Two years ago, traditional rubber boots and galoshes from work shoes, which were used only by summer residents, fishermen and hunters, turned into the latest fashion. The cost of one branded pair of rubber boots can reach up to 12-15 thousand rubles. And, despite the fact that dress shoes for rainy weather are gradually disappearing from the world's catwalks, in Russia, where in many regions heavy rains are a common occurrence at any time of the year, the forgotten and newly revived fashion for special shoes is unlikely to pass without a trace.
But, of course, this promising niche is not characterized by a lack of offers. In addition to foreign brands, whose shoes are in less demand due to their rather high prices, domestic manufacturers have to compete with Chinese factories that supply their cheap and varied products to our market.
Currently, on the Russian rubber footwear market one can single out one largest domestic manufacturer - Pskov-Polymer. In addition, there are several dozen smaller factories that produce similar products: PC "KhimProm" (Rostov-on-Don), LLC "Dailos" (Moscow), LLC "Tomsk Rubber Footwear Plant", LLC PKF "Dune" -Ast" and LLC "Sardonyx" (Astrakhan), etc.
When asked whether it is worth opening a new company for the production of rubber shoes in conditions of relatively high competition and a gradual decline in demand among consumers, experts cannot answer unequivocally.
As in any other industry, the originality of the idea behind your proposal and its competitive advantages are critical. For example, Rain Level rubber boots from the Italian company Regina Regis, which are available in nine colors and sell for 69 euros per pair, would hardly have been in such high demand among buyers if it had not been for the scale printed along the entire height of the boot, as in an ordinary school ruler, which allows you to literally measure the depth of puddles with your feet. A simple idea, the implementation of which did not require any significant investments, brought its author great profits.
Before a shoe is put into production, it goes without saying that it must first be designed. This process includes the development of the shape of the future boot, the size of the lasts, or, depending on the manufacturing method, the creation of appropriate molds and the construction of shoe models.
The main requirements for rubber shoes: they must be comfortable, durable and, as many Russian manufacturers forget, beautiful. If you do not have the opportunity to hire a good shoe designer, perhaps your Western colleagues can help you. For example, the Pskov-Polymer plant, when developing a new model line of rubber boots, turned to Italian designers for help, who acted as consultants.
Nowadays, rubber shoes are produced in three ways: by assembly (gluing), stamping and shaping. Such shoes, like any other, consist of individual parts connected to each other. The quantity, shape, size and materials of these components depend on the model and production method.
Glued shoes have the largest number of parts (mainly galoshes, which are assembled from 13-17 parts, and boots from 16-21 parts). In shoes that are produced by stamping and shaping (the most common production methods), the number of parts is 3-4 times less than in glued shoes. Parts are usually divided into groups according to their location: external, intermediate and internal.
The main materials for the production of rubber shoes are components of rubber and textile mixtures, organic solvents, knitwear and other fabrics.
Rubber mixtures of rubber, filler, vulcanizing agents, vulcanization accelerators, pigments and reclaimed material are processed on calenders, after which the mixture is converted into sheet rubber. From this sheet the outer parts of the shoe upper are cut out, and from the profiled sheet sole mixture, respectively, the sole parts are cut out. The rubber mixture is coated and covered with textile materials on calendars.
Rag mixtures, prepared from a rubber mixture with unvulcanized scraps of rubberized fabrics, are used for lining fabrics used for internal and intermediate parts of shoes or for cutting out textile parts.
In addition, in the production of rubber shoes, cotton jersey is used for lining, hosiery tube (for molded boots), and cotton fabrics for various parts of shoes (for heels and insoles, for socks and as decorative elements).
Most large manufacturers have already switched to using polyvinyl chloride (PVC) for the manufacture of such shoes. The cost of this material is 25-30% lower than the cost of the rubber base. However, it has similar properties.
And the most progressive method of producing rubber boots is the shaping method. It represents the simultaneous formation of a rubber frame and vulcanization of shoes. Boots, boots and even shoes are made this way.
For the production of boots by molding, rigid metal cores or cores with an elastic chamber are used. The technology itself is quite simple. First, textile and rubber parts are prepared. Textile elements are cut out of fabric covered with a thin layer of rubber mixture, and then the shoe frame is sewn together in the shape of a stocking. Rubber parts are also cut out from corresponding rubber blanks.
The resulting stocking is put on a metal block and covered with rubber parts. This core with a blank for the boot is placed in the mold of a vulcanizing press. With subsequent pressing and heating, the actual formation of the boot and its vulcanization (the technological process of converting rubber into rubber) occurs.
After which the boots are sent for trimming the upper edge of the boot, burrs and pressing out. Then they pass control, they are sorted and packaged. Plastic bags are usually used for packaging rather than cardboard boxes, which further reduces the cost of one pair of finished shoes.
The production of rubber boots by the molding method has a number of undoubted advantages: it is a much less labor- and time-consuming method of producing shoes than others. Shoes made in this way are more wear-resistant. The disadvantages include the increased weight and relative rigidity of the boots, increased rubber consumption due to the need to compact some areas of the shoe and the presence of a large amount of waste (extrusions), the possibility of the lining coming away from the facing rubber, the complexity and labor intensity of making molds.
Therefore, manufacturers are constantly improving and finalizing this technology in order to get rid of the listed disadvantages. For example, the use of combined cores made of a metal body and an elastic rubber chamber reduces the labor intensity of shoe manufacturing, reduces the abrasion of the lining during the wearing of boots, and allows the textile “sock” to be securely attached to the rubber. An elastic rubber chamber on the core helps reduce the weight of the boot and increase its flexibility and softness, reduce rubber consumption and facilitate the process of making molds.
The cost of a used production line is about 30-40 thousand dollars. However, the quality of shoes produced on it directly depends on the equipment. And the quality of products directly affects their demand and sales. Therefore, if it is possible not to save on equipment and materials, then when choosing, give preference to Italian production lines and imported raw materials.
Add to this the costs of renting production and warehouse premises, wages to employees (you will need, at a minimum, a fashion designer, a chemical technologist, an equipment adjuster, an equipment repairman, seamstresses, purchasing and sales managers, an accountant, etc. .).
If you do not have several million rubles as initial capital, then you should consider the possibility of either collaborating with existing factories for the production of rubber shoes according to your design, or think about creating a retail store selling finished products.
The production volume of large factories producing rubber shoes is 2-4 million pairs per year. And the revenue of the rubber footwear business reaches $8-12 million. The most forward-thinking manufacturers spend most of their profits on developing new lines of shoes, updating existing assortments and equipment, positioning and promoting sales of their products.
Both small and large producers sell their products to wholesale companies. At the same time, the lowest wholesale cost of one pair is about 150-200 rubles (with a cost of 70-100 rubles). In retail, the same shoes are sold at a price of 500-600 rubles per pair. 20-30% of the total output of large factories is exported to European retail chains.
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Rubber shoes are those made with a top made of rubber and fabrics and a bottom made of rubber. The group of rubber shoes also includes shoes with tops and bottoms made of plastic.
The main advantage of rubber shoes is their moisture-proof properties (water resistance), which allows these shoes to be used in the most unfavorable wearing conditions.
In addition, rubber shoes must meet the following requirements:
♦ correspond to the shape and size of the foot, if rubber shoes are worn on bare feet, and to a certain type of shoe, if they are worn on other shoes;
♦ have as little weight and flexibility as possible;
♦ protect the shoes or feet covered with it from moisture; the outer parts of rubber shoes and the places where they are connected must be waterproof; under the influence of water there should not be any changes in the appearance, strength and other properties of the external parts of the shoes;
♦ have a long wear period; during operation, the appearance, shape and size of the shoes should be preserved for as long as possible;
♦ absorb spilled dirt as little as possible, which should be easily washed off from shoes;
♦ easy to put on and take off from the foot and stay on it well;
♦ do not change the appearance and consumer properties under normal storage conditions before use;
♦ meet the tastes of consumers and the purpose of the design in terms of appearance and shape.
Production of rubber shoes
The production of rubber shoes is currently carried out by three main methods: assembly (gluing), stamping and molding. The general technological scheme for the production of rubber shoes by assembly, stamping and molding methods is shown in Fig. Rubber shoe details
Rubber shoes consist of separate parts connected to one another. The number, shape, size and materials of rubber shoe parts vary greatly and depend on the type of shoe and the method of its production. Glued shoes have the largest number of details. Thus, glued overshoes are assembled from 13-17 parts, glued boots from 16-21 parts. In stamped and molded rubber shoes, the number of parts is 3-4 times less than in glued ones.
Based on their location in shoes, parts can be divided into three main groups: external, internal and intermediate. External parts form an outer cover that protects the shoe or foot from mechanical and atmospheric influences and at the same time determines the appearance of the shoe. Internal textile parts form the frame of the rubber shoe; in the process of wearing the latter, the internal textile parts are in direct contact with the shoes on which the rubber ones are worn, or with the foot (stocking).
Intermediate parts of rubber shoes increase the stability and strength of the shoe frame, improve its heat-shielding properties, ensure the evenness of the outer and inner surfaces of the shoe, and serve to interconnect parts.
Materials for the production of rubber shoes
The main starting materials for the production of rubber shoes are components of rubber and rag mixtures, organic solvents, knitwear and fabrics.
The purpose of rubber compounds in the production of rubber shoes is varied. The calendered rubber mixture, converted into sheet rubber, is used to cut out the outer parts of shoe uppers; Shoe soles are cut from a profiled sheet of sole rubber mixture; textile materials are coated with the rubber mixture and placed on calenders; rag mixtures are used for lining fabrics used on the internal and intermediate parts of rubber shoes, or directly for cutting out individual intermediate parts; The rubber mixture, when dissolved in organic solvents (gasoline), produces liquid and thick adhesives (ointments) necessary for coating fabrics and for gluing parts in the manufacture of rubber shoes.
The main components of rubber mixtures for the production of rubber shoes are rubbers, fillers, vulcanizing agents, vulcanization accelerators and pigments, reclaim.
The production of rubber mixtures in the production of rubber shoes essentially coincides with their production in the production of rubber products for the bottom of leather shoes; the difference is manifested only in the selection of components and their quantitative ratios. The composition of rubber mixtures varies widely depending on their purpose in production.
Rag mixtures are prepared by mixing the rubber mixture with appropriately treated unvulcanized scraps of rubberized fabrics obtained by cutting out the internal and intermediate parts of rubber shoes. The quantitative ratios of the rubber mixture and crushed fabric scraps in the manufacture of rag mixtures vary depending on whether the latter are intended for lining fabrics or for cutting out rag parts.
From knitted materials, cotton knitwear is used for lining galoshes, boots, boots, ankle boots, boots, stocking tube for lining molded boots, etc.
Cotton fabrics are used for various parts of rubber shoes: cotton - for textile backs and colored insoles of galoshes and boots, plain calico - for backs, gray ribbons, socks; colored calico - for colored insoles and other internal parts of boots and shoes; semi-velvet, tarpaulin, other fabrics of various colors - on the top of shoes, etc. Woolen fabrics are used on the parts of the top of fabric boots, and woolen flannel is used on the lining of boots, semi-high and high galoshes.
The design of rubber shoes, which precedes their mass production, consists of developing the shape and size of lasts or corresponding molds and constructing shoe models.
The shape and size of rubber shoes are determined by their purpose. Depending on whether it is intended to be worn over other shoes or on bare feet, the shape and dimensions of rubber shoes vary significantly.
The design of rubber shoes intended to be worn on bare feet is usually carried out according to the models of lasts used in the shoe industry.
Production of rubber shoes by assembly method (glue method)
The assembly method consists of mutually gluing the outer, inner and intermediate pre-prepared parts that make up the rubber shoes.
The external parts of glued rubber shoes include: in galoshes - front (sides), soles; in all-rubber boots - fronts, barrels and backs or tops, soles, curbs; in fabric boots - fabric fronts, barrels and backs, rubber welts (back and front), soles, cuffs; in shoes - sides (front), boots (clubs), tongues (valves), rubber welts, socks, soles. External rubber parts are cut out from advanced and sole rubber, fabric parts for boots are made from cloth, woolen fabrics, semi-velvet; parts for shoes are made of cotton fabrics.
The internal parts of glued rubber shoes include: in galoshes - lining of the front and heel parts or a through lining, colored insole; in boots - a through lining of two halves or a lining under the front part and under the boot, a colored insole; in shoes with laces - lining of the heel (inner heel), pads, colored insole. Internal parts must be cut out of fabrics and knitwear that have high tear and abrasion resistance, the necessary heat-shielding properties, and good appearance.
Taking into account the different wear patterns of the lining and colored insole of rubber shoes, they are cut out from different materials: the lining is made of fabrics and knitwear, lined with a rubber mixture or coated with rubber glue, the colored insole is made of fabrics, lined with a rag mixture. In some types of shoes, the forefoot and heel lining are also made from different materials.
All types of glued shoes (with the exception of shoes) basically have approximately the same intermediate parts. These include: thick and thin backs, glued to the heel part of the lining from the wrong side and giving strength and stability to the heel part of rubber shoes; half-insole and heel, glued to the colored insole from the wrong side, serving to level the depression on the colored insole formed when the edges of the textile frame are pulled onto it; a black insole, glued over the half-insole and heel before applying the sole and creating a smooth surface on the shoe footprint; reinforcements on the toe, heel, and sometimes on the heel.
Certain types of rubber shoes have additional intermediate parts: a spur in the heel of galoshes for ease of removal; a face glued to the front of the boot lining to give greater elasticity and strength to the top of the shoe; an arrow glued to the lining along the center line of the heel to strengthen the heel of the shoe; gray ribbons used to interconnect parts of the lining or top.
Intermediate parts are cut out from different materials: thick and thin backs, black insoles, spurs - mainly from calico, coated with rubber glue on one side and lined with a rubber mixture on the other; heels and half-insoles are made of rag mixture; reinforcements on the toe, heel and heel are made of advanced rubber.
The process of assembling rubber shoes from individual parts is divided into a significant number of operations carried out on conveyors. When assembling rubber shoes on a conveyor belt, the parts are coated with rubber glue, sequentially placed on aluminum pads of the appropriate styles and sizes and glued together; a conveyor belt transfers blocks of parts from one operation to another. In addition to the manual operations of smearing parts with rubber glue, applying them to the block, rolling (pressing the parts to be glued with stitching rollers) and stitching (applying a pattern using a rotating narrow disk with a smooth surface or notch around its circumference), during assembly
In order to give rubber shoes greater strength and solidity, appropriate machines carry out comprehensive crimping of parts, rolling of soles and final rolling of products. The sequence of operations for assembling rubber shoes varies depending on the type of shoes being manufactured, the organization of work on the conveyor and other conditions.
Rubber products assembled on pads are coated with varnish, which, upon subsequent vulcanization, forms a durable, elastic, shiny film on the surface. This film gives a beautiful look to rubber shoes, and also protects them from dirt, water and sunlight. For varnishing, galosh varnish is used, prepared on the basis of linseed oil, seal and cod oil, or oxidized sodium butadiene rubber with the addition in both cases of rosin treated with glycerin, dye (indulin) and solvent (heavy gasoline). Rubber shoes are varnished manually or using special machines or in a high voltage electric field.
To give it the necessary performance properties, rubber varnished shoes are subjected to vulcanization in horizontal boilers at high temperatures and elevated pressure.
After cooling, the vulcanized rubber products are removed from the pads, if necessary, are finalized (blocks and buttons are inserted, buttons are sewn on, laced), and then sorted and packaged.
The method of assembling (gluing) rubber shoes is labor-intensive, as it involves the preparation of a large number of parts and the use of manual labor to connect the parts. This method of making rubber shoes, although the most common at present, is continually being replaced by the molding method, especially in the production of rubber boots and other types of rubber footwear.
Production of rubber shoes by stamping
The stamping method, first developed and mastered in our country, is used in the manufacture of men's and boys' galoshes. Stamped galoshes are made from four parts: a lining, a textile back, a colored insole and a blank facing rubber.
The lining is cut out of cotton pile jersey, not lined with a rubber compound. The textile back is cut from paper, twill and other fabrics, and the colored insole is made from paper, lined with a rag mixture. A blank of facing rubber in the form of a thick (24-28 mm in diameter) cord 350-500 mm long is obtained by squeezing out the rubber mixture on a worm press and then cutting it into separate pieces.
Galoshes are stamped in sliding molds consisting of two half-matrices 1, core 2 and punch 3, on the working surface of which the design of the sole is engraved. The mold is the main working part of a hydraulic stamping press.
The process of making stamped galoshes is as follows. First, on an aluminum or steel core shaped like a block, installed on a conveyor chain, a frame of galoshes is assembled from textile linings, backs and insoles pre-coated with rubber glue, or a textile frame pre-sewn from separate parts is put on the core. When the stamping press is started, the core with the parts assembled on it and a blank of facing rubber placed on the foot is inserted by a chain conveyor next upward into the open mold. Next, the mold is closed, the half-dies cover the core on both sides, hugging its side surfaces, and the punch, the working surface of which faces down, is lowered into the upper part of the half-dies. Under press pressure transmitted through the punch, the facing rubber blank, spreading, fills the free space between the textile frame of the overshoes assembled on the core, the punch and the inner surface of the semi-matrices and forms the outer rubber cover of the overshoes. At the end of the stamping process, which lasts several seconds, the mold is automatically opened and the core with the stamped galoshes is removed from the mold by a chain conveyor. The pressing and burrs are cut off from the stamped overshoe, the overshoe is removed from the core and put on an aluminum block. Then the galoshes are varnished and vulcanized in horizontal vulcanization boilers or in continuous vertical vulcanizers (without excess pressure). Subsequent operations are similar to those in the production of galoshes using the manual assembly method.
Stamping of galoshes has significant advantages over assembly: labor productivity increases, working conditions improve due to a reduction in the number of operations associated with the use of rubber adhesives.
The disadvantages include: uneven thickness of the walls of rubber galoshes, their excessive thickness, reduced elasticity of the front part of the top of the galoshes due to the use of a rubber mixture of the same formulation on the top and bottom of the shoes.
Production of rubber shoes by molding
The main distinguishing feature of the molding method, the most advanced method of producing rubber shoes, is the combination of the formation of a rubber lining frame and the vulcanization of the shoes in one operation. The molding method is used to make boots, shoes, boots and boots.
The most common production method is boot molding; they are made on rigid metal cores or on cores with an elastic chamber.
The production of rubber boots by molding on rigid cores (pads) is as follows. The necessary textile and rubber parts are pre-prepared.
Textile parts - the lining of the boot and front, the heel and the colored insole - are cut from fabric covered with a thin layer of a rubber compound that does not contain soot and is vulcanized. From the cut out textile parts, a boot frame is sewn on sewing machines in the form of a stocking closed at the bottom.
Rubber parts - the boot together with the front, the sole, the heel - are cut out from appropriate rubber blanks (different in recipe). The resulting stocking is put on a metal block, which is the core of the mold, and covered with rubber parts. The metal core with the boot assembled on it is inserted into the mold of the vulcanization press. With subsequent pressing and heating, the boot is formed and vulcanized. Molded boots are not varnished; they are sent for trimming the upper edge of the boot, burrs and pressing, and then for inspection, sorting and packaging.
The method of molding rubber boots on rigid cores reduces labor costs by more than 30% compared to the manufacture of glued boots, and the wear time of the products is significantly increased. At the same time, the method of molding rubber boots on hard cores also has a number of disadvantages: increased weight and stiffness of the boots; increased rubber consumption due to the need to thicken certain sections of boots and the presence of vulcanized waste (extrusions); weak connection of the lining with the facing rubber; the complexity of the operation of putting the lining frame on the core; complexity and labor intensity of manufacturing molds.
To eliminate these disadvantages, rubber boot molding technology has now been introduced, based on the use of combined cores consisting of a metal body and an elastic rubber chamber placed on it.
When making boots on cores with elastic chambers, textile frames made of non-rubberized stocking tube, sewn at the bottom, are usually used. The use of such frames is associated with a reduction in the labor intensity of their manufacture and at the same time ensures reliable fastening of the lining to the facing rubber, which eliminates the lining lag and reduces its abrasion when wearing boots. Thanks to the use of cores with an elastic chamber, the weight of boots is reduced, their flexibility and softness are increased, rubber consumption and the complexity of manufacturing and molds are reduced.
Molded boots and shoes have significantly superior performance properties to glued shoes; They also differ from the latter in a more elegant appearance and a clearly defined surface pattern of the soles and side lining.
Assortment of rubber shoes
Rubber shoes are divided according to the following characteristics:
♦ intended purpose - for household footwear, technical footwear used as workwear, and sports footwear;
♦ nature of use - for shoes worn over other shoes, and for shoes worn directly on the foot (on a stocking, sock);
♦ gender and age of consumers - for men's, women's, boys', girls' and children's;
♦ types - for galoshes, boots, boots and ankle boots, boots, shoes, shoes and low shoes, sandals;
♦ upper material - for shoes with all-rubber uppers (galoshes, chuni, boots, ankle boots, boots, sandals), with textile uppers (boots, low shoes) with all-rubber or textile uppers (boots, shoes);
♦ color of upper materials - black and colored;
♦ heel height - for shoes with low, medium and high heels;
♦ production method - glued, stamped, molded and latex.
Rubber shoes are also divided into styles depending on the design features of the upper of the shoe, the shape of the toe (round, semicircular, blunt, wide, narrow), the shape of the heel and other characteristics.
Let's look at the main types of rubber shoes.
Galoshes are one of the most common types of rubber shoes. Depending on the height and design of the top, galoshes are divided into small (low) - without tongues and with tongues, semi-high, covering the instep of the foot, and high, covering the entire back of the foot above the ankle. Currently, mainly high galoshes are produced.
Tall galoshes are produced for men and boys, lined with brushed knitted cotton fabric or woolen flannel, with a rubber or textile back, with a narrow toe; They are intended to be worn without shoes or on leather shoes in winter. Along with various types of galoshes made with lining, glued and latex galoshes without lining are also produced for putting on felted shoes.
A special group consists of technical galoshes, divided into dielectric, anti-acid and anti-alkaline, dielectric (high-voltage) boots with lapels and chuni. The latter are molded products such as semi-deep galoshes without lining, with thickened sides and soles. Technical galoshes are made with an unvarnished all-rubber top.
Boots and ankle boots are intended to be worn directly on the foot. They are made of all-rubber glued ones, lined with knitted cotton or half-woolen fabric (the lining under the boot tops is also made of twill or cotton wool), without fasteners, with overlay molded heels, with or without folding insulated insoles, for women, girls and children. Boots are produced in various colors, mostly patent leather, with finishing (especially in shoes for children) in the form of decorative thickenings, applied (glued-on) rubber decorations, figured tops, borders, fur edges.
Boots, like boots and ankle boots, are intended to be worn on bare feet. Boots differ in the height of the tops, lining material and other characteristics. Along with boots without holding devices, high (fishing) boots with a trouser leg reaching to the waist and with eyes for threading a waist belt are produced
Boots are produced with an upper made of unvarnished rubber, with a lining made of rubberized fabric, special fabric for boots (TDS), hosiery tube, knitted fabric, twill and cotton wool (for lining under the tops), with molded overhead heels, men's (short and high) and women's Other types of boots are made in small quantities: without lining; insulated with a lining made of sponge rubber, as well as with an internal two-layer lining made of half-woolen and woolen fabric; frost-resistant, etc.
In the group of rubber boots, various industrial special shoes are essential: fishing boots, mining boots, anti-acid and anti-alkali boots for work in the chemical industry, petrol-resistant boots for work in the oil production and oil refining industries, etc.
Boots are intended to be worn on bare feet. Currently, along with sports boots, household insulated boots are becoming widespread. They are made mainly by molding, with a top made of various woolen fabrics and cloths, lined with a woolen flannel (sometimes with a top made of insulated cotton fabrics, duplicated with a cotton flannel), various types of cut, on laces with blocks or with a zipper, a strap with a buckle, a flap with buttons, with a rubber cushion, with a false heel (in glued products), with or without an insulated insole, for men, women and girls.
Low shoes and shoes. In recent years, the range of low shoes and shoes produced by the rubber industry has expanded significantly due to the production, along with sports shoes, of shoes for wearing outside and at home.
Textile-rubber shoes are made with an upper made of various fabrics with different textures and colors.
Production methods for rubber shoes. To produce rubber (polymer) shoes, the adhesive method, stamping, molding, injection molding, liquid molding and plastisol molding (thermoforming) are used. The adhesive method produces all-rubber and rubber-textile shoes, which are assembled (glued) onto a last from separate parts.
The parts are connected using rubber glue.
The assembled shoes are varnished and vulcanized. In glued shoes, the sole and facing rubber have different thicknesses, and the places where the parts are connected are clearly visible. The gluing method is used in the production of all types of rubber shoes, but in recent years it has been replaced by others due to its significant labor intensity. All-rubber galoshes are produced using the stamping method. The outer parts and sole of the shoe are formed in a mold from a rubber mixture.
The finished shoes are varnished and vulcanized. Stamped galoshes have thick walls of facing rubber and are therefore rough and heavy, but are highly wear-resistant. An external distinctive feature of stamped shoes is the presence of mold marks. All-rubber boots and galoshes are produced by molding. In the production of molded shoes, rigid or elastic cores are used, onto which a lining is placed. The lined cores are lined with unvulcanized rubber and placed in a mold where the shoes are finished and vulcanized.
Molded shoes are produced unvarnished and are used for wear in difficult conditions. The molding method is also used to attach the sole to rubber-textile shoes. The injection molding method is used in the production of footwear from polyvinyl chloride plastic (boots, galoshes). The liquid molding method from microcellular polyurethanes (MPU) is used in the production of shoes with uppers made of fabrics, knitwear, leather, artificial shoe materials with soles and vamps made of polyurethane.
The formation of the sole and facing parts (vamp) occurs in a mold into which a mixture consisting of diisocyanates (component A) and glycols (component B) is alternately poured. When these components interact, a solid porous mass is formed, which is then bonded to the textile parts of the shoe. The liquid molding method is used in the manufacture of boots, boots, and two-layer shoes.
Using the casting method from polyvinyl chloride plastisol (thermoforming), polymer shoes are produced that resemble leather ones in appearance. To produce shoes using this method, polyvinyl chloride layers - plastisols - are used. At elevated temperatures (180-200°C), plastisol particles stick together and form a film. The seamless plastisol shoe shell is produced in sealed hollow molds into which the plastisol composition is poured. The molds are then placed in ovens, in which, when heated, a layer of polymer of the required thickness is deposited on the inner surface.
The heel is molded separately to the resulting shoe shell. The shells with the heel are cooled and connected to the lining with nairite glue. Thermoforming is one of the most promising methods for producing polymer shoes, and shoes made of polyurethane and polyvinyl chloride are replacing rubber ones. 4.
End of work -
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Business idea: how to start a rubber boot production?
Where we do business from: workshop, rented premises
Main costs: purchase of production equipment, purchase of raw materials, electricity, wages
Necessary equipment: vulcanization lines for rubber products
Consumables: rubber, glue, fabrics
Starting capital: from RUB 950,000. up to 1,500,000 rub.
Payback period: from 6 to 24 months
Possible profit: from 60,000 rubles. up to 130,000 rub.
Before the Great Patriotic War, rubber boots and galoshes were very popular footwear among residents of the Soviet Union. For women, it was possible to purchase galoshes that had a hollow heel so that they could be worn on shoes. After the war, these shoes lost their former popularity and turned into work shoes for production and agriculture, only children's rubber boots continued to be produced in bright and very beautiful ways.
At the end of the last century, there were attempts to revive the business of producing fashionable and stylish rubber shoes, but they were not successful. The population, paying attention to Western countries, refused to accept rubber boots as an item of fashionable clothing, but now, at the beginning of the twenty-first century, residents of the country again turned their attention to these products.
When drawing up a business plan, you need to think through everything, familiarize yourself in detail with the equipment and production technology, the needs of the market and the market price.
What are the products of these factories? What are modern rubber boots?
These shoes are made from synthetic rubber, on a knitted base and are of fairly high quality.
The industry produces many models and varieties of such shoes for consumers of different age groups.
Now you can find rural off-road boots with high soles and very elegant imitations of sneakers with high lacing, there are even leather imitations and stylish boots.
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Production technology.
Today, one of the most progressive methods for producing rubber shoes is the shaping method. It is based on the simultaneous formation of a rubber shoe frame and its vulcanization. This method can be used to make boots, boots and shoes.
To make boots using the shaping method, rigid metal cores or cores with an elastic chamber are used. This technology is very simple. First, the rubber and textile elements of the shoes are prepared. Textile elements are cut out of fabric, which is covered with a thin layer of rubber mixture, after which they are connected into a frame. It is shaped like a stocking. Rubber shoe parts are cut in a similar way. Then the frame is put on a special metal block and covered with rubber elements. This core is placed in a special mold of a vulcanization press. The boot is heated, formed and vulcanized. After the process is completed, the finished boot is sent to trim the edge of the boot. After this, control and sorting are carried out. Then the boots are packaged in plastic bags. Unlike cardboard boxes, this reduces the cost of shoes.
Cost of equipment.
The cost of a used production line is approximately 30-40 thousand dollars. The quality of the shoes produced directly depends on the state of the production line. And the quality of the product greatly affects both the price of the product and the demand for this product. When choosing a production line, give preference to Italian equipment and it is best if the raw materials are imported. To these expenses, add also the costs of renting premises for installing the line and warehouses, and salaries to employees. For normal work, you will need the following specialists: fashion designers, technologists, adjusters, repairmen, seamstresses, managers, accountants.
Profit.
The lowest wholesale price on the market for one pair of rubber boots is approximately 150-200 rubles. These shoes retail for 500-600 rubles. The cost of one pair is about 70-100 rubles. The output of a large rubber shoe factory is approximately 2-4 million pairs of shoes per year. At the same time, sales revenue is approximately 8-12 million dollars.
