Economic efficiency of introduction of additive technologies in the meat processing industry

This research work presents an assessment of efficiency of introduction of additive technologies in a meat-processing enterprise. The agricultural industrial complex and the food industry are no exception though. Introduction of additive technologies will allow solving a range of primary tasks, for example – the capability to manufacture certain individual parts of equipment directly in the production site. That will reduce downtime and reduce production costs. Using a piece of equipment as an example, it is proposed to manufacture on 3D printer some parts which are most sensitive to tear and wear. Along with introduction of additive technologies in production, the net profit will increase by 1.957.795 rubles. The estimated payback period of the project is 1 month. The obtained data confirms that introduction of additive technologies increase the financial stability of the enterprise.


Introduction
Today 3D modeling and 3D printing is a dynamically developing area. The products obtained on 3D printers are used both on an ongoing basis in existing production and for various experiments in new areas. The use of additive technologies is systematically included in the life of modern person; this type of technology is already widely used in design, visualization, manufacture of specific products, and production of experimental samples.
Using of additive technologies in manufacturing, marketing, design, visualization for customers and company management keeps expanding every year.
The world expert community claims the following: • The most of companies with high innovative potential already use additive technologies; • Within the next 20-30 years up to 90% of large manufacturers will use additive technologies in their production, as a result most complex products will be manufactured with additive components; • Due to development of additive technologies their availability for common manufacturer and consumer will only increase, and in some areas the additive technologies will replace existing classical technologies.
Nowadays the degree of integration of additive technologies into production varies significantly; the leading positions in additive technologies application are occupied by the space industry, aircraft and automobile manufacturing, medicine and dentistry. The additive technologies are most widely spread in these industries in manufacture of prototypes, production of spare parts, creation of sophisticated products.
The reason for the rapid growth of the market for additive technologies is believed to be the following: • simplicity and convenience of modeling new products of any complexity level; • reducing of production costs, especially for conceptual development; • capability to solve non-standard tasks.
The development of market for additive technologies also demonstrates the development of new technologies in this industry, the emergence of new consumables and techniques for their use. For example -in recent years steel, gold, silver, titanium ceramics, resin have been used as a material for 3D printing. So thermoplastic is not the only material for printing, but one of many. The agricultural and industrial complex and the food industry are no exception. Introduction of additive technologies will allow solving a range of primary tasks, for example, capability to manufacture certain individual parts of equipment directly in production site. That will reduce downtime and reduce production costs.

Materials and methods
For the experiment # 1 the following parts were manufactured: the bushings for sausages twisting machines NL 17, made of polyamide 12, and the gear for the packaging machine Ulma TFS 500 was made of polyetheretherketone. The parts were made on a printer VSHAPER Pro.
This experiment failed. The reasons of failure were the bushings themselves. The inner part of the bushings had small roughness and the edges had a sharp end. These factors caused the sausages casing to break when stuffing the meat product.
For experiment # 2 new bushings for sausages twisting machines NL 17 were printed on the printer VSHAPER PRO. In order to remove roughness and sharp ends, these bushings were placed in a special chemical solution. This solution was assigned to make the part a little softer, to remove internal roughness and thereby try to avoid deformation of the sausage casing.
As result of this experiment, it was found that the sausage casing was torn again with these bushings, but not immediately. In the very first experiment the bushings tore the sausage casings right after the machines started their operation.
For experiment # 3, the bushings for sausages twisting machines were printed on a printer VSHAPER Pro. In order to stop the bushings tearing the sausage casing a video was shot that clearly showed the operation of the machine. And also, the following characteristics were found: the average turnover of the bushings is 1500-2500. The bushings are often changed because they grind off very quickly, and due to that the weight of the meat product varies a lot, but it must be adjusted in order to be accurate. In view of this data a new batch of bushings was printed. The article below provides calculations of economic parameters according to the following formulas: Let's calculate the cost of a unit of production using the formula: Let's calculate the payback period of financial investment to the project: To where Cicapital investments, CRcash receipts (Net profit).

Results and discussion
Below in the table 1 the costs for original parts consumption and the costs of additive technologies were considered. According to the results of the data given above in the table, the cost of purchasing the original parts per year will amount to 7.974.532.8 rubles. The cost of new parts manufacture with the help of additive technologies will amount to 2.450.710 rubles per year. The estimated savings achieved by introduction of additive technologies for production is 5.523.823 rubles per year.
To compare two technologies let's consider the efficiency of experiment using the meat production as an example. The volume of products output, in monetary terms, on the production line where this twisting machine is installed accounts for 172.800.000 rubles. Further it's necessary to determine the costs for salaries. There were 8 employees. The monthly salary fund amounted to 410.000 rubles. Contributions to extra-budgetary funds for the year were 1.499.640 rubles. The total amount of annual costs for salaries was 6.419.640 rubles. The next step is to calculate the cost of equipment and depreciation charges. Depreciation is calculated in a linear way. Along with the cost of sausages twisting machine NL as 17, 1.600.000 rubles and its service life of 7 years, the annual amount of depreciation deductions was 228.600 rubles. Electric power consumption of the sausages twisting machine NL 17 was equal to 7.5 kW/h. For sausages twisting machine NL 17 the cost of 1 kW/h of electric power is 0.9 rubles. The electric power consumption for 1 sausage twisting machine is 7.5 rubles kW/h. The cost of electric power per batch -6.75 rubles. The cost of electric power per day is 162 rubles, per month -4.860 rubles, per year -58.320 rubles. The cost for fire safety declaration is 15.000 thousand rubles, purchase of fire extinguishing equipment is 900 rubles per one fire extinguisher, fire insurance for the building -200.000 rubles, maintenance of fire alarm system is 30.000 rubles per month and 360.000 rubles per year. These costs include checking all fire-fighting equipment: panels, devices and related fire extinguishing systems, fire alarm systems and management of evacuation of people, smoke protection, elevators. The total cost of fire safety is 784.000 rubles.
After analyzing the data above, we considered in table 2 all annual costs of production when using original parts. Further let's consider the costs with additive technologies. The volume of products output, in monetary terms, on the production line where these sausages twisting machine is installed, is equal to 172.800.000 rubles per year.
The price of the printer (including delivery, adjustment and fine-tuning) is 2.150.000 rubles.
In table 3 we consider the salaries of the employees along with the new positions recently added. Taking into account the introduction of new equipment, the staff were increased by 2 people. The following positions were introduced -2 locksmiths (for new parts maintenance). So the total number of employees is 10 people.
The monthly salary fund amounted to 435 thousand rubles. Annual amount is 5.220 thousand rubles. Annual deductions to off-budget funds are 1.581.72 thousand rubles. The total amount of annual costs for salaries amounted to 6.801.72 thousand rubles. The next step is to calculate the cost of equipment and depreciation charges. For the sausages twisting machine NL 17 the data and figures remain unchanged.
Calculation of the cost of equipment (printer) and its depreciation. The annual amount of depreciation charges for the 3D printer VSHAPER PRO is 537.400 thousand rubles. Based on the data above the cost is 2.150.000 rubles, the service life is 4 years. The calculation is made in a linear way.
After that we'll calculate the cost of electric power for the new equipment. The power consumption per item is 3.6 kW. As the cost of electric power of 0.9 rubles per kW/h, the cost of electric power consumption is 3.24 rubles. It is planned to print 6 parts per day. The cost of electric power per day is 19.44 rubles, per month is 583.2 rubles, per year is 6.998.4 rubles. After analysis of data provided in the tables above, we represent in the table 3 all annual costs of production when using the additive parts.

Conclusion
The table 4 below shows a comparison of using of original and additive parts on the example of the meat production enterprise. Therefore, the introduction of additive technologies in production will increase the net profit by 1.957.795 rubles. The estimated payback period of the project is 1 month. Based on the obtained data it can be concluded that the use of additive technologies in the meat processing industry is highly promising. This approach will reduce production costs, as well as will let avoid downtime of production process.