport systems, as well as in the event of a malfunction of any equipment included in these systems (air ducts, fans, cyclones, hoppers, dust collectors, etc.), leading to the formation of explosive steam and dust-air mixtures and the emergence of sources pollution.

Technological equipment intended for mechanical processing, processing and transportation of fire and explosive substances and materials must be equipped with metal detectors or other foreign object catchers. Working with disconnected or faulty metal detectors (catchers) is prohibited.

All types of conveyors must be equipped with automatic devices to turn off the electric motor in case of overload.

When operating conveyors, friction of the side edge of the conveyor belt on wooden structures, slippage, and accumulation of sawdust, dust and other small particles under the belt are not allowed.

When performing manual decanning operations, it is necessary to use fireproof detergents. In exceptional cases, it is allowed to use flammable liquids and flammable liquids if there is a justification drawn up by technologists and approved by the head of the enterprise about the unacceptability of TMS for carrying out specific technological operations.

These operations must be performed in cabinets, shelters, chambers and other devices equipped with local suction.

Hydraulic drives of equipment and machines.

It is prohibited to operate the hydraulic system if the following malfunctions occur:

the appearance of noise, knocking and vibration;

the appearance of external fluid leaks;

damage to measuring instruments and signaling devices.

It is not allowed to tighten bolts, nuts and other connections on a system under pressure and during its operation.

It is prohibited to operate the drive at a temperature and pressure of hydraulic fluid exceeding the values ​​specified established by the instructions manual.

Systems must be equipped with pressure gauges, safety valves and other devices that protect against pressure increases above the value established by the technical documentation.

In hydraulic drives it is necessary to use the working fluid specified in the technical documentation. Mineral oils should be replaced, if possible, with fireproof liquids.

Metal trays should be installed under hydraulic system containers and other possible places of smudges and oil spills.

Refilling of hydraulic equipment and hydraulic drive systems with working fluids must be carried out centrally. When manually refueling, methods should be used to prevent liquid spills and standard containers that meet fire safety requirements.

Refueling of hydraulic drive systems operating outdoors must be done during daylight hours.

Leaks of oils and working fluids in hydraulic drive systems and hydraulic equipment must be eliminated in a timely manner; spilled oils and fluids must be removed immediately.

Technological pipelines of fire and explosive substances,

materials and finished products.

The laying of technological pipelines must be carried out in accordance with the project developed in accordance with the “Instructions for the design of technological steel pipelines Ru up to 10 MPa, SN 527-80” and “General explosion safety rules for explosion-hazardous chemical, petrochemical and oil refining industries” and adopted in the prescribed manner.

The maximum speed of liquids moving through pipelines and flowing into containers is determined from the condition of preventing their dangerous electrification. Calculation of permissible speeds is carried out in accordance with RTM “Permissible speeds of liquid movement through pipelines and outflow into containers (apparatuses, tanks) RTM 6-28-007-78”.

It is prohibited to use flexible hoses (rubber, plastic, etc.) as stationary pipelines.

The use of flexible hoses is permitted to perform unloading and loading operations into railway tanks and other non-standard equipment, as well as to perform auxiliary operations (purge of pipeline sections, removal of exhaust gases and vapors, clearing pipelines of flammable liquid residues, etc.).

The movement of flammable liquids by pressing must be carried out with an inert gas.

Pipelines must be provided with the possibility of purging them with inert gas or other products that prevent the formation of explosive concentrations. The supply of inert gas or other product to process pipelines must be carried out using removable sections of pipelines or flexible hoses, with the installation of shut-off equipment on both sides of the removable section; upon completion of purging, these sections of pipelines or hoses must be removed, and plugs (with tails) must be installed on the shut-off equipment.

In order to protect against static electricity, as well as electrostatic and electromagnetic induction from the secondary effects of lightning, pipelines throughout their entire length must represent a continuous electrical circuit connected to a grounding device. Between pipelines and other extended communications (structure frames, cable sheaths, etc.) in places where they are mutually close by 10 cm or less, metal jumpers should be welded or soldered every 25-30 m.

The flange connections of process pipelines must have protective covers to prevent the jet emission of products when gaskets break.

IN production workshops Pipeline diagrams must be posted indicating the location of valves that shut off the supply of products in case of fire, as well as instructions for their safe operation, including methods for cleaning the internal surfaces of pipelines, and repairs.

Carrying out any repair work on pipelines filled with these products is not permitted.

It is prohibited to leave valves open on idle pipelines. Idle pipelines must be disconnected from existing communications and pipelines with plugs.

The installation and removal of plugs on pipelines must be noted in a log signed by the person who installed or removed the plug. All plugs must be numbered and rated for the required pressure.

On all taps, the position of the plug must be clearly indicated by a line sawed through the end part and painted white.

Ventilation, aspiration and pneumatic transport.

The design and material of fans and other devices of ventilation, aspiration and pneumatic transport installations * for rooms where the air contains flammable gases, vapors or dust must exclude sparking. Fans of aspiration installations designed to remove wood dust and fibers formed during the refining of paint and varnish coatings, must be explosion-proof or spark-proof.

Ventilation and pneumatic transport air ducts must have devices for periodic cleaning (hatches, dismountable joints, etc.).

At places where fire barriers intersect, air ducts of ventilation units must be equipped with automatic fire-retarding devices (dampers, valves).

Installations serving fire and explosion hazardous premises must have remote devices to turn them off in case of fire or accidents in accordance with the requirements specifically specified for each room.

Fan impeller blades must not have dents, bends, or tears, and the impellers must be balanced and not interfere with the shrouds.

It is prohibited to operate the units if any of their equipment, air ducts, devices and elements are faulty, as well as if the fan drive belts are slipping and the units are overloaded.

Switching on supply and general exchange exhaust ventilation units serving rooms in which the formation of explosive steam and gas-air mixtures is possible must be done 10-15 minutes before the start, and turning them off 10-15 minutes after the end of operation of the process equipment.

Activation of local exhaust ventilation and pneumatic transport systems must precede commissioning production equipment. They are turned on 3-5 minutes after the end of operation of machines, machines, and devices.

It is prohibited to connect more receivers to the installations than provided for by the design.

In the event of a fire, ventilation must be turned off immediately, with the exception of installations designed to supply air to the airlocks of premises of production categories A and B, as well as ventilation installations serving hardening chambers in the production of fiberboards.

Internal surfaces, air ducts of local suction units and fans should be cleaned as they become dirty, but at least once a month. The separators of spray booths and booths should also be cleaned as they become dirty, but no less than after 160 hours of operation. It is prohibited to clean separators in the workshop:

To prevent the entry of random objects into aspiration pneumatic transport units that remove flammable substances, air ducts behind local suction outlets must be equipped with meshes.

Operation and maintenance of installations must be carried out in compliance with the requirements of the all-Union rules for the operation of gas purification installations, and conditions that exclude the possibility of the emergence of ignition sources and initiation of an explosion.

Installations that remove wood dust from grinding, calibrating and calibrating grinding machines, dust from machines for grinding paint coatings, dust and fabric fibers from machines for polishing paint coatings must be aerodynamically separated from installations for other purposes and from each other, those. must have independent air duct networks, separate collectors, dust collection equipment and bunkers.

In installations designed to remove wood dust or dust and fibers formed during the refining of paint and varnish coatings, dust (fibers) are collected in dust collection equipment before the aspiration air enters the fan.

Dust collection equipment, bunkers; sludge settling chambers and other components (elements) of installations must be fire and explosion proof.

Dust collectors and bunkers for the discharge and short-term storage of production waste must be located outside production buildings (on the territory of the enterprise).

Cyclones, bins (for dry chips and explosive dusts), bag filters, pipelines of pneumatic transport systems and external sections of air ducts of installations using the dry method of air purification from explosive dusts and fibers must be equipped with emergency pressure relief devices (safety membranes, anti-explosion valves).

Air ducts of installations must be made of non-combustible materials.

Air duct routes should be laid within the floor where technological processes associated with the formation of combustible dusts (fibers) are carried out.

It is prohibited to place air ducts of aspiration units in basements and basement floors, technical undergrounds and underground ducts.

Gates for alternating connection of process equipment to installations, valves, hatches on air ducts and other devices with moving elements must be made of materials that do not create sparks upon collision (friction) that can be sources of ignition or initiate an explosion.

These devices must be easy to open and close, and also be fixed in a given position.

Aspiration and pneumatic conveying installations must be equipped with devices for removing static electricity.

Electrical equipment of installations, as well as control and measuring instruments used during operation, must comply with the requirements of the Electrical Installation Rules and environmental conditions.

The placement of cyclones and installation bunkers, as well as fans, on the territory of the enterprise must comply with the fire safety requirements of building codes and regulations.

The procedure and methods for complying with explosion and fire safety requirements during operation and maintenance of installations must be specified in the instructions on fire safety measures or in the instructions for operation and maintenance of installations.

Personnel involved in the operation and maintenance of installations are obliged to carry out scheduled checks, preventive inspections and cleaning of equipment, air ducts, as well as all devices and elements of these installations and take measures to eliminate malfunctions that may cause the occurrence and spread of a fire or explosion.

Checking, preventive inspection and cleaning of equipment, air ducts, as well as all devices and elements of installations from flammable deposits must be carried out according to the approved schedule.

Results of checks, inspections, cleaning work, detected faults and measures taken must be recorded in plant operation and maintenance logs. The logs should record the dates of the specified work and the names of those who performed the work.

Repairs and cleaning of installations must be carried out in the presence of a responsible person, in ways that exclude the possibility of fire and explosion.

During the operation of installations, it is necessary to carry out constant monitoring in order to:

1) identifying and eliminating leaks in air ducts and places of their connection to equipment, especially in the discharge sections of air ducts of pneumatic conveying units;

2) checking the performance of metal detectors;

3) checking the operation of blocking devices, as well as the condition of emergency pressure relief devices.

Bin gates should be opened only for the period of unloading production waste from them. The waste collected in them must be removed in a timely manner. It is impossible to overload cyclones and pollute the area where they are located with production waste.

Protection against static electricity.

Protection against static electricity * must be carried out in accordance with the requirements of regulatory documents and guidance materials specified in Appendix 2 and the relevant sections of these rules.

Each enterprise should make a list technological processes, equipment, structures, installations and utilities that require protection from static electricity. The list must indicate the protective equipment used.

A list of technological processes, equipment, structures, installations and utilities that require protection from static electricity must be compiled by technological enterprises and periodically updated.

Means of protection against static electricity must comply with the requirements of regulatory documents and be in good condition.

Specialized wheeled trackless vehicles intended for transporting flammable liquids, as well as separate containers for transporting such liquids installed on vehicles, must be grounded.

During the operation of static electricity protection equipment, it is necessary to ensure constant monitoring of their serviceability, as well as compliance by maintenance personnel with operating instructions and maintaining operational logs.

To remove charges of static electricity that accumulate on people, especially when performing certain manual operations (washing, cleaning, wiping, gluing) using non-electrically conductive substances, it is necessary:

provide for the installation of floors with increased electrical conductivity or electrically conductive grounded zones, platforms and work platforms, grounding of door handles, handles of devices, machines, apparatus;

provide those working in these premises with special clothing and special shoes in accordance with current regulations;

Avoid wearing clothes made of synthetic materials (nylon, perlon, etc.) and silk, which contribute to electrification, as well as rings and bracelets that accumulate static electricity charges.

Electrical installations.

When installing and operating electrical installations, the requirements of PUE, PTB and PTE must be observed.

The construction and operation of temporary electrical networks is not permitted. An exception may be temporary illumination installations made with a hose cable.

After replacing burnt-out electric lamps in industrial premises of explosive and fire hazardous categories, the level of explosion protection and (or) degree of protection of the lamps must be ensured depending on the class of the explosive and fire hazardous zone established by the facility.

Malfunctions in electrical networks and electrical equipment that can cause sparking, short circuits, or excessive heating of the flammable insulation of cables and wires must be immediately eliminated by the personnel on duty. The faulty electrical network should be disconnected.

In switchgears, cables should be equipped with tags indicating the brand, voltage, core cross-section, number or name of the connected consumer.

During operation of ballasts, electrical panels and cabinets, it is necessary to constantly monitor their serviceability and sealing. Storing foreign objects in cabinets and panels is prohibited.

During operation of luminaires, constant monitoring of their serviceability must be carried out. The operation of faulty lamps is prohibited.

Electric heating devices may be used only in exceptional cases in specially designated isolated rooms that do not belong to categories “A” and “B”, if it is impossible to replace this heating method with another. Such cases may include the use of electric heating devices in first aid stations, laboratories, etc., as well as for technological purposes (glue dispensers, electrically heated clamps, etc.) in woodworking shops in the manner provided for in paragraphs. 3.1.6.9 and 3.1.6.10.

The use of household electric boilers in production warehouses and administrative premises is prohibited.

The use of electric heating devices intended for performing technological operations or repairing parts is permitted in cases where this is provided for in the technological documentation approved by the chief engineer.

The use of electric heating devices in all cases must be formalized with written permission from the fire department and the person responsible for the operation of electrical equipment.

Electric heating devices must have closed electric heating elements, be installed on a fireproof base and be under constant supervision.

Electric heating devices intended for technological purposes must be equipped with indicator lamps indicating that the voltage is turned on.

After finishing work, it is necessary to turn off electrical equipment (with the exception of emergency lighting) in all buildings and premises.

Lighting of the enterprise territory, as a rule, should be carried out with xenon lamps or floodlights installed on masts.

Installation of floodlights on the roofs of buildings with roofs made of flammable materials is prohibited.

During the operation of electrified mechanisms and portable electrical equipment, measures should be taken to protect their cables from mechanical damage.

Operation of mobile electrified mechanisms in the event of a faulty electrical equipment, lack of protective equipment and grounding of the power cable is prohibited.

Each enterprise must have an executive diagram of external and internal electrical networks and electrical installations.

Evacuation lighting networks must be connected to power sources independent of the main network or automatically switch to independent power sources when the main sources are turned off. These networks must not have plug sockets.

Protection of electric motors subject to overloads for technological reasons must comply with the requirements of the PUE.