Today's heroes are Kirill and Ulyana and their small forged products production. So, how to forge your own business in a mini-forge with a profitability of over 80%?

If successful people in our time are considered to be those who managed to turn their hobby from an expense item of the family budget into a profitable business, then Cyril can be safely called not even twice, but three times successful. He managed not only to combine in a new business idea his two greatest hobbies - history and forging, but also to interest his wife Ulyana in this, organizing a real family contract.

Youth builds prospects

When Cyril proposed to Ulyana, he had nothing to offer his future wife as the first family investment. All he had was a diploma in history teaching and big ambitions to succeed in one of his favorite pastimes - history and blacksmithing.

Realizing that he could not survive on a teacher's salary now, Cyril got a job as a blacksmith in one of the private forges. With each passing day, his dream to build his own house, and with it his own forge, became stronger. Thoughts gradually lined up in a concrete decision on how to quickly and inexpensively build their own family fortress on an inherited summer cottage. On six acres of land, you can’t really accelerate, because the house turned out to really look like a watch fortress - although there are four floors, but narrow walls. The forge was placed in the basement floor. Three or four people could work there if they managed to build their own business - the production of forged products. This was the next goal of our hero.

Where is business forged

At first, the forge equipment consisted of a minimal set of hand tools. Part of the money received from each new temper was invested in the purchase of machines that allowed only cold forging. That is, the tradition of a metal blank of the desired shape was carried out by a strong method without preheating. Metal in such a forge does not pour out. Workpieces of simple forms are taken into work, which can be bought even in a building supermarket. Thus, a furnace in such a forge is not needed, a welding machine is enough.

In fact, the welding machine replaces the hearth, in which all the necessary elements of the future product can be connected by heating. The result is significant savings in the production process: if you do not need to heat up the furnace and melt the metal, then you will not have to spend money on gas (firewood) and, in fact, on the arrangement of the furnace and its maintenance.

And in order to be able to produce beautiful forged interior items, furniture and more serious things, such as fences and doors, you need special equipment (you can buy new with a manufacturer's warranty or find a used one while capital is small).

The entrepreneur buys raw materials for the production of forged products in wholesale markets. These are both iron rods of different diameters, and ready-made stamped elements that are economically unprofitable or difficult to manufacture on your own.

House - business card of a blacksmith

Being true fans of their craft, the couple used metal to the maximum in the manufacture of decorative elements, exterior and interior of their own home. The housing turned into an impromptu showroom, entering which each potential client could be convinced of the quality and aesthetic perfection of the goods offered. Window bars, cornices, chandeliers, candlesticks, mirror and picture frames, chairs, stools, tables. The range of products manufactured in such a mini-forge is quite wide.

The entrepreneurs decided to place the main focus on the products most in demand in this segment: forged railings, window grilles, visors, forged garden furniture (stools, benches, tables). Today, the range of products also includes cornices, chandeliers, candlesticks, frames for mirrors and paintings, chairs, stools, tables for interior design.

On the one hand, the competition in this group of goods is the greatest. After all, the manufacturing technology is as simple and understandable as possible for development. On the other hand, for starting almost from scratch, this is the most optimal option.

Before starting his own business - the production of forged products, Kirill studied the market for products offered by local manufacturers, and also managed to work in the production of some of them. He clearly understood that he could offer his client in many ways the best quality for the same money.

In addition, larger companies were interested in bulk orders, trying in every possible way to avoid small things. For Cyril, with his still small production return, any small order was quite acceptable.

Undoubtedly, a small forge, where only two people work, is not the right time to fully compete with more technologically advanced well-known companies. And yet you can always find your client.

Original and unique

“Of course, I prefer working on single samples of exclusive collectibles, which allows me to develop my abilities to the maximum, discover new methods of working with material,” says Kirill.

So, one of the clients ordered the manufacture of an exact copy of the sword of the long-standing secret Order of the Templars. In search of the most reliable image for a preliminary sketch, Kirill's knowledge of history and some old university acquaintances were very useful. But far from always there is a client who is ready to pay a tidy sum for an expensive toy.

But the attempt to master the technology of Damascus steel was unsuccessful. The knife, manufactured according to the existing description, as expected, turned out with an interesting texture pattern of the blade. But it turned out to be too expensive at cost for the client: in order to forge a product weighing 300 grams, I had to spend a whole kilogram of already expensive metal.

The first clients of the entrepreneurial spouses were neighbors in the dacha cooperative, who had just finished building a house and were looking for craftsmen to manufacture literally everything that could be made of metal, at the best price and of good quality.

Forged Products: Word of Mouth

From time to time Ulyana called friends and acquaintances, offering all sorts of options for cooperation: from ordering products "at friendly prices" to participating in sales on partnership terms - for 10% of the cost of each successful transaction. The calculation was such that the launched wave of word of mouth would allow a small customer base to be formed in a very short period of time. And as production capacity increases, it will be possible to think about a full-scale advertising campaign.

To some extent, this marketing model worked, and a few close friends actually secured large orders. But in general, this turned out to be too little. In addition, a relatively large percentage of referral clients were expecting more significant discounts than our heroes could afford.

Closer communication with potential customers was also hindered by the location of the forge - a kilometer from the city limits.

Therefore, in addition to the page on social networks, which Ulyana diligently maintained from the first day of the forge, a full-fledged website appeared, with contact information, a product catalog, a description of additional services for delivery and installation, as well as the ability to place an order, formulating the basic requirements. Maximum options for a site visitor who is ready to place an order.

Family contract

So far, Kirill and Ulyana are in no hurry to hire new employees.

Firstly, the work is seasonal, there are very few orders in winter, and it is not possible to work with metal at sub-zero temperatures. And paying employees for downtime or hiring new employees every season, teaching the intricacies of the workflow, is simply unprofitable.

Secondly, the forge is an integral part of the common family "fortress", with its everyday secrets, which it is not necessary for outsiders to know. In addition, it turned out that with a competent distribution of duties, there is no need to involve hired personnel.

As befits a male hero, Kirill took over all the types of power work. Although Ulyana tries not to yield to her husband, actively participating in the manufacture of small metal elements. In addition, she paints finished products with acrylic paints, giving an attractive visual effect to products, and helps her husband with installation.

The spouses organize the delivery of their works to the client on their own in their region or use the services of logistics companies. The inherited car had to be somewhat re-equipped, having made a roof rack according to its own drawings.

Forged products production: Pricing

Several unpleasant moments during the crisis, when the currency fluctuation was too big, taught Kirill to approach pricing based on possible financial risks.

So far, this is just a small family business, which, nevertheless, allows the spouses to spend a lot of time together and continue to do what they love, regardless of any external factors.

Despite numerous attempts to arrange the supply of its products abroad, the main orders still remain at the local level. And these are by no means serial things, copies of consumer goods, but always something original. Even a banal lattice for a window or gate, thanks to the aesthetic taste and skills of a blacksmith, looks “not like everyone else”, although the client chooses from a catalog of simple, fairly common solutions.

Based on the experience of entrepreneurs, the initial investment in equipment can be returned in a matter of months. The couple still prefer to reinvest all the money they earn in the development of the business. To assess the attractiveness of their business, you can do a simple calculation.

How much does the production of forged products cost? The simplest forged window grill costs from $20/sq. m. despite the fact that its cost is not more than $ 7. For a month of measured work, you can forge a couple of hundred of these window bars, resulting in more than $ 400 in income. And if you bet neither original author's products, items of exclusive design in a single copy, then the business can be very profitable at least 80%. The main thing is to be able to find a client for such an order and guarantee the quality of the work performed. ⓂⒷ ( 2 ratings, average: 5,00 out of 5)

Business idea: cold forging of metal products
Where we do business: garage, territory of a private house
Main costs: purchase of equipment
Necessary equipment: welding machine, cutting machine, vise, drill
Consumables: metal, varnishes, paints
Initial capital: no more than 30,000 rubles.
Payback period: several months
Possible profit: 50,000 rubles. per month

A business idea based on cold forging of metal products. This idea can be attributed to a business with small financial investments; at the initial stage, only skill and no more than 30,000 rubles are needed.

At the initial stage of organizing this business, it is better for you to learn all the intricacies of manufacturing cold forged items yourself. To start, you will need a room under which a garage or an area near a private house will come down. Also a set of equipment:

1. Welding machine
2. Grinding machine (Bulgarian)
3. Vise
4. Drill, drilling machine
5. Other small tool

The main skill will be the ability to use a welding machine.

Once you are familiar with cold forging, learn how to make simple objects, and perhaps find your first customers, you can purchase an additional set of bending equipment that will help you make complex elements. The cost of such a kit is about 55,000 rubles. Such a kit will help you make complex objects, make bends of the same shape at the same angle, and many other useful things.

The main decorative elements are sold separately. These elements include: flowers, peaks, monograms and others. You only need to weld them to the finished product, then clean the welding seams with a grinder and paint the product in the desired color. The main color that the products are painted in is matte black, but the ability to work with paint will help you create truly unique products. By mixing paints, you can achieve the color of aged bronze or copper, which will give your product a certain character.

Cold forging, unlike hot forging, provides many advantages and allows you to produce unique products, such as fences, gratings, fences, peaks, flower beds, door hinges, accessories for fireplaces, , smokehouses, chandeliers, candlesticks, figurines of people and animals as decorative elements and much more.

Find a good decor supplier, usually a good supplier has over 1000 different items.
The final price for metal cold forging products consists of the cost of raw materials, the complexity of the work, the resources spent (fuel and lubricants, electricity), plus 100% of your work. That is, the profitability of the cold forging business is at least 100%.

How can you realize your abilities?
At the initial stage, it is better to take a course, at least self-learning forging. If there are forging courses in your city, in extreme cases - a welder, take them. If there are no such courses, then study on your own. Surely there are already companies in your city that make forged products, offer them your services as an independent craftsman, in case of a large number of orders. It will be good if you are offered a job, you can study and at the same time receive money, forging masters earn an average of 40,000 rubles. per month, with such an income, you can save up for a good set of equipment. When working in a company, keep in mind the main goal - to create your own company for the manufacture of forged products.

Sales of cold forged products.
As a rule, all products are made to order according to individual wishes and sizes, so making products for sale is not the best option. It will be better if you are looking for clients. Which you can see in the face of the owners of country houses. These are the main clients.

Legal entities can also become good clients, this is the design of cafes, restaurants, bars, the exterior design of buildings, from gratings to the porch.

Summing up, we can say that the business of cold forging metal products is not devoid of a creative process, not in the manufacture of objects itself, not in the options for marketing finished products. Based on this, the conclusion suggests itself - The more creative abilities you have, the more you can achieve in this business. Happy forging!

Ideas for Business from the section:

Welcome to the website of earning Business Ideas. Today we will talk about organizing a small business for the manufacture of forged products, using the cold forging method.

Based on the name cold forging is the processing of metal without raising the temperature. This means that this method does not require expensive and costly forging furnaces, forges, the use of which is necessary for standard metal forging. Well, it’s clear that you don’t need to spend money on a pneumatic hammer or spend physical strength wielding a blacksmith’s hammer. Products made using cold forging are durable, which allows them to overtake stamping and casting.

Primarily units and machines for cold forging act on the material by mechanical force, bending the original material (rods, sheets, pipes, strips, fittings) and giving it the shape conceived by the manufacturer. The impact on the metal is carried out by manual effort using levers and turn signals or by means of a machine tool with an electric motor.

The machines are equipped with various equipment, which allows you to produce a large number of identical parts. From which one or another object will be assembled later. The range of possible products is directly related to the number of operations that the tooling is capable of. You can take this fact as negative, although with only imagination and this number of operations, it is enough to create a huge number of metal processing options.

An approximate list of areas where the use of cold forging and further implementation is possible:

• Various fences, gates.
• Decorations of residential buildings, namely lamp holders, railings for balconies, verandas, stairs.
• Arbor decorations, garden furniture.
• All kinds of grids.

When organizing your own business based on cold-rolled metal by hand, you should pay attention to some of the nuances that make cold forging a great start for an entrepreneur almost from scratch. To get up to speed on the above mentioned nuances, you need to have a specific idea of ​​what stages the production consists of and, of course, the required forging equipment.

do-it-yourself equipment for cold forging metal

Naturally, it is necessary to start from the imagination. In other words, you need to clearly present the finished product.

Building a sketch. If you have enough artistic skills, you can create a sketch yourself or ask an artist for help. Well, of course the Internet, at the moment you can find a huge variety of different sketches on the network.

Bringing the sketch to the natural dimensions of the product. This is done in order to calculate the number of required elements that will be used in further assembly.

Calculation of the spent material. Base material preparation, cutting and layout.

Before any manipulation, the metal must be cleaned of rust, if any.

Direct cutting and cutting of starting material.

The intended elements of the future product are produced by means of a cold forging machine.

Product assembly. This process can be carried out in stages or in one go. It depends on the previous sketch work.

At the end of the assembly, the welding spots are cleaned, and the assembled product is primed and painted.

At the end of the manipulations done, you simply need to install the product in its intended place.

To produce things through cold forging, you need to stock up on the necessary equipment, such as:

• Gnutik. It is used in the case of bending a square, a circle, or turning a bar at an angle.
• Wave rig. Based on the name, the material processed in this way takes the form of a wave.
• The snail allows you to roll the rod into a spiral.
• The twister turns the rod along the longitudinal axis, the distance for this can be adjusted.
• A flashlight is essentially the same twister, only you can additionally twist several elements of the starting material at once.

Cold forging machines

Please note that the devices suggested above require physical effort. In this regard, the use of a square or pipe with a bark diameter exceeding 1.4 cm is a rather difficult process in terms of human physical strength.

The machines are not the only ones in the required equipment, you should definitely purchase add-ons:

• Circular saw or grinder with a cutter. These tools are required when cutting pipes, rods, etc.
• Apparatus for welding.
• Tools for cleaning metal from rust and grinding welded seams.

Required financial injections

Six machines in the case of metal rolling by cold welding can be bought for approximately 100 thousand rubles. Additional tools have a cost of 50 thousand rubles. You can often find advice that to save money, you should place the production in your own garage. But this idea is not entirely successful. You just need to put yourself in the place of your neighbor, who constantly hears the sounds of working tools. In this case, conflicts cannot be avoided. A good option would be to place production in a rented warehouse somewhere in the industrial zone.

The size of the room must be at least 60 square meters. It is desirable to have a covered ramp, which will allow you to store stocks of metal, finished products. And it will not complicate the process of loading or unloading the products to be installed.

The workshop must be equipped with workbenches, slipways and work surfaces. The workshop should be well ventilated, that is, a high-quality ventilation system should be installed.

The preparation of the production premises will approximately amount to 60 thousand rubles. The result is 305 thousand rubles.

Expenses in the present

Approximately five people are required for production:

• Two employees who will be employed in the production of individual components, with a salary of 20 thousand rubles a month each.
• Welder with a salary of 30 thousand rubles.
• Two auxiliary workers with a salary of 15 thousand rubles each.

Remuneration for labor activity of the staff will amount to 100 thousand rubles. Expenses for the purchase of electrodes, special clothing and payment for electricity spent - 15 thousand rubles.

The average estimate of the cost of the required material is 25 thousand rubles. The approximate weight of one span of the fence 2 by 2 meters is 30 kg. The shop has the capacity to produce 30 spans per day. In one day, 900 kg of material will be spent, and in a month - 27 tons. Based on these calculations, 675 thousand rubles a month will be spent on providing metal.

Profit and payback

The estimated price of a fairly simple span of a forged fence on the market is 8 thousand rubles. The workshop produces 30 flights per shift, that is, the income per day is 240 thousand rubles. As a result, the profit for the month is 720 thousand rubles. Net profit will be equal to 6409500 rubles. The initial investment will pay off in about a week. It may seem that expectations are too high, but the business will be profitable even if only 5 sections are sold per day. Naturally, payback periods increase.

The peculiarity of this type of entrepreneurship lies in the fact that if the product is complex, its artistic value increases, increasing the profit from the sale. There is a geometric progression in the growth of complexity and price.

It is easier for an enterprise to start with simple structures, but in the future it is imperative to grow professionally.

The same is true for machine tools. At the start of a business, you can also use homemade equipment. And the state is limited to two employees. It should not be forgotten that cold forging requires large physical costs, and the productivity relative to costs is not great. If production is fully automated, the costs will be 2 million rubles.

Watch the video

The constant technological progress inherent in modern times is gradually replacing handicraft (manual) production and crafts that have come down to us from our ancestors from our lives.

But cold forging can undoubtedly be attributed to crafts that not only keep the competition, but are also gaining more and more popularity.

Forging elements are actively used:

• in the construction and design of country houses, residential premises and offices,
• in the production of furniture products,
• in the funeral business.

It is very difficult to imagine the exterior of a modern building without beautiful wrought iron bars, gates and gazebos. Concerning cold forging products are in high demand and relevant. This is one of the main factors that beginner businessmen pay attention to.

Forging combines art and an ancient craft, thanks to which the cost of production is estimated not by the cost of the material, but by the complexity and beauty of the structure being created.

Thus, the sale of finished products or the provision of cold metal processing services for the population is a very profitable and promising line of business for beginners.

Features of the organization of production

Forging is usually associated with traditional blacksmithing, where metal is manipulated after it has been heated. Such forging requires special training and a certain level of skill from the blacksmith, which is honed over the years.

The process of "hot" forging is very labor-intensive and time-consuming: the metal is heated in special forges to the point where it becomes "soft" and with the help of hammers, presses and other devices it is given the desired shape, after which the part is cooled.

Today, cold forging technology has gained popularity..

Craftsmen process the metal using special equipment, so the process takes less time, and finished products are much cheaper for customers.

It is much easier to master this technology, which is attractive for beginner entrepreneurs.. However, according to professionals, the cold forging business has its own specifics, which should be taken into account when organizing a business.

Market analysis and competition

Before starting any business, it is necessary to analyze the sales market, determine consumer preferences and identify the level of competition. However, cold forged products do not belong to the category of essential goods, which complicates the solution of these problems.

In the process of determining the need for forged products the following points need to be clarified:

• The number of workshops and forges that are already operating in your area.
• What is the demand for forged products and in what volume?
• Where can products be sold?
• Determination of business seasonality.
• The product of what price category will satisfy the needs of users.

After the answers are received, the entrepreneurs will be able to make a final decision: is it worth doing a cold forging business in your area?

Technology mastering

It is difficult to organize a cold forging workshop without special knowledge and skills.

It will be a great temptation for an entrepreneur to hire an experienced specialist, however, at the initial stage of the business, this is not recommended, as he will need to pay a large salary and you will be very dependent on him.

Therefore, before starting a business, a businessman will need to undergo training himself. Theoretical knowledge can be obtained even via the Internet: there is a lot of information on the Internet on the technologies of artistic and cold forging.

However, in order to learn how to cold work metal, practice is needed:

• You can get a job as a production worker or become an apprentice to one of your competitors.
• An experienced specialist should be hired only if there is no other choice. But in this case too, be sure to agree with the master that he will teach you his craft.

After the entrepreneur has gone through the learning process, he needs to draw up a detailed business plan to implement your idea. In this case, it is imperative to use the information obtained in the process of market analysis and training.

The success of a business will depend on how well the business plan is drawn up and how accurately it will be implemented.

It is worth noting that in some regions of Russia there are programs for state subsidies for small businesses, and the idea is financed on the basis of a business plan.

What is required at the start?

Practical steps for organizing any business must begin with state registration. The procedure is described step by step in the law “On State Registration of Legal Entities and Private Entrepreneurs”. In accordance with the law, a person engaged in entrepreneurial activities and receiving a steady income must be registered as an individual entrepreneur or LLC.

Room selection

The room must first of all comply with all fire safety requirements. The minimum area of ​​the workshop should be 20 square meters. m. In addition, it is necessary to conduct electricity.

An insulated garage can be an ideal place for a workshop. It is worth taking care that the noise of production does not disturb the inhabitants of nearby residential buildings.

The cold forging process involves welding, which cannot be carried out in a small enclosed space. In addition, you will need a place to store finished products. For these purposes at the workshop it is necessary to organize a canopy.

The entrepreneur must ensure that the premises had a wide access road for trucks. Otherwise, the process of unloading raw materials and loading finished products will become more difficult.

Workshop equipment and tools

It is impossible to imagine a cold forging workshop without special equipment and tools. One of the main items of expenditure is investment in fixed assets.

At the initial stage, for manual cold forging, you need:

• Welding machine.
• Gnutik used to bend metal. It is the main tool for cold forging.
• Wave. Serves to give the metal a wave-like shape.
• Snail. It will help to give a spiral shape to metal rods.
• Twister. Used to twist a metal rod around an axis.
• "Flashlight", which is one of the varieties of twister.
• Workbench, with the presence of a vice.
• Bulgarian.
• grinder for cleaning the surface of metal structures.
• Perforator, which may be needed when installing finished products.

At the initial stage, this equipment will be enough in the workshop.

The most well-known brands on the market that produce high-quality equipment are the German Eizenkraft and Metalkraft.

The process of making curls by cold forging with a snail, see the video:

Purchase of raw materials

For, to save time and not miss an urgent order, stock up on raw materials in advance.

The cold forging process uses:

• Low carbon steel blanks.
• Various metal profiles: square, sheets, corners, rods, etc.
• Auxiliary compositions: anti-corrosion paint, primer, solvent and electrodes.

It is necessary to purchase raw materials from trusted suppliers which can also be found online. At the same time, it is worth paying attention to the correspondence between price and product quality.

Product range

Ideally, a cold forging workshop should work to order, because in this case there is no need to sell the goods.

However, for start-up entrepreneurs, especially if there is a lot of competition in the market, it is difficult to get an order. So at the first stage of work, you can engage in the production of actual products and their subsequent sale.

As the portfolio expands and authority emerges, large orders will also come.

At the initial stage, it makes sense to produce the following types of products:

• Metal bars on the windows.
• Gates.
• Peaks for the porch.
• Fences for various purposes.
• Fireplace accessories.
• Garden gazebos and garden furniture.

Example of financial calculations

The cost of starting a business is 720,000 rubles.

One-time expenses- 635,000 rubles.

• State registration - 10,000 rubles.
• Organization of the working space (repair and equipment of the workshop) - 25,000 rubles.
• Purchase of a minimum set of equipment and tools - 400,000 rubles.
• Purchase of the minimum amount of raw materials - 200,000 rubles.

Monthly expenses- 85 000 rubles.

• Room rental - 15,000 rubles.
• Salary fund for employees (2 masters) - 50,000 rubles.
• Utility expenses - 10,000 rubles.
• Other expenses - 10,000 rubles.

The average markup is 200% on the cost of production. In a highly competitive market, this is the most common markup on cold forged products.

For example: 535 rubles are spent on the production of 1 m of a lattice for a garden 2 m high. (metal - 500 r, anti-corrosion paint - 15 r, electrodes - 20 r). The corresponding share of current expenses is added to this amount (85,000 rubles / 250 products per month = 340 rubles).

The planned markup is added to the sum received as a result (535+340=875 rubles). As a result, the minimum cost of 1 meter of the lattice is 2600 rubles.

Conclusion

Cold forging is more related to the service sector, therefore to determine the profitability of a business, it is necessary to calculate the finished product.

It is worth noting that the success of your business will depend on how well you manage it. If the entrepreneur manages to use all production capacities and quickly sell finished products, then the profit from the business will be large and constant.