Production of PVC profiles for windows by extrusion

• Reviews. Users can objectively talk about the features and disadvantages of a product. Therefore, when compiling the rating, comments and reviews about a specific brand were taken into account.
• Quality. At factories, production is constantly monitored before reaching the buyer; products undergo testing and mandatory certification.
• Safety. Well-known brands use polyvinyl chloride with an updated formula for the production, which does not contain lead and other heavy metals.
• Technical specifications. Companies that have been working in this direction for a long time produce windows of different sizes and thicknesses, so the buyer can choose glazing to suit their needs.

Equipment for the production of PFC profiles

The production of PVC profiles is carried out using the extrusion method , in which a molten polymer compound is squeezed into molds under high pressure.

PVC profiles for window production are manufactured on special lines, which are a complex of special equipment.

PVC profile production line includes:

• Extruder – equipment for squeezing raw materials into a sizing machine;
• Track – a mechanism for pulling material out of the calibrator;
• Calibrating equipment;
• Saw – cuts the profile into pieces;
• Packaging equipment – ​​for applying a protective coating and stacking finished products.

Today you can easily purchase inexpensive equipment from China or give preference to local manufacturers. On average, the cost of a line starts at $10,000.

What parameters of window profiles do you need to know to make the right choice?

A window frame is formed from the profile - a frame into which a double-glazed window is inserted. The quality of the profile affects the overall tightness of the window, the strength of the fit in the opening, the ability to withstand wind loads, the amount of heat loss in the room and the level of street noise entering the house.

Depending on the ability of a PVC profile to solve these problems, it is divided into classes.

The main parameters by which profile systems are divided into classes are as follows:

• Heat transfer resistance is the ability to retain heat in a room without releasing it outside.
• Air and water tightness is an indicator of how much pressure must be applied in order for the window unit to allow air and water to pass through.
• Sound insulation is a parameter showing how much the system dampens noise coming from the street.
• Light transmittance. The amount of light that a window lets in compared to an empty opening.
• Resistance to wind load. Shows the product’s ability to withstand wind pressure.
• Rigidity. Profile strength under compressive and pressure loads.

Each manufacturer has several series of window profile systems, including products with different technical parameters.

Heat transfer resistance

The ability of a window profile system to retain heat and prevent it from escaping from the room is one of the most important technical characteristics. The level of thermal resistance is indicated by the Ro indicator, measured in m²C/W, and shows how much heat is lost through a unit area in a certain amount of time.

The higher the Rо index, the more heat the window structure retains. Based on the level of thermal resistance, PVC window systems are divided into 10 classes, which are designated by letters from A1 to D2. The best indicator is A1 with a resistance coefficient of 0.8 (some newer models have more than 1), the worst is D2 with parameters of 0.35.

Profile classes depending on heat transfer resistance

Air and waterproof

Based on air and water resistance, window profiles are divided into five classes, which are designated from A (highest) to D (lowest). The higher this parameter, the greater the pressure must be at which the window will begin to let air and water through.

Profile classes based on air and water resistance

Soundproofing

One of the most important parameters, especially if the room in which the unit is installed overlooks a noisy city highway. According to the level of sound insulation, PVC window profiles are divided into five classes from A to D: the first reduce noise over 36 dBA, the latter - 25 dBA.

Profile classes for sound insulation

Light transmittance

It is indicated by a coefficient by which products are divided into 5 classes. Products of the highest class A have a light transmittance with a coefficient of 0.5, the lowest class D - 0.3.

Profile classes based on total light transmittance

Wind resistance

Resistance to wind load is provided not only by the force of fastening the window to the opening, but also by the profile itself. This parameter shows how much pressure the window unit can withstand. Based on this ability, products are divided into 5 groups - the best belong to class A, withstanding over 1000 Pa. The simplest class D window blocks can withstand pressure in the range of 200–400 Pa.

Product classes based on wind load resistance

Profile rigidity

Polyvinyl chloride (PVC), from which window profile systems are made, is itself a fairly plastic material. To increase the rigidity of the window frame, manufacturers reinforce PVC profiles with metal inserts - steel or aluminum. The stiffer the profile, the more you can increase the size of the window without losing strength.

Metal reinforcement of PVC profile.

Rigidity is achieved due to two indicators - the composition of the PVC material from which the profile is made, and the presence of reinforcing metal liners inside. To enhance the rigidity of PVC, stabilizers, modifying additives and various fillers are added to the raw material.

Metal inserts inside the block solve the following problems simultaneously:

• give increased rigidity to the window block;
• allow you to make large windows from the profile;
• ensure dimensional stability of the structure when heated from sunlight - the frame does not deform;
• When opening/closing the sash, it does not sag over time.

The rigidity of the window profile also depends on the thickness of the PVC profile itself. The German RAL standard requires that the outer wall of the profile have a thickness of 3 mm with a maximum possible tolerance of no more than 0.2 mm. The thickness of internal partitions is not standardized.

1. Front (outer) wall of the profile. 2. Not the front (inner) wall of the profile.

Profile classes depending on the thickness of the external walls of the profile

Number of air chambers

PVC profiles are made by extrusion, i.e. squeezing molten polyvinyl chloride through molds having a certain configuration. By changing the configuration of factory molds, manufacturers get a different number of air chambers in the profile - from one to eight.

It is believed that the more there are, the higher the ability of the profile system to retain heat. It is considered optimal to have from three to five profile cameras. Increasing the number of air cavities in products is not always justified - this increases the overall weight of the structure and increases the price.

Three-chamber profile.

Five-chamber profile.

Profile uniformity

High-quality plastic profile is distinguished by a uniform structure, smooth surface, absence of inclusions and persistent white color. A counterfeit made by hand has an uneven structure, graininess, inclusions on the surface and turns yellow over time.

Profile width (installation depth)

The width of the profile system is one of the main numerical parameters that the user should pay attention to when choosing. The standard width of the window profile is 58 mm; such windows are suitable for most houses and apartments; they can have 1–3 air chambers. Window systems with a width of 70 are even warmer, they have more than four air chambers. Wider samples 82 and 90 are distinguished by excellent heat-retaining and sound-proofing properties, and therefore belong to premium class products.

Raw materials for the production of PVC profiles

PVC window profiles are made from polyvinyl chloride , which has several advantages over wood and aluminum.

Polyvinyl chloride is a durable material, environmentally friendly, and also resistant to various weather conditions.

The technology for manufacturing PVC profiles is that during production special additives are mixed with polyvinyl chloride - stabilizers (zinc, lead, tin, cadmium compounds), pigments (titanium dioxide), as well as fillers (processed chalk).

The material, ready for production, is supplied to the production of PVC profiles in the form of a white translucent powder. Then the necessary additives are mixed into the raw materials to obtain the desired consistency.

Ideally, the result should be a white material that is resistant to mechanical damage and moisture.

Deceunink

This Belgian company was founded in 1937 and began extruding PVC window systems in 1960. Deceunink now has 14 factories and 22 warehouses in 19 countries, which has created 3,600 jobs. Moreover, in 2012 the company opened its own waste treatment plant in Belgium. In Russia, the Deceunink plant is located in Protvino (Moscow region).

PVC Profile Manufacturer Deceunink

PVC profile production technology

The production of PVC profiles consists of the following stages:

1. PVC resin, as well as additives, are placed in special tanks in which mixing, feeding and control systems operate. According to the recipe, the weight of the necessary components is measured.
2. The resulting mixture is kneaded in a hot and cold mixer, after which it is sent through a vacuum into tanks for ripening.
3. The raw materials are placed in extruders, where the mixture melts, resulting in a homogeneous viscous mass. This mass is placed in molds.
4. In the molding container, the mass takes shape.
5. A calibration table with wet and dry baths calibrates and cools products.
6. The resulting workpieces are sawn and placed in a storage bin.
7. The profile is packaged and delivered to the warehouse.

Extrusion

Mixing of all components of the recipe is carried out in three stages: mixing in a hot mixer, mixing in a cold mixer, holding the mixture at a temperature of 15-30 degrees for 24 hours. The mixture prepared in this way is fed into the extruder.

Extrusion is a method of producing long profile products from plastics and rubber. The process is continuous and consists of squeezing the polymer melt through a hole of a certain cross-section. The first screw extruder for processing thermoplastics was created in Germany in 1935. The function of the extruder is to ensure the melting of a continuously supplied solid polymer mixture, the formation of a homogeneous viscous melt and the injection of the melt under high pressure into a profile head. The production line includes an extruder, tools (die, dry and wet calibration device), marking printer, pulling device, profile cutting saw, device for laying and packaging of finished products.

The prepared PVC mixture is fed into the material cylinder of the extruder, captured by a screw and moved through zones, the heating temperature of which increases from 150-170 degrees at the inlet to 190-210 degrees at the die. In the first zone, mixing and preheating of the material occurs. In the next plasticization zone, the material passes into a viscous-flow state, is compacted and enters the degassing zone to remove gaseous inclusions, trapped air and moisture. In the last exit zone, the pressure of the material necessary for the melt to pass through the die is created.

The “heart” of the entire extrusion line is rightfully considered to be the tool: the die and calibrators. It is the tool that decisively determines the quality of the profile and requires maximum care in its production. The die consists of a matrix and a mandrel, which form a slot channel for the flow of the melt. There are 15 such lines at the enterprise. Their total productivity can reach 70 tons. per day of finished products. A large number of lines allows us to provide a wide range of products, both in profile configuration and color range.

Our own accredited laboratory ensures quality control at every stage of production, including incoming control of the received raw materials. The products have all the necessary certificates and meet the high standards of the Russian market.

Staff

start a business by hiring employees in a workshop (from 2 to 4 people) to work in one shift. If you plan to expand the production of PVC profiles, you can attract new employees to the workforce. For production you need to hire:

• technologist capable of organizing the technological production process;
• shift employees;
• Warehouse Manager;
• employees to measure products;
• director of operations;
• movers;
• cleaners.

Accounting calculations can be outsourced, which will reduce costs and also get rid of the unnecessary hassle of finding a qualified accountant to get a job.

VEKA

This German company appeared in 1969. Production branches were opened in the USA, Canada, Belgium, Great Britain, Poland, China, Spain, France, and in 1999 the first VEKA plant appeared in Russia in the Moscow region (near Naro-Fominsk). Later, in 2004 and 2005, two more plants were opened - in Novosibirsk and Khabarovsk. All production is carried out under the control of the main plant in Germany.

Now the products of this company are imported into more than 40 countries, and the brand itself is firmly entrenched in the market for manufacturers of PVC products.

PVC profile manufacturer VEKA

Required Documentation

Registration of individual entrepreneurship is more profitable if you plan to produce PVC profiles for windows on a small scale. In this case, you will not have to pay taxes in full .

In any case, when expanding production, there is always the opportunity to re-register the business as an LLC.

It should be remembered that it is necessary not only to provide documentation, but also to pay a state fee.

During the documentation process, it is necessary to select the OKVED code 22.21 “Production of plastic plates, strips, pipes and profiles.”

List of required documents

1. Receipt (payment of state duty).
2. Passport and a copy certified by a notary.
3. Application for state registration.
4. TIN certificate (copy).
5. Notification about the selected taxation system (out of five possible).

A package of documents is provided to the tax office . In a few days, the entrepreneur will be able to pick up the documents and receive a permit on the activities of the individual entrepreneur.

You should also open a current account, enter into agreements with service organizations, and obtain a production permit from the fire inspectorate.

Products must comply with GOST 30673-99 “Polyvinyl chloride profiles for window and door units.”

Salamander

And again a German brand! This company has perhaps the most unusual history. Since its founding in 1913, the Salamander brand has specialized in the production of quality footwear. Working with synthetic polymer materials and the accumulated experience in this area opened up a new horizon: in 1973, the company began producing translucent profile structures. Success in the domestic market prompted the expansion of the sales territory. In 2008, the Salamander company organized production in Belarus, which reduced transport costs when delivering products to Eastern Europe and the countries of the post-Soviet space. Now individual window buyers, repair teams, and developers know this brand not only as a manufacturer of boots and shoes, but also as a manufacturer of high-quality PVC profiles with competitive prices.

Manufacturer of PVC profile Salamander

KVE

Also a German company that has been producing window profiles since 1954. The manufacturer conscientiously uses selected polyvinyl chloride, which contains only harmless additives. This brand can be considered an innovator - it has 35 patents in the field of profile architecture. Many technological solutions are borrowed by competitors, which only proves the company’s viability.

Profiles advantages:

• Environmental safety and high energy efficiency.
• Elegant appearance.
• Burglary protection.
• Excellent thermal and sound insulation characteristics.

Complaints arise only when the installation technique is violated.

Mont Blanc

It appeared on the market in 2001 and definitely deserves respect: a lot of effort had to be made, as well as producing really high-quality products in order to attract customers in an environment where the competition is from world-famous giants. The PVC profile line is produced under the MONTBLANC brand. At 20,000 sq. m of factory premises, Montblanc produces PVC profiles and other components for the assembly of plastic windows. Production is located in Elektrostal (Moscow region).

Manufacturer of PVC profile Mont Blanc