Shoe production: what equipment is needed + shoe manufacturing technology - 9 main stages. What you need to organize the work of shoe production: raw materials, premises, personnel + detailed financial calculations.

Capital investment (factory): from 150,000,000 rubles.
Payback period for footwear production: 3.5 - 4 years.

The Russian market is full of goods that are produced all over the world, but the situation is not so good with domestic producers.

Most likely, this is due to the fact that countries like China produce a large number of products for every taste.

Yes, it's not very high quality. However, its prices are quite low, while well-known foreign brands of high quality have a correspondingly high cost.

One such industry is footwear production. This type of activity is also not particularly developed in the Russian Federation.

Therefore, we can assume that if you create an excellent product offer on the territory of Russia, then demand will also appear.

This business is not for everyone.

You need to be a person who understands all the subtleties of the tailor profession. Also have experience in tailoring, repairing or manufacturing shoes.

Even if you yourself do not plan to work, but only to manage, such experience will help determine what may be needed for production.

What format to choose for the production of shoes?

To summarize, we can distinguish two formats for the production of shoes:

• a small place where the master sews shoes to order or for retail sale;
• full-scale production, factory.

The first option is chosen when there are no funds for the arrangement of a large enterprise with a factory building and a large staff.

In this case, you can try to open a small boutique with designer shoes.

But to reveal all the possibilities, if available, both for a novice entrepreneur and for an experienced businessman, will allow the option with a shoe factory.

The cardinal difference is that in the case of a large production, it is necessary to focus on its mass character, the speed of release of new models and accessibility for the masses.

And in the case of a private boutique, the main task is the production of exclusive models with individual design, as well as the highest quality.

Another point on which the shoe production format differs is its style. It is necessary to diametrically separate the sports and classic format.

If there are no particularly complex differences in the technology of sewing summer sandals and winter boots, then sneakers are a completely different type of product, the production of which requires different knowledge, technology and equipment.

Basic equipment for the production of shoes - what is needed?

Regardless of the size and purpose of a shoe factory, it is clear that without sewing machine can't get by.

Already delving into the nuances of production, we can emphasize the fact that the standard model will not work when working with leather and other hard materials.

	Detailed list and estimated costs (rub.):
	1) transition bending machine and the edges of some parts - 640,000 rubles. 2) setting to create a form the bow of the boot (or shoe) - 450,000 rubles. 3) special press for the manufacture of insoles - 295,000 rubles. 4) grinding equipment edges of the insole - 235,000 rubles. 5) installation that lowers the edges of the parts products in order to make them more convenient to sew in the future - 230,000 rubles. Total: from 1,850,000 rubles
Optional equipment, required for large scale production (in order to significantly speed up the manufacturing process)	1) special installation that will attach some parts with glue - 460,000 rubles. 2) equipment that will put a stamp on each pair, to give it an ID. room - RUB 355,000 3) installations that will fasten the upper part of the shoe and the sole RUB 355,000 4) production conveyor - 465,000 rubles. 5) a cutter for dividing the material into parts, of which will consist the upper part of the shoe - 335,000 rubles. Total: from 1,970,000 rubles
For finishing products will need equipment, which will perform such functions	1) tightening - 240,000 rubles. 2) moisturizing - 155,000 rubles. 3) drying - 550,000 rubles. 4) cooling - 445,000 rubles. 5) thermal activation of adhesive layers - 240 000 rub. 6) removal of pads - 225,000 rubles. 7) smoothing the shin area - 140 000 rub. 8) final cleaning and polishing finished shoes - 130,000 rubles. Total: from 2,125,000 rubles

In most cases, you may need additional equipment, the choice of which will be determined by the characteristics of production. This is due to the desire to innovate even in such a familiar industry as the production of shoes.

Well-known brands are especially active in this.

Notable examples are Geox's "breathable shoes" and Reebok's "Easy Tone" soles (which, according to the ads, help tone the butt muscles).

9 stages of shoe manufacturing technology

As with any sewing process, it all starts with a pattern.

If we consider an example in which we have already finished processed leather or other material of the color we need, then the next step will be the manufacture of parts.

These components are cut out with the help of special cutters according to a pre-prepared stencil of the future product.

To make one shoe, on average, you need to divide a piece of material into 20 or more parts. But it all depends on the complexity of the idea of ​​this model.

The next step will be shoe insole shaping.

This is done with the help of special equipment - a press.

This apparatus, using a strong compression method, connects several layers of different materials, and gives a certain shape and curves to the shoe insole.

1. Farther markings are applied where and how the connecting seams will pass.
2. The edges of the parts are fired and polished in order to make them thinner and more suitable for further stitching.
3. Seamstresses start sewing, which give the workpiece the shape of future shoes.
4. Thereafter plates are attached, which give the shoe the ability to remain in its original form, without losing shape under the influence of temperatures.

The last step in manufacturing is connection of the workpiece with the sole.

The sole itself is made in a special oven, after which it is processed and cut off all unnecessary.

After connecting with the sole, finished model being polished.

This is done with the help of sheep wool and a special wagon for shoes.

5. The process of tightening the laces into the finished product always done manually.

What raw materials may be needed for the production of shoes, and where is it best to take it?

Since we are still talking about the production of good and high-quality shoes, natural leather is considered to be the main material for its production.

It is not necessary to contact foreign companies for the supply of high-quality material, since half of the cost will be only delivery, and customs expenses and.

Throughout Russia, there are many enterprises that offer material for the manufacture of shoes. You can refer to such as:

1. "Ronnon" - Moscow ( https://www.ronnontk.ru/leather)
2. "Ostashkovsky plant" - Tver region ( www.okz.ru)
3. "Russian skin" - Ryazan ( https://www.leather.ru/ru)
4. "Kirov Tannery Arteks" - Kirov ( www.arteks.su)

And it's far from full list all factories in Russia for the production of leather.

Chemical production materials will also be needed for further processing of this skin. Chemical treatment means various liquids, creams, oils etc.

For processing shoe soles, you may also need liquid polyurethanes. All this can be ordered from local chemical plants. Again, there are more than enough of them on the territory of Russia.

Packing material most often ordered from companies that manufacture custom-made packaging. Most often, the larger the order, the cheaper the unit.

How to choose the right room?

Space for small production.

If we are talking about mini-production, you can get by with a small room.

Some of the equipment that will be needed for conveyor production is not needed in this case, since half of the work will be done manually.

Also, as a rule, in the production of this format there is no need for a large number of personnel.

Based on these data, it can be determined: you need a room with a small area.

But General requirements to production remain unchanged, regardless of its volume:

• the presence of a gas pipeline;
• plumbing installed;
• availability of telephone lines;
• the electrical wire is able to withstand the load corresponding to the features of production;
• heating and thermal insulation are also important, since the storage of material for manufacturing requires a certain temperature regime.

Nowadays, quite often there are workshop points where the store itself is located in the same building with.

This makes it possible to save on rent and sell products on the spot.

A place for a shoe factory.

In the case of a large-scale shoe-making workshop, it is obvious that it is better to choose a factory room in the industrial zone of the city.

Usually, the cost of renting or buying a building in this part of the city is not that high.

If all the necessary areas are included (office department, manufacturing, tailoring and processing workshops, staff room and warehouse), an area of ​​\u200b\u200babout 7,000 square meters will be required. m.

How to organize work in a shoe shop?

Selection of personnel for the mini-production of shoes.

For a small trade + production point, in fact, one person is quite enough. But for greater convenience it is better to separate administrative work and the process of creating a product.

Ideally, you need at least one more administration representative(for example, manager or salesman, if the production is located in the same room as the store), designer(since we are talking about designer shoes), cutter and seamstress in one person, and master who will take care of all the installation and similar work.

Shoe factory staff.

For the operation of a full-fledged shoe production, in addition to a sufficient amount of equipment, it is necessary to hire a fairly large staff.

In general, about 150 people are needed to work in production (based on the fact that they will work in two shifts). And we are only talking about workers in the sewing and other workshops!

There will also be enough administrative staff, as well as warehouse workers. But, again, it all depends on the characteristics of the enterprise.

Each manager determines the exact amount himself, depending on the scale of what volume he is interested in.

Sales and sales of shoes

You can sell shoes both through and with the help of various showrooms and boutiques that sell various brands.

The second option is much more profitable - there is no need to pay for the rental of premises, wages, etc.

All that is needed is to simply provide the goods to the store for sale, set a certain amount per unit, depending on the model. The mark-up that the store sets, its owners can take for themselves.

In fact, there are many methods for selling shoes: from a point in the market to a large gallery in mall. But the method indicated above is considered the most profitable.

Capital for the organization of shoe production. Profitability.

In the case of a small point of production and sale, it is difficult to calculate the costs.

We can definitely say only that this business will pay off faster than factory production. Already in the first year of work, all initial costs should pay off, after which the company will begin to make a profit.

If not, this will be a sign that you need to change the strategy.

In the case of a large workshop for the mass production of shoes, approximate figures can be given - from 150,000,000 rubles.

This amount includes the cost of not only equipment for the production of shoes, but also rent, wages, utilities.

Item of expenses	Amount (rub.)
Total:	from 150,000,000 rubles
Business registration	5 000 000
Premises rent (year)	From 25,000,000 (7,000 sq. m. in the Moscow region)
Utilities (year)	10 000 000
Compensation (for approximately 150 employees)	From 3 000 000 / month From 36,000,000 / year
Equipment for the production of	From 5 945 000
Raw materials (material for manufacturing)	25 000 000 /year
Freight transportation	2 000 000 /year
Rental of premises for the sale of shoes (about 5 pcs.)	30 000 000 /year
Other expenses (troubleshooting, advertising, events)	11,000,000 / year

If we take into account the average indicators of domestic production, then the profitability of such a business (on a large scale) will be about 48-50%.

It can fully pay off in 3.5-4 years of work.

The development of this production is impossible without knowledge of all the nuances of the industry.

How is the shoe made? All manufacturing steps are shown in the video:

Conclusion on how to start the production of shoes and what is needed for this?

Taking into account all the above, we conclude: footwear production large scale is not so suitable for entrepreneurs who are not ready for such huge costs, and also do not have the opportunity to wait for payback for such a long time, since they do not need large scale equipment for the production of shoes.

However, it is always possible to start with a smaller business, but in this case, you can expect success only if you have really fresh and interesting ideas.

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Dmitry Mezentsev

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Russian shoe manufacturers are on the list of 350 factories and shoe factories. Major brands and new brands. Catalog 2020: official websites, addresses, contacts and prices of manufacturers. Suppliers of shoes of our own production are reliable wholesale partners. Become a dealer, order a price list!

Leading domestic shoe manufacturers present a worthy assortment - you will be convinced of this by viewing the catalog at the online exhibition. For several consecutive years, footwear production in Russia has shown growth of up to 10%.

Factory shoes of Russian manufacturers are more often interested in buyers in stores, they prefer recognizable brands and time-tested quality and evaluate new companies in the shoe market. Shoes that cannot last even one season are no longer of interest to buyers, even at cheap prices.

In Russia they introduce government programs growth in domestic footwear manufacturing and recovery of the sector. Investments are being made in the development of the shoe industry, and shoes imported from abroad are subject to additional duties.

Nevertheless, the share of shoes from foreign manufacturers remains significant, it is still difficult to find and buy wholesale shoes from Russian factories, especially sneakers and fashionable high-heeled women's shoes. Although measures to restore the footwear sector of the industry are yielding results. In addition, when choosing between goods of the same quality and price of a domestic and foreign brand, buyers give their choice in favor of Russian manufacturers.

special success Russian companies managed to achieve in the production of children's and winter shoes. Factories of children's shoes, as a rule, pay more attention to the safety of materials and the reliability of accessories.

At the online exhibition, there is a catalog of only Russian shoe manufacturers that produce products on the territory of the Russian Federation. Now it is easy to buy shoes from Russian manufacturers - just select the company you are interested in from the list and contact it - the published contacts belong to the manufacturer.

Manufacturers are looking for wholesale clients, dealers, corporate customers, shoe stores for uninterrupted supply of products, including for export.

Shoe factories are light industry enterprises that produce shoes - mass and everyday products that protect feet from external influences and perform utilitarian and aesthetic functions.

The process of modern production of footwear for the mass consumer includes a large number of operations: cutting material, processing cut parts, assembling upper parts into a blank, obtaining finished product by assembling blanks for the top and bottom parts.

The general scheme of the technological process used in shoe factories is as follows: the material assembled in the warehouse is fed for cutting, the cut parts are pre-processed and enter the blank department for fastening the upper parts into the blank. Then getting into the assembly department, the upper blank is molded on the last, after which the insole is attached to the molded upper, the sole and the heel are attached.

Shoe production is a mechanized industry, but in Lately significant changes have taken place in the technological process due to the introduction of automation, chemicalization and new forms of labor organization. The low-operational technology used in shoe production is based on the introduction of automated machines and units that perform several operations: machines for automatic processing of flat soles, semi-automatic sewing machines, injection molding machines, hot vulcanization presses. For optimal placement of templates during cutting, program-controlled equipment is used. For welding parts made of synthetic materials, high-frequency currents (HF) are used.

Classification features finished products shoe factories are diverse:

• by purpose: household, sports, special (working, uniform, protective) footwear, medical;
• according to gender and age, small children's, children's, school, boys', women's, men's shoes are distinguished;
• by type of design: shoes, low shoes, boots, boots;
• according to the upper material: chrome, yuft shoes, made of synthetic and artificial leather, textile, combined, solid, shoes made of polymer materials;
• bottom material: rubber, polymers, thermoplastic elastomers;
• according to the methods of attaching the bottom, shoes are pierced, doppelny, nailed, glued, molded, hot vulcanized, combined, etc .;
• by production methods: shoes made by machine or by hand;
• by the nature of production: model (smart) and mass (everyday);
• according to the season of socks: summer, autumn-spring, winter.

Each Russian on average purchases 2.6 pairs of shoes per year (residents of the US and Europe - 4.5-6.5 pairs). Shoe factories in Russia provide 10% of demand in the domestic market. The net profitability of Russian shoe production is 15%. The share of imported materials in the production of Russian footwear is about 40%. The annual growth of the domestic footwear market is 4-5%.

The main problems of the Russian footwear industry are low customs duties on imported shoes and a high share (up to 40%) of contraband and counterfeit products on the Russian shoe market.

The stereotype that domestically produced shoes are significantly inferior in design and quality to imported samples was formed in the minds of our citizens back in the Soviet years. However, due to the well-known events that led to the growth of the foreign exchange rate, the cost of foreign shoes increased, and the eyes of even the most hardened fashionistas and fashionistas turned towards domestic manufacturers. A small private shoe factory opened in a small Russian town is a business that has excellent potential and can become quite profitable. We recommend that beginners and experienced entrepreneurs look at our business plan for the production of shoes with calculations in order to draw a conclusion for themselves about the feasibility of this undertaking in a particular region of the Russian Federation.

Starting investments in the opening of their own shoe factory will amount to 800 thousand rubles. The amount is relatively small - it can be taken on credit or from the personal savings of a businessman (if any).

Concept summary

The first step that an entrepreneur has to take in order to put his business on official "rails" is the registration of an individual entrepreneur. An example of a business plan for the organization of shoe production, which is described here, a priori implies this particular legal form of business. As for the taxation system, the standard "simplification" with a tax rate of 15% of the difference between income and expenses for the reporting period will be the best choice.

So that subsequently the inspection bodies do not have "unnecessary" questions, the entrepreneur needs to carefully approach the choice of OKVED codes. The following codes are suitable for registering a shoe manufacturing business:

• 15.20.1 "Manufacture of footwear, except for sports, protective and orthopedic."
• 15.20.5 "Tailoring of shoes and various accessories for shoes by individual order of the population."

The process of making shoes consists of several successive stages, relatively simple technologically, but requiring attention and well-developed skills from production workers:

• Production of blanks from pig or calf skin. The number of parts in one pair of shoes can be quite large.
• Pressing blanks to give them the desired shape.
• Cutting insoles and making additional elements of a pair of shoes from other materials.
• Marking blanks, including manual drawing of seam lines.
• Stitching the finished model and firing it in a special oven so that the shoes do not subsequently lose their original shape.

An important point: the range model range a private shoe factory largely depends on the professionalism of the craftsmen who work on the blanks. The more experienced the master shoemaker, the more complex models he can make.

How much to invest in opening

The costs of starting a shoe manufacturing business in a provincial Russian city are shown in the following table:

The table shows that the main cost items at the initial stage of business development will be the purchase of equipment and the purchase of the first batch of production materials. Moreover, one should not immediately purchase a large batch of materials, since the demand for shoes will initially be unstable, and stale leather may lose its properties. Equipment for the production line can be purchased second-hand from domestic manufacturers. Its cost will be significantly lower, and the quality is quite acceptable for many years of uninterrupted service.

Marketing plan

So that the costs of opening a shoe production pay off in as soon as possible, the entrepreneur should conduct a competent marketing policy. The template of the most successful marketing plan is presented below:

• Placement of modular ads in the most significant print media in the region.
• Outdoor advertising in the form of several bright banners in crowded places in the city.
• Creation of a website for a shoe factory with creative information about products and stores where they can be purchased.
• Development of informative presentations for wholesale and retail potential buyers.
• Establishing direct contacts with suppliers of materials and buyers.

It is understood that on early stages development in the shoe production workshop, an average of 1,000 pairs of different shoes per month will be produced. The average selling price of a pair will be 500 rubles. It is easy to calculate that in this case the monthly income from the work of the shoe shop will be 500 thousand rubles. In a year, shoe production will bring its owner up to 6 million rubles in revenue.

Production plan

To accommodate a shoe production workshop, you will need to rent a room with an area of ​​​​100 square meters. Most of the usable area of ​​the workshop (about 90 square meters) will be occupied by the production line. The remaining 10 sq. meters - a warehouse of finished products and materials. It is mandatory to install a fire alarm, as the production of shoes is associated with an increased fire hazard. It also doesn't hurt to install a burglar alarm.

The optimal variant of the work schedule for the shoe shop is as follows:

• Monday - Friday from 08:00 to 18:00.
• Saturday from 10:00 to 15:00.
• Sunday is a day off.

This table shows a list of employees in the shoe industry and the estimated amount of their salaries:

№	Position	Number of people	Salary, rub.	Monthly payment fund, rub.	Payment per year, rub.
1	Production director	1	30 000	30 000	360 000
2	Technologist on the production line	2	20 000	40 000	480 000
3	Equipment adjuster	1	15 000	15 000	180 000
4	shoemaker	3	20 000	60 000	720 000
5	Sales manager	1	25 000	25 000	300 000
6	loader worker	2	10 000	20 000	240 000
TOTAL				190 000	2 280 000

Calculations of income and expenses

The following table lists the articles running costs private footwear factory:

Profitability of a private shoe factory opened in small town with a population of up to 300 thousand people, is calculated in the following table:

The above calculations show that the net profit of the footwear business, after tax, will be 1.5 million rubles. The monthly net profit will be at the level of 125 thousand rubles. Accordingly, the profitability of a private shoe factory will be 25%, and this is a relatively average figure. The full payback of investments in shoe production will come in just six months.

Possible risks

The organization of a private shoe factory in a small town is a rather risky undertaking, starting to implement which a businessman must first carefully weigh the pros and cons. The most likely risk factors in this business the following:

• Interruptions in the supply of materials for the manufacture of shoes (leather, rubber, fabric).
• The emergence of competitors, including those importing shoes from the CIS countries.
• Falling demand for Russian-made shoes due to an increase in the supply of imported shoes from Europe.
• Increase in purchase prices for materials used in shoe production.

The above risk factors can have a very adverse effect on the stability of the shoe industry. However, if an entrepreneur develops a set of measures to counteract these risks in advance, he will significantly mitigate their negative sides.