What machines are used for the production of PVC windows: characteristics, price, selection rules

Sales volumes of PVC windows increase annually.
This is due to the replacement of windows in the existing housing stock built before 1995, in terms of volume this is 28% of the produced PVC windows, 68% is consumed by new construction and the remaining 4% goes to re-equipment of Euro-windows that were installed after 1995.

It is important that domestic manufacturers confidently dominate the domestic market today. This can be explained by the fact that the products are in demand, so creating a mini-workshop for the production of PVC windows has become possible for many beginning entrepreneurs.

High production profitability ensures low payback periods of 3-4 years. In addition, there is a sufficient amount of equipment on the market that is needed to organize such production and even ready-made lines.

PVC profile cutting saws

Any production begins with the production of blanks. In the production of window blocks, such a process is also inevitable, because the accuracy and quality of the workpiece depends on the quality of the equipment, in particular cutting saws. It is recommended to choose a saw based on the productivity of the workshop and, of course, on the customer’s requirements for window quality.

Rice. 2. Double head front saw for PVC products

Let's look at some more types of cutting machines.

Machine SK-450

Saw for serial cutting of PVC with feed bottom disc. It is used in mass production for numerous cutting of workpieces, various bookmarks and other connections.

The machine is mounted on a reliable steel frame with one saw head and a circular saw Ø 450 mm. Sawing of the workpiece is carried out automatically after fixing the product with the following parameters:

• The cutting error along the entire length of the workpiece is 0.1 mm;
• The shortest length of the cut piece is 5 mm;
• The longest length of a stationary cut product is 600 mm;
• The longest cutting length when moving the workpiece is 1000 mm.

As a result of the introduced control system software, the technological process is fully automated.

Saw Yilmaz DC 421 MS

This modern universal machine is designed for cutting plastic products with one or two circular saws. The right saw head can be adjusted to any size using the handwheel.

For cutting at an angle from 45 to 90 degrees, the saws are adjusted manually. The Ø 450 mm disc allows you to cut two workpieces at the same time.

Saw Yilmaz DC 421 PB

This model is used for cutting PVC workpieces. The parameters required for the manufacture of window units can be entered into the control system, either directly or via a USB interface.

Two heads are equipped with circular saws Ø 420 mm, covered with protective covers. Up to 60 thousand operations for sawing products are stored in the machine’s program control memory.

The saw feed is carried out through hydraulics and pneumatics, and it is adjustable, which allows for smooth movement of the product and, accordingly, a clean cut is obtained.

There are also other machines for cutting PVC blanks, such as: SDT 275; SC 550P; ACK 420; CK 411, but their design is structurally the same and the difference is only in some characteristics.

Why are they needed?

High-performance modern machines for the production of metal-plastic windows, semi-automatic or equipped with a program control system, make it possible to increase labor productivity by reducing the production time of parts and technological operations.
Such a machine allows you to simultaneously perform a number of technological operations, and the highest accuracy and built-in power ensure the production of high-quality products without defects.

Modern software supplied with the equipment increases cutting speed and automatically calculates the optimal rotation speed for the spindle. Such a device can even be controlled remotely using modern wireless communication lines.

Machining centers on the PVC window production line perform complex processing of the part, without changing its position: milling, cutting, welding and grinding. The profile sequentially goes through all stages of the process after taking the dimensions of the window opening.

Production algorithm:

1. Based on the data received, an electronic drawing of a PVC window is generated;
2. cut PVC profile blanks;
3. holes are made for fittings and moisture removal;
4. cut, assemble and fasten reinforced profiles;
5. weld PVC profiles;
6. grind the resulting seams;
7. imposts are milled.

Welding machines for PVC

Welding machines are designed to melt two mating workpieces and then connect them together under high pressure. They come with manual, semi-automatic and automatic control.

Rice. 3. Double head welding machine

RS-2 for PVC windows (Russia)

The welding device for plastic windows is used to connect PVC products by welding at right angles. The unit has cam workpiece clamps.

The machine is also equipped with an adjustable microcontroller, which can provide operating temperatures from 0 to 340 degrees. In addition, the remote control contains a light and sound alarm warning that the product is ready.

Yilmaz DK 502 – unit with two heads

The welding machine is designed for soldering PVC products at different angles without human intervention.

It has the following modes:

• Automatic clamping of the workpiece before processing and the same release at the end of welding;
• A timer is installed for welding the product;
• Selecting a specific temperature from specified parameters.

This device is capable of welding two pairs of mating products simultaneously, with the right head at different angles. It also has a pneumatic clamp - spinning the workpiece at a given time. Automatic temperature adjustment depending on the specified parameters.

Kaban BB 2030 machine with two heads.

Used when soldering two PVC products at temperatures from 0 to 260 degrees. The unit has a manually operated control head, which is located on the right side of the machine.

On the left head, welding is carried out in the range from 30 to 180 degrees, and on the right - from 30 to 90 degrees. For safety reasons, the product is clamped in a cold state. The permissible seam thickness is from 0.2 to 2 mm.

What to choose?

Selection of equipment is one of the main tasks when organizing such production. In order to perform it correctly, the following indicators must be taken into account:

• type of processing required;
• precision processing and flexibility of machine settings;
• machine power, spindle speed and parts feed speed;
• overall dimensions of the machine;
• cost of equipment;
• possibility of waste collection;
• convenience and safety of operations.

In mass production, when one machine must perform several different operations, it must comply with all technical standards

Note! When choosing automatic equipment for the mass production of plastic structures, it is also necessary to check that its performance matches the cycle of production or processing of PVC parts.

Machines for cleaning the end of the impost

The milling machine is designed for processing the edges and ends of PVC profiles. It is equipped with air clamps and manual feed of the head with the cutter.

Rice. 4. Automatic machine for stripping the profile end

The following types of machines are distinguished:

Yilmaz KM 212 is a unit for milling the end part of a profile.

These machines have a manual cutter feed, and the mechanical clamping of the product is adapted to different profile configurations.

Tabletop profile processing machine Ozelik POLAR-I

The device has:

• mechanical clamps of the product at the top and in the front;
• manual movement of the cutter;
• convenient control on the switching handle of the cutting tool drive;
• The largest size of the socket head is 135 mm;
• landing diameter 30 mm;

It is possible to process a workpiece with a maximum protruding height of 60 mm and a minimum size of 10 mm

Machine for milling profile ends IS-212

The machine is an analogue of the milling machine of the Turkish company Yilmaz KM 212 with some changes: the cutter diameter has been increased to 70 mm, the engine power has increased (1.1 kW instead of 0.8 kW)

Production costs

To start production, initial investments are required. Considering how the business will be conducted, expenses are divided into two groups.

Direct costs required for production:

• Renting premises – you should look for a good premises outside the locality.
• Expenses for equipment needed for production.
• The cost of production equipment depends on the country of manufacture, the degree of novelty, and condition.
• Expenses for the purchase of materials necessary for manufacturing, such expenses are incurred monthly.
• Paying staff is a monthly, permanent expense.
• Utility costs. These include electricity and water bills.

Utility bills are one of the expense items

Indirect waste is necessary, although it has nothing to do with production:

• To register, a certain amount is required to purchase a license and certificates. These documents are necessary for production.
• Advertising creation - product promotion is necessary for successful business.
• Tax expenses amounting to twenty percent of all profits.

Copy-milling machines for processing PVC profiles

These units are designed for drilling and milling holes and grooves for fittings for window units. On all products, specified holes are made according to a specific template for a given sample on the PVC profile.

Rice. 5. Copy milling machine for PVC

Yilmaz FR 222 machine

The device is designed for drilling and milling grooves for the handle, lock mechanism and drainage channels. It must be clamped mechanically. Cutters with Ø 8 mm and lengths from 50 to 110 mm are used.

Yilmaz FR 222 has the following characteristics:

• Manufacturer – Nikmak;
• Pressure in pneumatic clamps – 6 atm;
• Air consumption in the compressor – 5 l/cycle;
• Machine dimensions – 670×1060×1250;
• Weight – 150 kg;
• Electric motor for the copier – 1800 rpm, 0.6 kW, 220 V.

Machine Nikmak MKMF02

The unit provides for milling various grooves in PVC profiles in the manufacture of window blocks. By changing cutters, it is possible to mill grooves of 3 sizes, as well as drill holes.

This operation is performed through a gearbox by a separate motor, and the holes are produced simultaneously due to a device in the machine device.

Unit Yilmaz FR225

The machine is adapted for standard milling of technological grooves for drainage systems, lock cylinders, slats, and for drilling three holes for the handle. In addition, the machine is equipped with a pneumatic clamping of the product.

The kit includes several drills from 5 to 12 mm, a cutter Ø8 mm and a length of 100 mm. The device is equipped with an additional cooling system and a copy matrix.

Machines such as P-1, VILMAZ FR-225, ST-264 are also used for milling grooves

Manufacturing technology

The main thing in the production of a metal-plastic window is the profile. The quality must be of the highest level, the strength of each machine for the production of PVC windows affects the result and profit. The service life depends on this element.

Manufacturing stages

First, the profile is cut according to the specified dimensions, frames and sashes are produced.

At the second stage of manufacturing, strength is added to the reinforcing profile. Its dimensions must match the dimensions of the plastic profile. Both components are connected to each other.

Next you need to do the milling. Here it is necessary to remove the moisture accumulated in the middle of the profile. To do this, holes are made using a milling cutter.

In order to dry the window profile, we make holes with a milling cutter

The next stage is the installation of fittings. The chassis is the fittings, so it must be of high quality.

After this, the parts are assembled into one structure - for this, everything is welded and the seams are cleaned.

After this work, the installation of glass begins. It must be of high quality. The glass is installed in the frame and fixed with aluminum. Then a second sheet of glass is placed and pressed.

Assembly, crimping and filling of double-glazed windows

And to create a profile, fittings are installed. It is she who holds all the structures in the castle.

Equipment and consumables

In addition to machines in the manufacture of PVC windows, it is often necessary to use pneumatic and compressor equipment from Turkey. In addition, there is a wide range of hand tools for the production of window blocks:

• glass cutters with an insert made of high-speed alloy;
• Velcro for glass;
• compasses;
• mechanical clamps;
• retainers.

In addition to this, there is always on sale a sheet bending device for making ebbs, skates, etc. from leading companies in the industry Tapco and Stalex.

Rice. 8. Segment bending machine

Requirements

All equipment for the production of PVC windows, which is located in the workshop, must comply with GOST in terms of safe operation throughout the entire standard service life:

• 
  The design of machines must minimize the occurrence of hazardous situations in production during setup, maintenance, repair or operation.

• Machines must be stable; they must not move or fall during operation.
• They must be well lit during operation, have protection and automatic stops.
• The design of machines must have protection that does not allow them to be used for other purposes.

Important! The equipment manufacturer must inform the consumer about all possible emergency situations on the machines, methods of prevention and personnel protection.

Machine equipment protection means:

• Fire shield.
• First aid kit for providing medical care.
• Automatic switch for emergency shutoff of power supply to the machine.
• If it is necessary to include auxiliary hand-held pneumatic tools, a pressure regulator is additionally included in the kit.
• Blow gun for cleaning machine equipment and working areas from chips.
• Box for spare parts and tools.
• Rubber mat or wooden shield on the floor in front of the machine.
• Electrical socket for turning on electric tools.

Assembly tables, stands, racks

Tables

Polypropylene pipes are used as the base surface of the table, through which it is easy to move products without causing damage. Convenient pull-out stops on the side of the table make it possible to increase the length of the table by 950 mm.

The table dimensions are 1900×1500×800 mm and it is also possible to raise the table in height. Devices on the stands allow you to quickly and securely fix the table to the floor.

Rice. 9. Table for assembling PVC windows

Stands

Sliding stands look like structures with a main surface. It is used for assembly and welding of window blocks. If manual welding is performed, then metal plates with slots for various clamps are often used.

An example of such stands for assembling and welding profiles are electromagnetic stands. This is a flat and shaped surface with mounted electromagnets, and between them there are flux pads with pneumatic clamps.

Rice. 10. Stand for simulating a window block

Shelving

The SMS-01 rack is a frame made of pipes in which finished window blocks are stored.

Rice. 11. Shelving for window units

Opening production and selling window units is currently one of the most promising entrepreneurship movements. And the sale of your product directly depends on what kind of equipment you buy for the production of double-glazed windows, and, accordingly, what quality the products will be.

Production of plastic windows

Plastic windows have become a trend in the construction industry and occupy first place among windows made from other materials.

Types of plastic windows

They are environmentally friendly, energy saving, but at the same time very easy to use. It takes a lot of effort to make them.

To start production you need to fulfill the necessary requirements:

• First you need to take care of the premises for the equipment of the manufacturing workshop.
• There must be enough space in the room to accommodate the necessary equipment.
• Workers had to have space and comfort to work.
• The minimum area for a workshop is 50 square meters.
• It is better to rent a room in an industrial zone, where rent is lower than in other areas.
• It is better to equip office space in places where there are a large number of people who can become potential customers.
• The equipment must correspond to the production capacity.

To start production, you can purchase basic equipment. At first it will be enough. In this case, it is better to use equipment from German manufacturers, but it costs a lot of money. French equipment for the production of windows has the characteristics of the domestic market, but costs in euros.

To save a little, you can buy equipment from Turkish manufacturers. Its price will suit a novice entrepreneur. Machines for producing windows are inexpensive, but their service life is shorter.

Another option is to use used equipment. To increase productivity, it is necessary to monitor the proper operation of equipment.

Start of activity

A room for assembling plastic window parts
To start production, it is necessary to establish an enterprise, obtain tax and state registration, conduct tests and obtain quality certificates. Tests for compliance with GOST standards, SNiP requirements, as well as for obtaining foreign quality standards - DIN and RAL. Having as many certificates as possible, you can profitably establish yourself in the market of metal-plastic products. Before starting production and sales, a sanitary and epidemiological conclusion must be obtained; without it, sales will be impossible.

Relevance of production

Enterprises engaged in the production of plastic windows are in great demand among individuals and construction companies. Consumers want a quality product, but they want it at a low cost. Plastic windows are ordered by companies involved in the installation of metal-plastic windows.

Profile windows are distinguished by their simplicity, at the same time they are durable, have excellent thermal insulation and sound insulation properties. For these reasons, most people are happy to replace old windows with profile ones. Since the construction of buildings is very active at the present time, the production of windows will always be relevant.

According to the assortment, windows are divided only into white and laminated, and they are created according to the same principle. But window models can be single-leaf, double-leaf, three-leaf or even four-leaf.

Four-leaf pvc window

But even in this case, the windows are manufactured using the same equipment.

Each window is made to order and to individual sizes. If a large batch of windows is ordered for the construction of multi-story buildings, in this case all windows are made according to a single template size. In addition, there is template modeling of windows.

Equipment needed for production

For an enterprise to be successful, production machines are needed. Therefore you should purchase:

• saw for cutting the profile according to size;
• saw for cutting glazing beads;
• machine for fastening the reinforcing profile;
• machine for making drainage holes;
• milling machines;
• profile welding equipment;
• end milling machine;
• machine for cleaning the profile surface;
• installation for the production of glazing frames;
• profile bending machine;
• press for processing corners.

Corner press for windows

In addition to the above equipment, it is necessary to install hoods to prevent dust from production from accumulating in the room. Additionally, you need to purchase equipment for assembling windows: washing machines, lifting finished products.