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An entrepreneur considering the production of shoes as a business idea must be prepared for serious investments and the need to carefully study all the nuances of the industry. In addition, the segment is highly competitive. And if it is quite easy to compete with domestic factories, then to ensure the same high quality as that of European manufacturers, you will have to try. On the other hand, Chinese suppliers, who are not particularly striving for high performance characteristics of goods, offer the lowest possible prices, can become a serious problem.

Features of this business

Footwear production is a costly and complex type of business in terms of organization. In addition, the entrepreneur must understand the technologies and types of products. Otherwise, it is impossible to create a product that can compete with a huge number of domestic and foreign brands. However, new manufacturers are constantly entering the market. So, if you have original ideas and a carefully thought-out strategy, there is every chance of success.

To do this, you need to decide what kind of shoes to produce. Traditionally, it is divided into women's, men's and children's for everyday wear. Here the competition is the highest, and the leading positions are occupied by Chinese suppliers of inexpensive goods. That is why many novice shoe manufacturers from Russia immediately go into narrower segments - the manufacture of shoes for the military, athletes, dancers, representatives of various professions, orthopedic, etc.

There are a number of factors to consider when choosing a niche. For example, women's fashion and sports shoes have a high cost, and also require the organization of high-tech and expensive production. In the case of the manufacture of rubber boots and beach slippers, the starting costs will be much lower. On the other hand, any investment can be justified if the target audience is correctly defined, the design is developed and brand promotion activities are competently carried out. By the way, entrepreneurs who managed to create an original solution and promote it on the principle of viral content are often the most successful.

Another component of success is the ability to follow fashion trends. Even excellent quality shoes will not be sold in volumes that a new product from a well-known brand can claim. At the same time, do not forget about branding - products should be easily recognizable among the "neighbors" on the shelves.

Raw material

Quality shoes can only be obtained from quality raw materials. Accordingly, you will need to find bona fide suppliers and sign a cooperation agreement. What raw materials are required depends on the type of footwear produced. Good leather is essential for leather models. Manufacturers of this material can be searched both in Russia and abroad. The choice is largely determined by the planned production volumes. Minimum order major suppliers, as a rule, is at least one ton of leather. But you can establish contacts with small factories and buy 300-500 kg. You can familiarize yourself with the list of leather industries in the Russian Federation, their prices and specifics.

You will also need accessories, dyes, liquid polyurethanes, reagents, creams, oils and others. expendable materials.

Don't forget about packaging. Shoes are sold in boxes wrapped in paper. You can order such containers at the nearest factory of the corresponding specialization. At the same time, the main thing is to think over the design of the boxes - different for different models.

Manufacture of leather shoes

Equipment for the production of

Today, in the profile market, there are many manufacturers of the most diverse shoe of all varieties, and its list is quite impressive. In addition to the industrial conveyor, mechanisms and devices are used that perform certain operations.

For cutting, special machines are used. Hydraulic cutting presses are used, as well as automatic cutting systems. These machines need special cutters (stamps), the manufacture of which is individually for a specific shoe model. But this is justified only for industries with a large turnover. For small batches, it is more expedient to use manual legs complete with tables, cutting plates, punches, etc.

The main cutting equipment includes:

• splitting machines and machines;
• punching press;
• machines for turning leather, lowering edges and rolling backs;
• embossing press;
• guillotine for small parts of the skin.

The subsequent stages of production will require equipment of various functional purposes. These are machines for the formation of various components of finished shoes - soles, insoles, heels. Apply:

• skin peeling machines;
• machines that produce the edges of the skin;
• presses duplicating additional lining material to increase wear time and improve the quality of shoes;
• gluing machines facilitate the work of gluing ribbons and soles;
• a machine that bends the edges of the material and cuts off the excess;
• equipment for working with different types braids;
• equipment for the volumetric formation of a stripe on the toe (socks);
• presses that produce embossing and die-cutting of the upper layer of material for making decorative elements, drawings, ornaments;
• machines for fastening shoe accessories.

The sewing process takes place using industrial shoe sewing machines, which must perform various functions. A full work cycle will require five sewing machines:

• Flat - for the assembly of non-voluminous blanks;
• Core - for the assembly of bulk workpieces;
• For flashing the lining - a zigzag machine;
• Heavy machine class - for sewing decorative seams, edges;
• Repair.

Shoe equipment is divided according to its main purpose:

• moisturizing the heel to give it the necessary elasticity;
• pasting the back into the workpiece and tightening - the formation of the entire heel part;
• tightening the sock on the block;
• lining processing;
• leg tightening;
• steam finishing and firing of threads with a hairdryer;
• sock moisturizing;
• smoothing defects with steam;
• cooling with refrigerator compartment;
• spraying glue;
• gluing the back seam;
• near the top layer of material;
• fixing the insole to the block;
• sole pressing;
• heel attachment.

The following equipment is required for the final production processes:

• Polishing machine with a rotating shaft and brushes (finisher);
• Device for the formation of the shaft;
• Chamber for painting and applying waterproof components;
• Sole gluing equipment.

Production technology

The process of making shoes from leather, suede and their substitutes is quite complicated. It includes a number of operations:

1. Cutting. At this stage, details are cut out of the material. It may take about 30 or more pieces to make one shoe or boot.
2. Insole manufacturing. In some cases, it is more profitable to work with ready-made insoles from a third-party manufacturer. If you decide to establish your own production, you will need to buy a number of units.
3. Marking blanks. Marks are applied to the cut parts, along which seams will be made at the next stage. Next, the edges are fired, painted and polished.
4. Sewing. The parts are sewn in a certain sequence, then thermoplastic inserts are placed in the blanks, for which the pairs are laced up and placed on a metal foot heated to 150 ° C, which is then quickly cooled to -20 ° C.
5. Product assembly. The blanks are placed on a ruffler, where they are straightened and cleaned of possible contaminants. Semi-finished products are sent to a special oven with a temperature of 60 ° C, and then the excess is cut off at the edges. After the sole is glued or sewn to the top of the product.
6. Polishing and lacing. At the final stage, the shoes are polished with sheep's wool smeared with wax and laced by hand.

The footwear production technology is quite complex and requires an extensive fleet of equipment. In general, it is not possible to determine its cost and composition, since everything depends on the type and volume of manufactured products. You can get a general idea of ​​\u200b\u200bprices and assortment on thematic sites, for example, on Tiu.ru. The lines of European manufacturers such as Durkopp Adler, FAV, Gilardi, Camoga enjoy a good reputation.

How shoes are made self made masters of their craft:

Production of felt shoes

On an industrial scale, felt boots and other felt products are made from semi-coarse sheep wool, which is purchased from sheep farms. On the territory of the Russian Federation, most of them are concentrated in the Volgograd region. You can also buy wool in Kazakhstan, Uzbekistan, etc.

After delivery to production, raw materials are checked for quality, sorted and placed in trunks. At the first stage, the wool undergoes a special treatment, after which it is aged for 24 hours and transferred to long-needle carding machines. The resulting fibers are loosened on scutching and carding machines. Next, the semi-finished product undergoes chemical treatment and is sent for compaction, as a result of which a thick and soft fabric is obtained, from which various felt products are subsequently obtained.

Felt boots themselves can be made both manually and industrially. The canvas is once again tested for quality and placed in a sculpting machine, where, under the influence of heated water and mechanical factors, the final rolling is performed. To reduce the cycle time can be used sulphuric acid, however, due to its danger to the health of personnel, this method is rarely used.

After the felt boots are rolled again, doused with steam and dried at a temperature of about 100 ° C, cut off and fed for cleaning. Ready felt shoes are put into pairs, insoles are put in, packed and sent to the warehouse. If necessary, at the same stage, the products are decorated with embroidery, appliqués or in another way. There are also models with a rubberized sole, which is “applied” by the vulcanization method.

To open a small workshop for making felt boots, you will need to buy a carding machine (about 150 thousand rubles), a steam press (about 30 thousand rubles), a washing machine (90-100 thousand rubles), weighing equipment (10-12 thousand . rub.). 2-3 people are enough to service the workshop.

Large-scale production will require more substantial investments. A set of equipment with a capacity of 50-70 pairs of felt boots per shift will cost 800 thousand - 1 million rubles. An embroidery machine and a sole vulcanizer may also be required.

The above equipment makes it possible to produce felt boots of different colors and models. Additional income can be obtained by producing decorative items made of felt, shoes for fishing, tourism, boots with soles and other goods. For example, it can be car or door mats, slippers, bags, insoles, vests, treatment belts.

Production of rubber shoes

This industry has prospects in the Russian Federation, since many regions are characterized by heavy rains. Also, such products are an integral part of the uniform of representatives of many professions. As an example successful business such domestic manufacturers as Pskov-Polymer, PK KhimProm, Dailos LLC, Tomsk Rubber Footwear Plant LLC, PKF Duna-Ast LLC and Sardoniks LLC can be cited.

Work on the creation of rubber boots begins with the development of models, which will require the involvement of a technologist and a designer. Modern shoes should be durable, comfortable and beautiful. There are three ways to make rubber shoes - assembly (by gluing), stamping and molding. They differ in the number of parts and how they are connected. Glued shoes like galoshes contain the largest number of elements (13-21 parts). Two other methods make it possible to reduce the number of elements by 3-4 times.

The process begins with the receipt of sheet rubber. To do this, a mixture of rubber, filler, vulcanizing agents, reaction catalyst, pigments and regenerate is placed on calenders, where sheet rubber is formed for the manufacture of shoe upper parts. The sole is cut out of a special profiled rubber sheet. Also on the calenders, textile materials are smeared and covered with a rubber mixture. However, to increase the profitability of production, it makes sense to use PVC instead of rubber. This material is 25-30% cheaper than a rubber base, and in terms of consumer properties it is in no way inferior to it.

The materials used for the manufacture of internal and intermediate parts are rag mixtures with the addition of unvulcanized scraps of rubberized textiles. For the manufacture of lining, backs, insoles, socks, decor, various cotton fabrics are used.

With regard to the production of rubber boots, boots and shoes, the most common method is the molding method, when the creation of the carcass and the vulcanization of the products are carried out at the same time. At the first stage, the details are cut out. Then a kind of “stocking” is created from textiles, which is put on a metal block and “wrapped” with rubber elements. The blank is placed in the mold of the vulcanizing press, where the rubber is converted into rubber. Then the shoes are sent for trimming and pressing out, undergo quality control, are packed and sent to the warehouse.

Forming method:

The average cost of a production line is about 2.5 million rubles. It is not worth saving, because the characteristics of the equipment determine the quality of the final product.

Manufacture of sports and special footwear

The production of sports shoes differs significantly from the manufacture of its other types, primarily by the use of complex modern technologies, high cost of equipment, raw materials and accessories.

It uses technologies designed to make shoes as comfortable, lightweight and stylish as possible, as well as to provide them with accessibility. The main difficulty is that existing manufacturers are in no hurry to disclose information about their own developments, so a new market player will have to invest a significant part of the funds in the search own decisions. And it's expensive.

An example is the recent 3-D printing technology, which creates sneakers that perfectly follow the line of the foot. To date, the mass production of "printed" sneakers is only being introduced by Adidas, but there are prerequisites for the fact that in a few years the solution will be released to the masses.

Another example of innovative implementations is Nike's Flyknit technology. Shoes are made by continuous weaving, without lining and textile inlays. This allows you to minimize the number of seams that can cause discomfort during intense sports.

To create the solutions mentioned above, significant financial resources. At the initial stage of activity, it makes sense for a sneaker manufacturer to work with traditional materials, as well as to select several patterns that meet the needs of the selected target audience.

Classic sneakers contain three structural element- upper, midsole and main sole.

For sewing the top, natural and eco-leather, as well as mesh materials made of nylon and polyester threads, a characteristic feature of which is light weight and excellent breathability, can be used. The difference between leather sneakers made of natural and synthetic materials is the ability of the first to deform during operation. The latter are more durable and hold their shape better, but have a lower air permeability. There are also a number of special fabrics for the uppers of the sneakers, designed for specific needs.

The midsole is necessary to provide comfort during active loads, cushioning and support of the foot. That is why it depends on the characteristics of this element how much this or that model of sports shoes will be in demand. The most commonly used materials for midsoles are:

• Philo. This is a lightweight foam compound made from EVA granules with excellent cushioning properties and the ability to take any shape.
• Polyurethane. Some time ago, due to its strength and hardness, the material was in demand in the production of sneakers. However, now, with the advent of new solutions, it is used less and less - primarily because of the large weight.
• Philite. The composition is obtained by adding rubber to phylon. This makes the shoes somewhat heavier, but in return increases its elasticity.
• EVA. Lightweight, flexible and inexpensive material that is often used for budget running shoes. Over time, under the wearer's weight, air is forced out of the foam, and the sole ceases to perform its functions.

In professional models of sneakers, more complex materials are used, such as Lumarlon, Nike Epic React and others.

For the manufacture of the main sole, main function which is to ensure high-quality adhesion to the surface, there are also many options. The most budgetary of them is Duralon. It is made from blow molded synthetic rubber. Products cannot boast of durability, but they have excellent shock-absorbing ability.

Another rubber compound is BRS 1000. For its manufacture, carbon is introduced into synthetic rubber. The result is a durable material ideal for running shoe bases. The DRC rubber compound soles offer superior durability and are designed to withstand almost any load, which is required in sports disciplines such as tennis and athletics.

When it is not possible to experiment with various materials within the ruler, you can use universal material- clean tyres. It is obtained by mixing several types of rubbers of artificial and natural origin. Due to its reliability and good grip with the surface and low cost, this solution can be used in almost any type of sneaker.

As you can see, the manufacture of special footwear is one of the most complex and costly segments of the industry. However, this is where you can count on the maximum profit.

Company registration

The scale of footwear production depends on the desire and capabilities of the entrepreneur. It can be a small atelier, a medium-sized enterprise or a large factory with an assortment of several hundred items. Accordingly, different documents will be required. For an atelier, status is sufficient, in other cases it is necessary. This will allow you to work with large batches of products. A lawyer will help you decide on the choice of taxation system.

When registering, you will need to indicate the OKVED-2 code 15.20 "Shoe production". This will make it possible to produce all types of shoes and parts for them, except for orthopedic, asbestos, rollers and skates for figure skating.

Close attention must be paid to the registration of the company name and logo. The name should be easy to remember and preferably not too long. When choosing a name, you need to take into account the presence of restrictions. First, you need to make sure that another entrepreneur has not already registered a similar name. Secondly, when using the names of cities, countries and some other subjects of the Russian Federation, the law prescribes obtaining permits, which will entail costs. The name must be registered in Russian, and if desired, in English and other languages. If the entrepreneur does not have experience in preparing such documents, it is advisable to contact a specialized company.

All types of footwear are subject to sanitary and epidemiological control. A manufacturer of children's shoes will have to obtain a mandatory quality certificate. In the case of products for adults, certification is voluntary, but a declaration is still required. In addition, products must comply state standards.

Product certification

The certification procedure for footwear in the countries of the Customs Union (CU) is required not only in production, but also in trade. For adult male and women's shoes certification is optional. Obtaining documents of conformity is mandatory only for children. Must have Required documents, certifying that the product of production or sale is of impeccable quality.

For an adult, it can be GOST or specifications(THAT). Today GOST 26167-2005 is in force, for children - GOST 26165-2003.

Certification involves checking shoes for quality, product characteristics by name, gender and age, types, materials used, raw materials and components for the bottom and top of shoes, seasonality, methods of attaching parts, finishing. It also includes a characteristic and the presence of an insulating lining.

* Calculations use average data for Russia

500 000 ₽

Minimum start-up capital

250-300 thousand rubles

Profit per season

15-20%

Profitability

shoe manufacturing can be profitable enterprise. But only if you are well acquainted with this industry, you know all the nuances of tailoring shoes, the choice of equipment and materials, and, most importantly, you have original idea that will allow your products to stand out from the competition.

The situation with the shoe business in our country is currently not the best. The profitability of shoe production is about 15-20%. At the same time, the volume of imported products on the Russian market is estimated at 90%. And most of it is cheap Chinese-made shoes. It is of low quality and low prices and a wide range.

Overview of the footwear market in Russia

The situation on the footwear market worsened in 2010, when a single duty of 10% was established for all types of footwear imported into our country. Until January 1, 2010, footwear was divided into several types. Most of the imported leatherette footwear products were taxed at a rate of 15%. The reduction in duty caused great concern and made life difficult for domestic manufacturers, who could still successfully compete with Chinese companies in this segment of inexpensive artificial leather shoes.

As a result of such innovations, in two years the number of Russian factories that make shoes has decreased in our country by more than three times. Another serious problem that domestic shoe manufacturers have to solve is “gray” imports. It is about half of the volume of imported products sold on the Russian market. The closure of the markets, proposed by the authorities as a solution to the problem of "gray" products, did not save the manufacturers, as the points of sale of illegally imported shoes simply opened in other places.

Nevertheless, despite all these unfavorable factors, the shoe manufacturing business in our country can be profitable and promising, according to experts, including the manufacturers themselves. Russian production provides about 15% of domestic demand and up to 20% in the men's footwear segment. Profitability of 15% is also hardly low. The largest grocery chains are known to operate with a margin three times lower. The main conditions for the success of the Russian shoe factory are the use of the most modern technologies and high-quality equipment, as well as competent positioning and promotion. True, both require considerable investment.

There are three largest segments in the footwear market:

• children's products.

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In addition, a separate place is occupied by special (for example, orthopedic) and work shoes. Best of all, things are with manufacturers of children's shoes, as they are purchased much more often than shoes for adults. Imported quality products turned out to be too expensive for many consumers, and Chinese shoes are widely believed to be of extremely poor quality and short life. Therefore, most parents prefer to buy their children shoes from domestic factories. Another advantage of the latter is that they still manufacture their products according to Soviet GOSTs, which regulate how medical standards and consumer properties of the product.

Many companies choose not to open own production in our country, but place orders with Chinese factories. Another problem hindering the development of Russian shoe production is the lack of high-quality domestic raw materials for the manufacture of shoes. The construction of one large tannery requires large investments - about $ 1 billion. At the same time, the payback period for such a large-scale project will be 8-10 years, according to preliminary estimates. With the production of other components of shoes - lasts, accessories and soles - the situation is much better, but this does not save the situation. The cost price of Chinese footwear products of the low price segment still remains lower than domestic ones, since the footwear that is produced in our country consists of almost half of imported materials.

Shoe business profitability

Many small regional enterprises that manufacture shoes operate semi-legally. They place their equipment on an area of ​​​​up to 50 square meters. meters in closed areas (for example, in a private house) and do not pay taxes. The main sales channel for such "gray" shoemakers is retail chains and private customers, which manufacturers are looking for through the Internet and specialized exhibitions.

Despite all the above problems and difficulties that greatly complicate the life of Russian shoe manufacturers, the business of manufacturing such products can become successful even with small investments. The main thing is to correctly define your target audience, price segment, develop an interesting design and pay great attention to quality. Majority Russian manufacturers work in narrow niches. For large production important has serial production, therefore, most of the assortment of such an enterprise is made up of sports and casual men's and women's shoes of the low and medium price segment. The release, for example, of model women's shoes with high heels requires serious investments. Such production cannot be unified, therefore, from the point of view of entrepreneurs, it is unprofitable and long-term payback.

New companies that only plan to produce shoes go in two ways: they either open a full-fledged production (in their own factory, which is very rare, or place orders with Chinese enterprises), or work in the atelier format, fulfilling private orders or making exclusive expensive models.

Features of tailoring shoes, the choice of equipment and materials

The materials that are used for the production of shoes are divided into natural and artificial. The first ones are different kinds leather for the bottom of shoes, which, in turn, are divided into leather for the bottom of shoes with a screw or nail fastening method and leather for the bottom of shoes with thread and glue fastening methods, leather for the upper and lining, suede. Dense hard types of leather are used for the manufacture of soles, basic insoles, welts, hard backs, heels.

They are produced by a combined tanning method. Leather, from which the uppers of everyday, model, sports, light, home and orthopedic shoes are made, are made from the skins of large cattle chrome, aluchrome, titanium-chromium and chromium-free tanning methods. The types of leather depend on the finishing method used, which determines the texture of the raw material (natural grain, treated, tufted). Distinguish skin smooth, cut and with an art stamping. Casein, acrylic, polyurethane and nitrocellulose coatings are used for top dyeing. The highest quality and most expensive shoe suede is deer skin suede. Also, suede material is produced from the skins of elk, calf and goats. In this case, the formaldehyde-fat tanning method is used, before applying which the front layer is removed from the skin.

The leathers that go to the lining of shoes are produced from the skins of cattle, pigs, goats, sheep and split leather using mineral and chrome-syntan tanning methods. As a rule, raw materials of not the highest quality are chosen for their production - thin, loose and with a large number of defects, which makes it unsuitable for the manufacture of leather, which is used for the uppers of shoes.

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Also, the lower and upper parts of the shoes are made from artificial and synthetic materials (rubber and synthetic polymers). There are several types of rubber. Ordinary non-porous rubber is used to make soles and heels in the form of molded parts. This material is highly resistant to abrasion, but weighs a lot and is not resistant to low temperatures. Ordinary porous rubbers, which are used to make soles, are light in weight, have good cushioning and heat-shielding properties. Leather-like rubber soles are flexible and durable. Both transparent translucent non-porous rubber and styronyl, a non-porous rubber with a high content of high-styrene rubbers, have high resistance to abrasion.

Synthetic polymers include ethylene vinyl acetate (EVA), thermoplastic elastomers, polyurethane, polyvinyl chloride (PVC). EVA materials weigh less than conventional foam rubber, are easily dyed in bright and light colors, are highly resistant to repeated bending and have minimal shrinkage. Thermoplastic elastomers are block copolymers that consist of alternating thermoplastic and elastic blocks. They are characterized by a finely porous structure, frost resistance, hardness and strength. Soles and heels are made of PVC, as this material is resistant to abrasion and to many aggressive environments. Unlike PVC, polyurethane is not resistant to low temperatures.

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In addition to natural materials, artificial and synthetic leather can be used to make uppers and linings. Artificial leather resembles genuine leather, but its hygienic properties and wear resistance are an order of magnitude lower. Synthetic leathers for their hygienic and physical properties are between natural and artificial materials. By structure, they are one-, two- and three-layer.

Shoe production technology

The shoe production technology is relatively simple, at first glance, but it has a large number of nuances. First, the parts are prepared, which are then interconnected. The details of the lower part are attached to the top in several ways using glue, thread, nails, screws and hairpins.

The main consumer properties of products depend on the method of fastening used - wear resistance, lightness, convenience, water resistance, heat-retaining properties, etc. There are several methods of fastening: chemical (adhesive, hot vulcanization, molding), sewn, reversible, moccasin), combined (welt-glue, sandal-glue, line-hot vulcanization). When using the glue method, the sole is connected to the protracted edge of the workpiece with glue, after which the shoes are kept for some time on the blocks under the pressure of the press so that the glue has time to grab. The technology of glue assembly of blanks is used in the production open shoes from natural, artificial and synthetic leathers by thermal method.

Shoes made in this way are water and wear resistant, lighter in weight, but have not as high hygienic properties as shoes made using the thread fastening method. On the other hand, shoes of thread fastening methods, although they have a beautiful appearance and good consumer properties, but does not differ in water and wear resistance. Hot vulcanization method is used to join rubber sole top, providing a strong and monolithic connection. In this case, a raw rubber mixture is poured into a special mold with the contour and profile of the future sole. After molding, the sole is vulcanized under pressure and at high temperature, and then attached to the workpiece, tightened on the insole.

The injection method also has certain similarities with the hot vulcanization method: the sole of the shoe is molded from plastics and thermoplastic elastomer in a mold. In this way, one-piece molded lightweight beach and sports shoes are made. In the last two cases (when using the hot vulcanization method and the injection method), shoe production is transformed into a purely assembly one, which helps to significantly reduce costs.

Expenses for opening a shoe-making production

Another significant expense item is participation in specialized exhibitions, where entrepreneurs look for new customers and strengthen relationships with existing customers. The largest shoe exhibition is Moshoes, which is regularly held in the capital. It is there that regional entrepreneurs conduct negotiations and conclude contracts for the supply of goods. However, the cost of participation in this exhibition is quite high and ranges from 100 to 300 thousand rubles.

For the organization of a small workshop for the production of shoes, about 500 thousand rubles will be required at the first stage. The revenue of such a company per season is about 250,000-300,000 rubles. Seasonal periods are considered from the beginning of autumn to the end of December, and then all the spring months. From January to March and from June to September, shoemakers develop new models, update equipment, review their assortment and conclude contracts for supplies by the beginning of the season. The net profit of a small shoe company is at first from 50 to 100 thousand rubles. But most of this amount during the first year of operation will be invested in the further development of the company.

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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 "Sewing shoes and various accessories for shoes according to custom order 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.
• Insole cutting and manufacturing additional elements shoe pairs 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 assortment of the model range of 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

In order for the costs of opening a shoe production to pay off in the shortest possible time, an 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 assumed that in the initial stages of development in the shoe production workshop, an average of 1000 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 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:

№	Job title	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 fitter	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 shows the operating expenses of a private shoe 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 are as follows:

• 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 shoes Russian production due to the increase in the supply of imported shoes from Europe.
• Raise purchase prices on 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.

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.

Process modern production 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-processing and enter the blank department for fastening the top parts into the blank. Once in 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 recently in technological process happened significant changes 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, equipment with program management. For welding parts made of synthetic materials, high-frequency currents (HF) are used.

The classification features of finished products of shoe factories are varied:

• 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. Net profit 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.