Entrance doors made of metal today are in almost every apartment and in many houses. This is a sought-after product, available in the product range of many factories. The number of manufacturers is constantly growing.
Unlike an interior door, a full-fledged front door is difficult to manufacture in artisanal conditions, without the appropriate equipment. What functional parts does the equipment for the production of metal doors consist of, and at what price does it cost?
Kinds
1. Cutting machine. Used for cutting metal. In production, laser and plasma machines are used. The price of this equipment is from 200 thousand rubles.
2. Press brake. This equipment for the manufacture of doors is designed to give the metal the desired configuration. Professional machines are controlled by CNC. The cost is about 1.5 million.
3. Welding equipment for the production of doors. The metal parts of the structure (frame, sheets, stiffeners) are pinpointed during the assembly process, then welded completely. For this purpose, both professional welding machines and welding machines are used. Price from 200 thousand.
4. Completely automated production all necessary holes and cutouts (for fittings, for glazing, etc.) are performed by a jig punch press. Its price is very high, only a large factory can afford this equipment.
5. The most common option for coating the outside of the door is powder-polymer paint. They require spray booth(from 120 thousand), polymerization chamber (from 300), compressors and guns.
6. Equipment for the production of metal doors (ready-made lines, fully equipped with everything necessary for the manufacture of doors), cost over 10 million. Complete set of such lines:
Press brake;
Plasma or laser cutting machine;
Equipment for welding tongs with a conductor;
Equipment for welding in carbonic environment.
This door production equipment can produce a dozen finished products per hour. Equipment for painting and other finishing is not included in the complex, it is purchased separately.
Features of the manufacture of fire doors
The main differences between fire doors and conventional door structures are resistance to open fire, high temperatures, as well as the possibility of hermetic isolation of the source of fire.
For the manufacture of such structures, refractory steels of certain grades, fire fittings and self-expanding seals are used. (Non-flammable filler of a leaf basalt wool is used not only in fire-prevention, but also in usual doors).
Equipment for the production of metal doors and the manufacturing process itself is similar to the one described above: laser cutting - bending - welding - coloring and polymerization.
Although modern market metal doors is literally full of this product, the demand for it remains huge. This is explained primarily by its extraordinary demand. And therefore, even despite the apparent competition, in any case, it will be possible to occupy its niche. In addition, highly qualified specialists are not required to organize this business, and the relative cheapness of production is another evidence that the enterprise will certainly be profitable.
Potential clients
This product is most in demand among:
Residents of new buildings;
Buyers of old apartments who inherited plywood doors that are more than a dozen years old;
Tenants of offices rebuilt from residential apartments purchased on the secondary market;
Residents of the private sector.
Metal doors can be made by any locksmith armed with a grinder and a welding machine. This is due to the fact that customers most often demand economy options that are designed to replace obsolete and thoroughly rotten wooden products. As your business expands, you can buy the necessary equipment for the production of metal doors, gradually increasing the capacity of this business.
Features of the door business
More than eighty percent of this market is accounted for by budget goods - the cost of such products is approximately 150 US dollars. It should be understood that expensive metal doors are a fundamentally different product (not fancy cheap), which, as a rule, is manufactured on specialized production lines.
For expensive products, safety is considered the main thing, and not fashionable finishes, for example, from natural oak veneer, which will delight any burglar. Customers with little to protect will never purchase a multi-thousand dollar door. Their philosophy is simple: the simpler the product, and even uglier, the less the apartment will attract the attention of the unreliable stratum of the population (thieves, scammers, and others).
That's why on Russian market doors with fashionable finishes, gothic fonts are not in great demand. This fact greatly facilitates the work of the entrepreneur, because the technology for the production of metal doors without all sorts of frills is very simple. Therefore, we conclude that the product we are considering is not a monument on the grave of some director of a vegetable warehouse. Simplicity and minimalism are the main advantages of a metal door.
What is needed for the production of metal doors: option one - economy
Consider what a novice entrepreneur will need to create his own business in this area. Mini-production, focused on the low price segment, will require capital investments - about fifteen thousand dollars. You will need to purchase a building license, rent production facilities (the workshop area will be approximately 250-300 square meters) and storage facilities, spend money on advertising, because the market is littered with these products.
An excellent advertising move is to exhibit samples of your products in large construction supermarkets. And, of course, you should purchase machines for the production of metal doors. You will need welding machine, metal cutting machine, grinder, milling and drilling machine. Also, one should not forget about the materials of production: sheet iron, corners, fittings and so on.
Specialists
A small business will require a small number of employees. You will need to hire locksmiths, welders and installers. In one shift, the welder is able to produce 2-3 doors. The installer spends about two hours on one door, plus the time for its delivery. The number of hired personnel must be calculated based on your planned production volume.
Option two - elite metal doors
It should be understood that the technology for the production of metal doors belonging to the expensive segment of the market differs significantly from that for the economical option. Such products must have several degrees of protection against burglary. After all, this is not only a beautiful decorative outer panel, but also an expensive reliable lock. Most often, Italian locking devices cost 200-300 dollars.
In addition, one should take into account the fact that it is necessary to provide a long-term warranty service. Therefore, you should not save even on decorative fittings, not to mention the load-bearing parts.
In addition to increasing the cost of materials, you will significantly increase the price of equipment for the production of metal doors. According to experts, the business for the production of such products will be profitable with sales of 60-100 units per month.
Organization of production
When creating such a business, you will need capital investments of about 150 thousand dollars. Half of these funds will be spent on equipment for the production of metal doors, the rest - on rent, exhibitions, salaries, and advertising. However, you should know that breaking into this market will be very difficult. Work experience and a well-established name are especially valued here.
To organize production, in addition to the equipment listed above, you will need the following machines for metal doors: hydraulic vertical bending presses, segmental bending machines, jig punch presses, system plasma cutting, electromechanical guillotines.
Production technology
First of all, you need to make a frame from profile pipes. A flashing is welded on the inside of the resulting box. The grille made of profiles serves as the frame of the door leaf, the basis of which is the stiffening ribs. The lock cuts into a special metal pocket.
Often two locks are installed in metal doors. To reinforce them, a plate two millimeters thick is additionally welded to the outer side of the web. The next step is welding the hinges and blockers to the profile. Then the outer sheet of metal is attached, to hide the gaps, its web should be 10 mm larger on each side. After that, platbands are welded on three sides of the box. Next, the door is sent for assembly and painting.
The final stage of production is the finishing of the product. The following materials are used here: wood, vinyl artificial leather, decorative nails, hardboard sheets, laminate, plastic, MDF panels, etc. Depending on the type of cladding used, you will have to use one or another finishing equipment for the production of metal doors.
Conclusion
The production we have considered is a highly demanded business, since often new settlers first of all change standard doors to new metal ones. Therefore, it is not so difficult to find customers for such products.
Despite the fact that there is a fairly wide range of these products on the market, there is always a buyer for any category of metal doors (economy or elite). According to experts, eighty percent of the market is occupied by cheap products. Therefore, it is recommended to start the production of metal doors with a cost of up to $ 200, and only then, only after mastering the technology, begin to conquer other market segments.
To make high-quality metal doors, you need modern installations and tool. Workshops for the production of such products may differ in equipment depending on the types of box construction and the finish of the canvases. But many of them will have most of the same equipment for the production of metal doors. Here are the main machines and devices used in this process.
Cutting and milling
The process of creating a metal door begins with marking the steel elements so that the final result has parameters exactly corresponding to the ordered dimensions. Next, cutting of iron sheets for linen and solid-bent boxes is carried out. This is done using hydraulic shears.
The huge machine has a powerful base plate for positioning the workpiece. On such a table there is an extreme point along which the cut is carried out. The sheet of iron is laid out in such a way that the marking line exactly falls on this edge. Metal cutting is carried out by a movable plate made of hard alloy driven by hydraulic power. The movement of the mechanism provides two cylinders at the edges of the installation. Such equipment is capable of cutting up to 10 mm thickness, which makes it possible to obtain smooth edges and high accuracy.
Equipment for the manufacture of metal entrance doors, in the case of a box from a profile, includes cutting machines with a large disk of abrasive rotating on high speed. This allows you to quickly cut blanks for vertical and horizontal beams, as well as future stiffeners. The final fitting and deburring is done with small grinders and grinding wheels.
Companies specializing in finishing metal fabric with MDF panels always have cutting machines for wood and milling equipment for pattern selection and relief creation. This gives a variety of surface designs and expands the design options for the sash.
Bending equipment and dies
Companies for the production of metal doors from a curved profile use sheet benders. These are large vertical machines with a matrix of 90 degrees and a counterpart, which is smoothly supplied by hydraulic cylinders. When the sheet of iron is marked, it is inserted into the gap between the working surfaces of the machine strictly along the lines and the bend is launched. The equipment allows to produce:
- door frames;
- stiffening rib;
- solid canvases with bends;
- internal frames.
The presence of this machine makes it possible to perform bends and create structures with three, four or more corners, depending on the production and technical needs. Equipment for the manufacture of metal doors, similar in principle of operation, but with stamping dies, allows you to extrude a pattern on the surface of the leaf.
Drilling and turning
For the manufacture of standard holes for locks in the canvas and additional plates, drilling machines are used, which allow changing the working part in the cartridge and obtaining various diameters for locking mechanisms. The adjustment of the alignment of the crossbar and the counterpart in the finished product is carried out locally with a hand drill.
Most companies buy web attachment loops from third-party manufacturers. Other companies prefer to make such units on their own and have a lathe and a set of cutters for external and internal turning of canopies for this.
Welding and forging
All manipulations with blanks are carried out on supports or tables made of thick iron. This provides comfort and evenness. finished product on surface. Adjustment and reduction of cracks is performed with clamps and clamps. Next, the welding work begins.
Equipment for the production of entrance metal doors for suturing can be in the form of:
- welding inverter for coated electrodes;
- semiautomatic device with continuously moving wire in an inert gas environment;
- pincers with contact welding.
Any of these devices is capable of applying high-quality durable seams, but the difference lies in the speed of work and the amount of deformation from overheating of the metal, which requires subsequent processing and straightening.
Forged elements on the doors are created by heating steel bars in a furnace or gas equipment, and then working on an anvil with various tools. This gives beautiful patterns in the form of leaves, curls and other objects that decorate and enhance the protection of the canvas.
Sanding and painting
The finished product must be processed to perfection. Sanding machines with sandpaper flap discs help with this. Rotation at high speeds allows you to remove small bumps, welding spatter and burrs. After that, the door is processed. This can be done with an airbrush, in the case of applying paints and varnishes, or by powder spraying. The latter is produced in a special chamber where the metal is heated and granulated powder is fed onto it, baked on the surface.
The company "Pantera" uses the most advanced equipment in the manufacture of metal doors, which gives high strength, evenness and beauty of the product. All products are tested and have a certificate.
Room.
Equipment for the workshop for the production of doors.
Staff.
6. Production of plastic doors
8. Production of veneer doors
10. Production of sliding doors for wardrobes
11. Production of paneled doors.
12. Manufacture of doors for baths and cottages.
Financial plan.
Investments.
Payback.
Additionally.
Production of doors in Russia.
Today in Russia there are many workshops and mini-businesses for the production of doors. Their directions are so different, because doors can be made from various materials, such as wood, metal, plastic and even glass. In this guide, we tried to consider the most profitable options for the production and organization of our workshop. As a result, there were twelve directions for starting a business. We also described the basics for any direction, such as production features and the necessary equipment.
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Organization of a workshop for the production of doors.
The production of doors in Russia belongs to the traditional direction of Russian handicraft. For the state, the development of the national woodworking industry at the expense of small business is interesting in that people of working professions “working with their hands” are involved in small business, which helps to increase the popularity of the business direction available to a wide range of potential entrepreneurs.
The opening of woodworking shops in the regions also makes it possible to diversify the product range through craft shops and reduce prices for door products due to the absence of transportation costs. We also note that for commodity group, which includes doors, is characterized by a polar segmentation of manufacturers, mainly foreign ones - that is, inexpensive economy-class doors and expensive exclusive models that are not available to the average buyer are widely represented on the market. Accordingly, through the involvement of small producers, it is possible to expand the range and increase the diversity of the product group, which will also lead to lower prices due to increased competition.
The production of doors can be organized both in a small workshop and in large-scale production. Small craft workshops can flexibly adapt to market changes and change the production process, as well as make doors according to individual sizes with optimal cost due to lower costs.
It is also assumed that competition will contribute to import substitution and will generally reduce prices for door products, since Russia has its own wood raw materials. High Quality. The efforts of the state in this regard are also aimed at creating prestigious jobs for specialists in working professions.
Regulatory Standards:
- GOST 475-78: Wooden doors. General technical conditions;
- GOST 28786-90: Wooden doors. Method for determining resistance to climatic factors;
- GOST 26602.3-99: Window and door blocks. Method for determining sound insulation;
- GOST 26602.1-99: Window and door blocks. Methods for determining the resistance to heat transfer;
- GOST 26602.2-99: Window and door blocks. Methods for determining air and water permeability;
- ST SEV 4181-83 - Wooden doors. Method for determining flatness;
- ST SEV 3285-81 - Wooden doors. Reliability testing methods;
- ST SEV 4180-83 - Wooden doors. Impact resistance test method
Room.
The premises for the door manufacturing workshop are usually rented or purchased in the industrial or warehouse part of the city. To the main technical specifications include: strip foundation or concrete blocks; walls and partitions - foam concrete, expanded clay concrete, brick; windows - metal-plastic or double wooden frames; floors - concrete industrial; insulated roof.
The choice of foam blocks, expanded clay concrete or bricks as the main building material is not accidental and is associated with the need to ensure an acceptable temperature for work in winter and summer time. To reduce the cost of heating the premises in winter, additional thermal insulation of the walls may be required. To improve climatic performance, it is important to install metal-plastic windows.
The storage room, which is allocated on the territory of the workshop, must be equipped in such a way as to ensure a constant temperature and acceptable humidity. This is due to the need to store lumber and finished products, which can change under the influence of atmospheric moisture. Premises for the warehouse of raw materials and finished products should be separated.
Of the communications in the woodworking shop, there must be: electricity, gas, water, sewerage, heating, alarm and telephone communications. Depending on the capabilities of the entrepreneur, infrastructure equipment may not be fully implemented. That is, perhaps, local heating of the workshop with heat guns or installation of electric heating, lack of telephone communication.
The recommended total area of the premises is 300-700 sq. meters. The presence of external infrastructure is required - an entrance and parking for cars, the proximity of a transport interchange. It is desirable to have premises for opening a salon-shop in the city.
Equipment for the workshop for the production of doors.
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To determine the characteristics of the equipment, you will need to do production planning. A woodworking door shop can specialize in interior, entrance metal doors, door products made of solid wood, furniture boards, MDF, using veneer, as well as sliding, paneled, interior doors and utility rooms.
The equipment package depends on the chosen specialization. An excellent fleet of equipment will be required if the workshop will produce doors from aluminum and metal-plastic. Such workshops will also be able to produce metal-plastic and aluminum windows.
As an example, consider a shop for the manufacture of wooden doors. Manufactured products can be made:
- made of solid wood. Doors are made from pieces of wood that are glued together. The array is polished, calibrated, then decorated with varnishes. Some workshops specialize in mosaic splicing and toning in bars, so a solid image can be created;
- covered with veneer. A wooden frame is made, which is filled with honeycomb cardboard, the door leaf is covered with veneer;
- covered with laminate. These are also budget doors with a leaf covered with lacquered film.
Product range: door frames, interior doors, architraves and door array. The production park will include the following equipment:
- band sawmill - 110,000 - 130,000 rubles;
- drying chamber (optional, drying can be done to order in another workshop) - 1800,000 - 2,200,000 rubles;
- tenon cutting machine for the manufacture of tenons before splicing - 200,000 rubles;
- press for end splicing - 220,000 rubles;
- pneumatic splicing press for the entire door leaf - 200,000 rubles;
- milling and copying machine for sawing and processing wood - 150,000 rubles;
- panel saw to create exact copies of designed wooden parts - 220,000 rudders;
- equipment for the production of honeycomb cardboard (optional).
Staff.
Here is the optimal composition of the staff of the woodworking shop, specializing in the production of doors from solid wood, veneer and laminate:
Shop manager (technologist) - 35,000 rubles;
Accountant - 25,000 rubles;
Workshop foreman - 35,000 rubles;
Machine operators - 2*25,000 rubles
Loading car driver - 18,000 rubles;
Rescuer-repairman - 20,000 rubles;
Handyman - 15,000 rubles;
Sales agent with a car - 25,000 rubles.
Since the woodworking shop belongs to potentially hazardous industries, it is therefore very important to train workers and comply with legally fixed labor protection standards. If they are violated and an accident occurs, the head of the shop or the shift foreman will bear criminal responsibility, regardless of the reasons for the defeat.
Workshop workers should be trained in the following areas:
- on labor protection;
- on fire safety;
- on safety measures;
- electrical safety.
On labor protection, primary, repeated, unscheduled and targeted briefings are carried out.
In accordance with the regulations, it must be drawn up and job description describing all the real functions of the shop worker. Only if the rules and regulations are observed, the probability of an accident is minimized, if it does happen, the workshop management is not responsible, including criminal.
12 profitable options for directions for this business.
To date, there are about a dozen technologies for the production of doors. Most of them differ significantly in the technological process, in some cases a completely different package of equipment will be required. For entrepreneurs who want to produce doors, experts advise deciding on the specialization of the workshop.
As the business develops, the equipment fleet can expand, other production methods will be mastered. This approach will optimize investments that will be invested in an existing business with a formed portfolio of wholesale and retail customers. For convenience, here are some of the most common technologies.
The production of interior doors is a popular and sought-after line of business, and products are actively bought up by consumers. The main task of the workshop is to offer the optimal cost of door leaves and a diverse assortment with various options for individual finishes. The company, obviously, must fulfill individual orders and produce doors according to standard sizes in order to sell products in retail chains.
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Peculiarities.
A number of technologies are used in the production of interior doors:
- production of solid wood doors. This direction is focused on the production of exclusive and expensive products, while doors from an economy class array can also be produced;
- production of MDF doors, economy class;
- production of doors from veneer and laminate, also refers to low-cost technologies;
- production of paneled doors, budget doors;
- production of sliding systems;
- production of glass doors, a modern high-tech solution.
The main requirement for technologies is that they must ensure the release of products with a certain level quality for indoor use.
Equipment.
For a workshop specializing in interior doors, in addition to the list of equipment offered in the "Equipment" section, you can purchase:
- CNC milling machines for the manufacture of facades of doors and furniture;
- thermal vacuum presses for coating workpieces with laminated film;
- membrane thermal vacuum presses for the manufacture of radius facades;
- a postforming machine necessary for the manufacture of plastic door facades;
- woodcarving is performed on CNC milling and engraving machines;
Materials.
For the manufacture of interior doors, you will need a door array, lumber, wood, veneer, laminating films, corrugated cardboard to fill the internal cavity of a door made using budget technology.
In the manufacture of doors, Kleiberit 303.2, Kleybit, Bindan-F, Adesivil D3, KRASS PVA D3, MERITIN GLUE D3, average cost will be about 110,000 rubles per ton.
Despite the variety of offers of finished metal doors sold at discounted prices, inexpensive and high-quality entrance metal doors are in demand among buyers. Moreover, the products are in demand products, both mass and individual production.
Peculiarities.
The features of this production line include:
- production of doors from high-quality raw materials and metal sheets with a thickness of 1.8-3 mm;
- rejection of welded joints, which increases the level of protection of a metal door from breaking;
- use of all variety of finishing materials.
Features of production are formed along with the market. The fact is that Chinese-made metal doors are quite common on the Russian market, which have a very attractive appearance, but are practically unprotected from breaking. Used metal can be cut with almost everyday items.
The manufacture of metal doors is regulated by the following standards:
- GOST 31173-2003 Steel door blocks. Specifications;
- GOST 5089-97 Locks and latches for doors. Specifications;
- GOST 23118-99 Steel building structures.
Equipment.
For the production of metal doors, you will need the following equipment. Minimum package: grinder, guillotine for cutting metal, milling and turning machine, welding equipment, hand tools.
To increase production productivity, additional equipment can be installed:
- equipment for preparation of rolled metal for work;
- machine for plasma cutting and metal cutting;
- installation for plasma or laser welding of metal, as well as devices for spot welding, for welding the door leaf, tongs and final carbon dioxide;
- polymerization furnaces for hardening metal blanks.
The metal that is used for production must be hardened in a special furnace or with the help of chemicals and galvanized. In small businesses, the metal structure of the door is coated with special primer mixtures that are resistant to corrosion. We also note that there are semi-automatic and fully automated lines for the manufacture of armored doors.
Materials.
Metal doors can be made from black rolled metal of various types, the price and level of security of the door structure will depend on this.
Budget metal doors are made from pipe bending metal - pipes, channels and corners. The most rigid construction is obtained from pipes with a rectangular cross section and stiffeners. The frame is covered with steel sheets 2 mm thick. In production, electric arc welding is used.
More expensive structures (steel doors) are obtained on the basis of a 1.5-2 mm steel sheet, from which a trough-shaped profile is made. We are talking about profile bending rolled metal. The door leaf is fixed using spot welding: the technology increases strength.
To reduce the cost of the construction of a metal door, combined methods are often used that combine the technological processes of the above.
MDF - Medium Density Fiberboard is made from waste wood products and has good performance. MDF is widely used in various areas of production, including the production of doors and furniture.
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Peculiarities.
In the section devoted to the production of interior doors, there is a video showing the finishing of an MDF panel on a milling machine, followed by coating with a laminated film. This is the technology for the production of MDF doors - the most demanded today due to the operational characteristics of the door.
Facades made of MDF can be used for cladding both internal and external doors (with lamination). Equipment for MDF facade panels allows you to expand the range of products and produce furniture. It should be noted that MDF boards swell from moisture.
Equipment.
For the manufacture of doors from MDF, you will need to purchase additionally:
- turning-milling machine with CNC for the manufacture of facades of doors and furniture from MDF and solid wood;
- vacuum press for lining MDF boards with vacuum films.
Facade semi-finished products can be covered not only with film, but also with paints and varnishes, including those imitating plastic.
Materials.
For production, MDF boards of various thicknesses are used. To distinctive features material include: bio-, fire and water resistance. Despite the fact that these plates are more expensive than chipboard, it is much more profitable to use them. Plates practically do not emit hazardous substances, and the strength of MDF is 2 times that of chipboard. The density may differ and depends on the specifics of production, in general, it is 600-800 kg / m3.
For the production of aluminum doors, you will need a specialized workshop that can specialize in the production of aluminum windows. This is a slightly different market segment, indirectly intersecting with the production of entrance and interior doors.
In general, the production of windows and doors from "warm" aluminum is promising direction production, as it allows us to offer a wide range of products on the market, including:
- aluminum windows and doors;
- aluminum entrance groups for offices of firms and public centers;
- aluminum structures for glazing balconies, terraces and winter gardens.
For the production of windows and doors from "warm" aluminum, you will need the following equipment:
- saw with cooling for cutting aluminum;
- industrial circular saw;
- two-head saw machines with cooling;
- roller table;
- crimping press.
For the manufacture of doors, a warm aluminum profile, “warm” aluminum, is used. Warm aluminum profiles are supplied by Hueck, Schuco, Heroal (Germany), RS SYSTEM Reynaers (Belgium), All.Co, INDINVEST, METRA, NEW TEC GROUP (Italy), MOSMETALLOKONSTRUKTSIYA, Agrisovgaz, Alunekst (Russia) and others
Doors made of solid wood today are usually referred to as an exclusive direction of production with characteristic handicraft traditions characteristic of Russia.
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Peculiarities
It should be noted that, despite the almost complete automation of the production process of solid wood doors. Production optimization not only improves efficiency, but also allows you to successfully compete with foreign suppliers.
It is worth noting that manufacturers miss the moment when setting the price of products, regional production at least saves on transportation and customs duties, and there is also a wide offer of inexpensive high-quality raw materials on the market.
Thus, small businesses that are willing to offer the market a flexible and justified pricing policy, have good prospects for development. An enterprise engaged in the manufacture of doors and furniture from solid wood using technologies traditional for Russian wooden architecture can be involved in the execution of design orders for the restoration of museums, palaces and other cultural heritage sites. In addition to doors, interior and facade design elements can be produced: carved platbands, shutters, cornices, etc.
Equipment.
Wooden doors can be installed both external and internal. In the production of high-quality metal entrance doors, decorative overlays made of wood can be used.
Customers can be offered exclusive woodworking technologies, we are talking about: carving, engraving, gilding on wood, artistic wood splicing technology to create images. Artistic splicing is more often used in parquet production, but can also be used to create exclusive door and furniture facades.
A park necessary equipment described in the "Equipment" section of the proposed review, it can be supplemented by the following machines:
- CNC milling and engraving machines, 2, 3 and 4 coordinate and 3D versions for mass production of carved structures;
- on-board machines or electrical places (for example, FOREDOM K.SRH 440) for woodcarving in an individual copy;
- wood burners for manual finishing of facades.
Materials.
For artistic splicing, the production of an array, expensive and precious breeds are used, for example: wenge, merbau (ebony and mahogany), walnut, Karelian birch, rosewood, cypress, amaranth, cefraz, zebra, boxwood. Also widely used varieties traditional for Russia - oak, ash, birch, maple, pine.
For decorative finishing, decorative oils, wax and modern paints and varnishes are used to achieve the desired design effect.
6. Production of plastic doors.
The production of plastic doors, as well as in the case of the aluminum door workshop, belongs to a different production segment and involves a completely different equipment package. On the basis of the metal-plastic profile processing workshop, it is possible to manufacture doors, windows, entrance groups, and glazing structures. This type of product is in great demand, as the product is characterized by an optimal ratio of low price and window quality.
A set of equipment for the production of metal-plastic doors and windows includes:
- pendulum miter saw;
- table saw for profile cutting;
- single-head welding machine;
- compressor;
- copy-milling machine;
- machine for processing the butt end of the impost;
- corner cleaning machine;
- staple cutter.
Materials.
For production plastic windows one of the available metal-plastic profiles is used. The production can be based on one of the technologies proposed by metal-plastic profile manufacturing companies:
Rehau, WDS, NOVOTEX, VEKA, AluPlast Gmbh, KBE, Salamander Industrie, OpenTeck, ALMPlast, etc.
For the production of glass doors, you need to choose one of the specialized technologies that will form the basis of the production process. Glass doors can be made of aluminum and metal-plastic profiles. These areas have been discussed in the relevant sections. At the same time, the production of glass doors without a frame made of impact-resistant glass can be singled out as a completely separate direction.
Peculiarities.
Obviously, the workshop will be engaged not only in the production of doors, but also glass partitions. A decorative image can be applied to the glass using sandblasting technique and paints and varnishes. The cost of a glass door is often commensurate with the cost of a good MDF door. For the manufacture of glass doors, tempered glass or triplex is used.
Equipment.
The production process of a glass door involves glass cutting, end processing and installation of specialized fittings. The following processing is performed in the following sequence: cutting, high-quality grinding, glass polishing, edge beveling, technological cuts and drilling are made. In addition, the workshop can perform decorative glass processing: bending (manufacturing of curved glass), fusing (sintering), engraving, matting, drawing, painting, glass gluing, lamination.
Specialists for the production of glass doors recommend the following equipment:
- table for cutting monolithic glass InterMac Genius 37 CT-RS;
- NORTHGLASS sheet glass tempering furnace;
- Furnace for bending and fusing Italforni glass;
- machining center InterMac Master 23 - performs grinding, polishing, milling, drilling on glass blanks;
- machining center InterMac Master 45 Plus - performs grinding, beveling, drilling, milling, dredging, sawing, engraving, sculpting, can be used for stone processing;
- Machines for double-sided processing of Bussetti edges.
Materials.
The use of high quality glass raw materials from AGC and Pilkington is recommended. Sungard reflective films are used for door leaf lamination. We use high-quality fittings for glass doors from SF, Casma, Minusco Colcom, Dorma, Kinlong, Target, etc.
Veneered doors are very popular among consumers who purchase budget products. At the same time, the possibilities of technology are quite wide. Doors can be made of traditional Russian veneer, noble and exotic woods.
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Peculiarities.
The technology is well known and widely used. A thin layer of wood is used as a door cladding - veneer, which is attached to the door frame and a solid base. Commercially available veneer thickness - 0.6 mm to 3 mm, rarely 4 mm. The market offers a wide range of veneers, including noble and exotic woods, such as: anegre, bamboo, wenge, as well as painted and tinted veneer. Due to the wide variety of materials, veneer door manufacturers can produce inexpensive doors with high-quality and expensive finishes.
Equipment.
Improved technology for the manufacture of veneered doors involves the following production processes:
- the frame is made of knotless wood (moisture content 7-9%) with gluing on the microthorn;
- the door leaf is trimmed with veneer of noble varieties;
- MDF panels are used, glued with veneer;
- fine-tuning, grinding and polyurethane finishing;
It is better to opt for automatic line for the production of panel doors, including production area for gluing veneer to ensure high quality products.
Materials.
In the production of veneer doors, products from Fibromade, Caleidolegno, Newood are widely used. Recommended glue for gluing veneer in working conditions-Kleiberit 332.0.
The production of wooden doors is justified for small workshops and enterprises specializing in exclusive products. At the moment, wood remains one of the most affordable materials, and the manufacturing technology, for example, of a paneled door, has long been and is widely known.
The previous sections covered the issue of manufacturing exclusive solid wood doors using expensive engraving and milling equipment. At the same time, wooden doors can be made with a minimum set of woodworking tools using the usual technology from raw materials available in the region. Depending on the nature of the finish, the door can be classified as elite or budget.
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To make wooden doors, you will need the following equipment:
- panel saw - used for sawing wood;
- milling and copying machine - used for the manufacture of door elements;
Any available high-quality lumber is used as raw material. Finished door blanks are subjected to decorative painting, waxing or varnishing.
10. Production of sliding doors for wardrobes.
The arrangement of household premises or dressing rooms in apartments with the help of wardrobes has already become a common technique for organizing living space. In order to save space, the doors in such cabinets are sliding. Obviously, almost all of the above technologies can be used in the production of sliding doors for wardrobes, but most often the facades are made veneered, mirrored or decorated with glass.
Veneered chipboard is widely used in production. The prepared canvas is mounted in a special aluminum profile, which is an integral part of the finished sliding system. The aluminum sliding system is installed in the finished cabinet opening.
For the production of sliding doors wardrobes required;
- a machine for cutting glass and processing ends (given above);
The manufacturing technology is very simple, you will need facades, mirror or glass decor, an aluminum sliding system, and a Sevroll profile seal.
The production of paneled doors involves the manufacture of doors from individual wooden elements - panels. This approach makes it possible to simplify the technological process, eliminate the need for wood splicing, as in the case of making solid wood doors. The basis of a paneled door is a wooden frame, which is a carrier for other panels.
The minimum equipment package must include:
- circular saw;
- format-cutting machine;
- milling and copying machine.
At the same time, you can completely abandon the milling and copying machine and use household carpentry tools, ready-made decorative bead, as well as carved decor elements for decorating the door leaf.
The paneled door can be made of solid wood or using frame technology. In the second case, the frame is made of pine bar and sheathed with moisture-resistant veneered MDF. Door elements are fastened with a glazing bead, which is also covered with veneer. Veneering of a door is carried out manually.
Doors for utility rooms, dachas and baths are made using a simplified technology. This is a demanded product, as it is intended for quite specific purposes - use in domestic premises - and meets the requirements. Classically, utility room doors are knocked down from individual wooden boards and fastened to rails made of wood in the shape of the letter "Z" or forged metal. Some manufacturers use paneled technology using wooden lining.
As a rule, the door for a bath should be massive and made of heat-saving material. Natural wood is excellent for these purposes, as it breathes, absorbs carbon dioxide, is relatively unresponsive to changes in humidity and retains its geometric dimensions. The door for domestic premises can be lightweight and made from improvised materials.
In the production of country, auxiliary doors and door structures for a bath, a circular saw, a grinder and a drill, or woodworking equipment available in the workshop, are used. Wood and forged decor are used as raw materials.
Marketing.
The nature of the promotion of products of a woodworking workshop for the production of doors significantly depends on the chosen technology and production volume. If we are talking about a fairly large workshop with a modern fleet of equipment, the company can produce doors to meet mass demand and for individual orders.
Mass production products are sold through hypermarkets and building materials stores, as well as through our own online store with delivery to the buyer's region. Regardless of the direction of production, door products must have an individual style, have an acceptable and competitive cost.
For businesses that focus on exclusive products, attention should be paid to improving personalized service, because it is necessary to create a certain opinion among potential buyers.
Aspiring entrepreneurs can be advised to adhere to two basic rules of promotion:
- if you sell doors that can be purchased from other manufacturers, the cost of production should be 10-15% lower than that of competitors. Stocks are a good tool for temporarily reducing the price;
- if exclusive products are sold, along with the optimal cost, you need to take care of expanding the range of products in different price categories.
Thus, if economy class doors made of veneer and MDF are sold, the cost should be reduced. In the manufacture of exclusive products, it is necessary, first of all, to expand the range of products of different price categories.
Advertising.
In modern conditions, almost any advertising support for a door production shop will not be effective enough. This is due to the fact that in recent years the approach of buyers to the choice of products has changed significantly. As a rule, a person who purchases a door chooses the model he likes at the cost that satisfies him. In many cases, the buyer does not think about the features of production. In this regard, there is no need to advertise the company.
To the most effective tools advertising can include a website where all the information of interest can be placed, including descriptions, images of doors and interiors, as well as an online store. The effective methods of promoting a woodworking shop include maintaining groups in in social networks VKontakte and Facebook, as well as opening your own video channel on YouTube video hosting, where videos will be posted production processes and installation. Certainly it will be required contextual advertising in Runet, which allows you to attract interested users.
Users are always attracted to the "Do It Yourself" headings, showing in detail the production process, this in most cases of targeted viewing leads to the purchase of a door from the manufacturer. For work sales representatives you will need advertising printing - booklets, brochures, pocket calendars, table calendars (optional).
Sales of products.
The sale of the products of the shop for the manufacture of doors, as mentioned, is carried out through outlets partners, so the focus should be on the work of sales agents with shops, supermarkets and hypermarkets. The main problem with working trading networks is associated with a delay in payments, in this case it will be effective to sell doors at retail in the construction market or in your own showroom. Online stores also show a fairly high efficiency in the sale of products.
Financial plan.
The financial efficiency of a business, as a rule, largely depends on good business planning. A pragmatic approach allows you to assess the factors associated with the business and the existing risks. The given examples of specialization of workshops are quite different from each other in terms of their characteristics and indicators.
According to the experience of specialists, on average, it is possible to recoup the costs of opening a workshop for the production of doors within 3 years. However, these indicators are conditional and can be significantly improved. In addition, the conditions of production, the cost of raw materials, the cost of maintaining the workshop, as well as the volume of sales differ significantly depending on the region of the workshop. Therefore, these figures are estimates.
What advice can you give to aspiring entrepreneurs?
It will be necessary to expand the range of products, make them as unique as possible and make them affordable. Almost every buyer who has visited a workshop or a showroom must find products that may interest him in his own way. appearance and cost.
We conclude the review with an example that we began to consider at the beginning.
Investments.
On average, investments in small production for the release of doors you will need:
- equipment:
a) without a drying chamber - 1120000; b) c drying chamber- 3,320,000 rubles; c) with a CNC milling and engraving machine - 3,585,000 rubles;
- 400 sq. m will cost 40,000 rubles / month, an advance payment for 3 months will be required;
- wages employees 223,000 rubles/month.
Total, taking into account the costs in the first three months of production: 4,374,000 rubles.
Payback.
Let's equate the minimum cost of an interior door made of wood to 8,000 rubles, with a profitability of 40%. The income will be 3,200 rubles. Which implies a full payback of the workshop when selling about 1400 doors. An average workshop produces at least 200 products per month, so with proper planning, you can fully pay off the production of doors and related products from natural wood within 7-12 months.
Additionally.
Production of non-standard doors according to the dimensions and drawings of the customer.
Provided that the workshop produces wooden doors from solid wood, customers can be offered doors with carvings, gilding, artistic splicing, decorated with wax, oil or varnish, as well as products made according to individual sizes and sketches. In addition, the exclusive series should be focused on the production of doors, for example, in the "Russian", "French" or "Italian" style, which can also be quickly adapted to individual customer requirements.
Additionally, the workshop can produce carved elements for decorating houses - shutters, platbands, cornices, as well as economy-class panel doors and doors for amenity premises, as per standard projects, as well as design sketches. With insufficient loading, it makes sense to adapt the workshop to the production of designer furniture, adhering to the idea of a single style in the interior. This approach will allow you to receive orders for the design and artistic restoration of interiors.
To provide the house with a real fortress, it is necessary to block the entrance to it with reliable metal doors that will protect against uninvited guests, noise from the street and cold winds. Entrance metal doors are a standard requirement for every inhabitant of his own home today. What equipment for the production of steel doors is used in their manufacture, the article will tell.
In the manufacture of metal doors, first of all, the technology of their production is determined. This sets the speed of the process, the design features of the product, the accuracy of fitting parts and the quality of the design.
Doors can be produced in three ways:
| Method for manufacturing a metal door | Process Features |
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This method uses manual labor with minimal equipment. Approach disadvantages:
The main advantage of the method is the possibility of manufacturing doors according to complex special projects. |
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Products are manufactured in a fully automated way using robotics. This allows you to minimize costs in the production of metal doors, and ensures the maximum quality of the finished product. On the automated line, you can get up to 600 finished doors per day. Process Disadvantages:
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When combining manual and automatic labor, the use of semi-automatic lines is envisaged, with some work performed manually. Thus, it is possible to obtain a product with a higher quality than that of an analogue produced by a handicraft method, but this option is inferior to the automatic production of metal doors in terms of speed and accuracy of the resulting structures. Up to 20 doors can be made per day. |
Main stages of production
Whatever method the doors are made of, the production process consists of such mandatory steps as:
- Preparation of materials;
- Frame assembly;
- Construction welding;
- Installation of fittings and protection elements;
- Filling the space inside the structure;
- Door upholstery and painting.
Materials for manufacturing
Metal doors can be made from profiled high-quality materials: corners, rectangular pipes or bent profiles. In the latter case, from rolled metal sheets are formed certain profiles. In this case, the thickness of the sheet should not exceed 2 mm.
Tip: Do not use a large sheet thickness. In this case, very heavy doors are difficult to open / close, the hinges will wear out quickly due to the high load on them.
Necessary fittings and protection elements:
- Hinges: hidden or hinged (see. ) . For doors weighing up to 70 kg, two hinges are sufficient. Armored structures are best attached to 4 loops.
- padlocks for locks from durable metal thickness from 1.5 to 4.5 mm, installed on locks of cylinder and lever types. These elements protect locks from drilling. Armored pads can be laid on, mortise, magnetic, classic.
- Burglar pins. These small devices are located on the door leafs and enter the frame holes when the doors are closed.
- Eyes of any type.
- Signaling, which can be autonomous, remote.
After familiarizing yourself with all the structural elements of metal doors, you can decide what equipment is required for their manufacture.
Billet Equipment
Before using metal for the manufacture of doors, you must:
- Sort it;
- Check marking;
- Determine the presence of deformations;
- Remove corrosion and scale.
For cutting rolled metal are used:
- Guillotine shears, saws, presses;
- Stationary machines with hand torches or gas cutting;
- Laser, plasma cutting.
For processing blanks in the manufacture of the necessary parts, bending equipment is used. In this case, under the pressure of the press, the metal sheet is given the desired shape: a standard rectangular or arched model. To obtain an arcuate profile of the upper part of the door, the workpiece is passed through rolling machine. After rolling, the profile is cut into the desired sections.
Burrs are removed from the blanks. This is done manually with a file or on a special filing machine.
Then the blanks are sent for punching holes of different diameters for the installation of locks and fittings, according to the prepared cutting maps.
Door assembly and welding equipment
Tip: To assemble the door leaf, use the resistance welding method to prevent deformation of the door leaf and ensure that there are no welds.
Instructions for assembling and welding the door:
- When welding sheets to the frame, an indent of about 20 mm is left on the front side, which will serve as a door porch;
- To increase the rigidity of the web structure, special stiffeners are installed;
- Simultaneously with the stiffening ribs, door locks are installed in special "technological pockets";
- A seal made of non-combustible basalt slab is mounted between the door leafs;
- Hinges are welded to the assembled door with their own hands. In this case, it is necessary to observe the required gaps between the leaf and the door frame.
The photo shows the equipment used for the manufacture of a metal door in the production workshops of the plant.
To better imagine the entire cycle of manufacturing metal doors, to get to know the operation of the equipment in more detail, you should watch the video in this article.
Processing the door with paints and varnishes
The assembled metal door goes to the area for painting. The coating is applied to a well-cleaned and degreased surface.
There are three main ways to apply paint:
- Jet flow;
- From a pneumatic sprayer;
- Spray paint in an electrostatic field.
As a coating, paints of various colors are used. Usually it is: nitro paint, powder, hammer or graphite. This allows you to get good protection doors from corrosion and minor mechanical damage.
The use of special equipment for the production of doors allows us to obtain a high quality structure, which ensures the use of the structure in its original form for many years.