Own business: production of double-glazed windows. Stages of production of double-glazed windows What is needed for the production of double-glazed windows

In this article we will talk about all the stages of manufacturing plastic windows.

It's no secret that any production begins with the purchase of materials and components. In addition, semi-finished products are needed. Therefore, the manufacturing technology of plastic windows, like any other, begins with input control.

For all components there are corresponding . Thus, seals must comply with GOST 30778-2001, fittings must comply, and profiles used for assembling windows.

As for storing the material, it must be stored indoors under normal conditions. Avoid direct sunlight and do not store near heating devices. The temperature in production workshops should not be lower than +18 degrees, otherwise at low temperatures the processing of PVC profiles may not provide the required quality.

Stages of production of plastic windows

The entire process of manufacturing plastic windows can be divided into 11 stages.

Stage 1. At this stage, the reinforcing profile is cut. To do this, use saws for cutting steel reinforcement with abrasive cutting wheels installed on them. Alternatively, metal cutting discs can be installed. The reinforcing profile is cut at a right angle. After cutting, burrs are removed using an emery wheel.

Stage 2. At the second stage, the PVC profile is cut. It is cut with double-head or single-head miter saws. Imposts are cut at an angle of 90 degrees, taking into account a margin of up to 6 mm on each side, depending on the profile system. The profiles of the doors and frames themselves are cut at an angle of 45 degrees, taking into account an allowance of up to 3 mm on the side for welding.

During the cutting process, the base surfaces of the profile are pressed against the vertical stop and the table surface. Clamps are used for this. However, care must be taken to avoid deformation of the profile.

Stage 3. After the PVC profile is cut, the drainage windows are milled into the lower profile of the window block box on a milling machine with an end mill. The diameter of the cutter should be no more than 5 mm. This can also be done manually using an electric drill with a specially sharpened drill with a diameter of 5 mm. For drainage windows it usually does not exceed 25 mm.

Stage 4. At this stage, the PVC profiles are reinforced. Reinforcing profiles are cut to length and inserted into them using a special machine or manually using a hand drill.

Stage 5. After reinforcement, holes are drilled and grooves for fittings are milled on a copy-milling machine. Also, if you have a power tool and special attachments and devices, this can be done manually.

Stage 6. The process of milling the ends of imposts using shaped cutters with their further assembly and installation of fittings. Before installation, silicone sealant is applied to the ends of the impost.

Stage 7. The profiles are welded on a special welding machine. The temperature of the welding knife is about 250 degrees.

Stage 8. At the eighth stage, the impost and are installed. All this is done by hand on an assembly table using a screwdriver or electric drill.

Stage 9. After the impost and support profile, sealing profiles are installed. Installation into the groove begins from the middle of the grooves of the upper horizontal profiles of the sashes and frames. The seal is installed as a single continuous contour without stretching. The ends of the seal are glued end to end with cyano-acrylate second glue.

Stage 10. Hanging of accessories. For a swing sash, a main lock, hinges, corner switches, middle locks and an additional middle hinge clamp are installed. Matching parts of the locking mechanism and hinges are installed for the frame. For a tilt-and-turn sash, a lower hinge on the sash, a main lock and corner switches are installed. If the sash is narrow, then a middle lock on the sash and scissors are placed on it. If the sash is wide, then the lower middle lock, the middle lock on the sash and scissors. Upper and lower hinges, a tilt-and-turn mechanism striker and locking mechanism strikers around the perimeter are installed on the response frame.

Stage 11. The final stage includes cutting the bead and installing the double-glazed window into the profile system (as tight as possible!). Attention! Cutting beads must have guides. To avoid sagging, the sash with double-glazed windows must form a rigid structure. After the beads are installed with a plastic mallet, part of the sash is settled. Preliminary adjustment of the fittings is carried out on the stand, and then on site after the window has been installed.

September 30, 2016
Specialization: professional in the field of construction and repair (full cycle of finishing work, both internal and external, from sewerage to electrical and finishing work), installation of window structures. Hobbies: see the column "SPECIALIZATION AND SKILLS"

The manufacturing technology of metal-plastic structures is complex and simple at the same time. It will be almost impossible for an unprepared person to understand all the intricacies of the process, but after reading the appropriate instructions (such as this article), questions will arise an order of magnitude less.

In addition, after familiarizing yourself with the working methods, you will be able to more clearly imagine the structure of the window. This, in turn, will allow you to order designs more intelligently, understanding which element is responsible for what.

Source materials

In order for the products to be of the highest quality, not only modern equipment for the production of plastic windows and the professionalism of the assemblers are important, but also the correct selection of materials. This article is of a review nature, so I will give only the main list, without touching on the nuances of the selection and production of raw materials - anyway, this information will only be relevant to you if you engage in the production process yourself.

So, what are metal-plastic windows made of?

1. PVC profile is the main raw material, without which, of course, no window will be possible. As a rule, a workshop works with several types of profiles; therefore, the warehouse must have all the elements of the system, from frames and sashes to glazing beads and additional elements.
2. Reinforcing profile – supplied separately, installed in a plastic profile directly at the installation stage. The range of reinforcement is not so extensive, but still about a dozen items (different thicknesses + different configurations) should be present.
3. Glazing is either ready-made double-glazed windows assembled at a separate factory according to the required dimensions, or sheet glass and spacer frames. In the second case, the materials are delivered to a separate workshop, where glass is cut and glass units are assembled.

1. Accessories - they are purchased in any case, since the process of producing accessories is very complex and labor-intensive. Fitting kits are stored in a warehouse and, as needed, delivered to the assembly area for tying the sashes.

Naturally, these are only the main groups of components with which equipment for the production of PVC windows works. In this list I did not include numerous consumables - fasteners, pads, sealing cords, packaging, etc. - in general, everything without which a Czech cannot function normally.

Working with a profile

Preparing for assembly

I will begin the description of the window assembly process in the sequence in which the parts arrive at the workshop and are processed. And first on this list will be a whole range of operations, which can be roughly called preparing the profile for assembly.

The work is carried out in the following sequence:

1. First, the reinforcing profile is cut in a separate section. Steel blanks are cut on a stationary circular saw either exactly to the size of the product, or - for large scale production - in increments of 50 mm. The second method is less labor-intensive, and the quality of the product hardly suffers - anyway, the fittings are made slightly shorter than the plastic part of the window.
2. At the same time, PVC profiles for frames, sashes and imposts are cut on a sawing machine. Here work is already underway in accordance with the assignment generated by the calculation department: the trimming accuracy is +/- 1 mm. Modern sawing machines allow you to set the size of a part by reading a barcode from a job sheet, which makes it possible to minimize the amount of scrap.

1. After trimming, the PVC blanks are fed to the milling machine. This device, controlled by a computer program, mills drainage holes to remove moisture from the profile cavities.
2. Next, the reinforcing profile and frame and sash blanks are assembled in one area. Here the reinforcement is inserted and fixed. To fix the metal liner, self-tapping screws with a drill are used, which are tightened either using a pneumatic screwdriver or on a special machine.
3. Sometimes at the same stage, counter strips are installed on the frame profile, which play the role of hooks for the locking pins of the fitting mechanism.

1. After reinforcement and installation of counter strips, the impost blanks go to the milling section. Here, the ends of the imposts are milled for a tight connection with the frame - according to GOST 30674-99 “Window blocks made of polyvinyl chloride profiles,” the difference in the front planes should not exceed 1 mm. Mechanical connectors are inserted and secured into the ends of the impost.
2. Holes are milled on the frame profiles to install the handle.

Welding frames and sashes

At the next stage, the set of parts is transformed into windows. In this case, professional welding machines are used for the production of windows.

The welding machine is a design with two or four heating elements (the so-called two- and four-head models). It works like this:

1. During the work process, the master places four parts into the machine guides, after which the corner cuts of the profile are joined to the heating plates.
2. The machine heads are heated to a temperature of 240 - 2550C - it is at this heating that PVC melts and becomes fluid.

1. After heating, the profile panels are folded and clamped in automatic clamps until the seam has completely cooled and the plastic has polymerized.

High-quality welding equipment for the manufacture of windows ensures uniform heating of the plastic and guarantees high strength of the seam due to its uniformity. When using homemade welding units (without exaggeration, I have seen models assembled from several pairs of ordinary irons), the plastic melts unevenly, and therefore the seam cracks at the slightest load.

1. The welded frame is fed to a stripping machine (sometimes stripping is performed directly on the welding machine in automatic mode). At the same time, special devices remove the influx of plastic from the front surface of the profile, leaving a smooth and clean seam.

Assembly area

After welding, frames and sashes go to the assembly area. Here, the craftsmen perform most of the work with their own hands: the operations require high precision, which is difficult to achieve with automated production.

A typical algorithm includes the following operations:

1. Cleaning the inside corners of frames and sashes using a cutting tool.
2. Installation of imposts according to the markings with fastening the mechanical connector to the frame: from the outside - using a long bolt, from the inside - using several self-tapping screws.
3. Installing the stand profile on the frame. The stand profile is equipped with a sealing cord made of foamed polyethylene, after which it is installed on the lower part of the frame, snapping onto the fasteners. To increase strength, the base profile is fixed with self-tapping screws.
4. Installing hinges on the frame. To fasten the hinge parts, holes are drilled in the frame (a template must be used, the configuration of the grooves in which corresponds to the configuration of the support rods for the hinge of the selected fitting system). The hinges are installed in the holes and fixed with self-tapping screws.

1. Installation of corner strikers is also carried out according to a template.

The standard instructions involve parallel tying of the sash with fittings:

1. After initial processing (cleaning the internal corners), the sash is delivered to the strapping section.
2. The fittings kit is adjusted in size to the dimensions of the sash. In this case, it is cut off on a special machine.
3. The fitted fittings are installed in the fitting groove, after which its individual elements are fixed with self-tapping screws.

1. Hanging the sash on the hinges. In this case, transport clips are often placed on the frame to prevent damage to the fittings during transportation, and the position of the sash is adjusted using hinges.
2. At the same stage, the master must check how easily the sash opens and closes.

To check moving parts, a so-called “duty” handle is usually used. The handle, which will be installed on the window later, is most often supplied packaged and mounted directly on the site to avoid damage.

1. Installation of additional fittings - microlift, micro-ventilation / step-by-step ventilation, transom scissors, etc.

This completes the work with the window frame. The frame with the sash tied goes to the next section, where it is carried out.

Working with double-glazed windows

Manufacturing of double-glazed windows

Most companies involved in the production of PVC profile windows prefer to work with ready-made double-glazed windows. Those. They provide the dimensions of the required products to the manufacturers, who then make the glazing to order.

But this way the price of the product turns out to be slightly higher, therefore, to save money (and to obtain additional profit), a separate workshop is created in which double-glazed windows are assembled from individual parts.

1. The sequence of actions is as follows:
2. Glass (regular sheet glass, energy-saving or multifunctional) is cut on special tables.
3. After cutting, the ends are treated with special abrasive materials - this removes small chips that can cause cracks to appear.

1. Glass cut to size is washed to remove dust, dirt, traces of abrasive powder, palm prints, etc.
2. After washing, drying occurs. This is best done with compressed air: its flow perfectly blows away dust particles and hairs adhering to a damp surface.
3. After this, the glass unit is assembled on a special table. Butyl sealant is applied to the edges of the spacer frame, which provides primary fixation of the glass.

At this stage, the chamber between the glasses can be filled with dried air, which is supplied from a hose. If you plan to fill the package with argon or krypton, then special valves are installed in the spacer frame, through which the inert substance is pumped.

1. During the process of assembling and pressing a double-glazed window, decorative profiles can be placed inside it - the so-called sprockets. They are used to imitate window frames.
2. When the primary sealing is completed, the ends of the glass unit are coated with a secondary sealant.
3. Then the structure is installed in the pyramid, where it remains in a vertical position until the butyl tape and other sealing substances are completely polymerized.

Finished double-glazed windows are either packaged and sent to the customer, or transported to the glazing site.

Glazing area

Glazing is the final stage. It is done quite simply:

1. The structures are installed on an inclined stand so that the installed double-glazed windows do not fall out.
2. Special gaskets are placed in the frames and sashes to evenly distribute the weight of the double-glazed windows.
3. The glazing is glued onto the gaskets, which is fixed using glazing beads.

1. Glazing beads, as a rule, are cut directly on the glazing area according to the dimensions taken from the structure. This approach allows us to minimize the amount of defects, since the permissible error in the length of the bead is +/- 1 mm, otherwise there is a risk of either getting a gap in the corner or causing cracking of the entire frame.

Glazed structures are packed in polyethylene and sent to the warehouse. There, the order is formed - additional profiles, window sills, ebbs, mosquito nets, handles and other details are added to the windows themselves.

Conclusion

Machines for the production of plastic windows are very different, and they perform a huge range of functions. And yet, the general scheme for manufacturing such structures remains unchanged - in any case, most companies work exactly according to the algorithm described above (of course, with adjustments for the specifics of the enterprise).

The video in this article will give you the opportunity to become more familiar with the process I described, and if you are interested in the nuances, I will be happy to chat with you either in the comments or on the project forum.

September 30, 2016

If you want to express gratitude, add a clarification or objection, or ask the author something - add a comment or say thank you!

Failure to comply with the requirements during the production of double-glazed windows entails a violation of the characteristics of the finished product, and as a consequence - the lack of possibility of an engineering design solution for the project.

The production of double-glazed windows is a multifaceted and complex matter, like any production process; it can be divided into several stages.

At the first stage, after processing and preparing the order for production, glass is cut to the specified type and size in the appropriate area. In parallel with this, the preparation of a spacer frame of the appropriate size is underway. When preparing the spacer frame, a molecular sieve is poured inside, which is necessary to absorb moisture from the inter-glass space of the glass unit. This eliminates the possibility of condensation between the glass panes during further use of the product. The appearance of condensation on the surface of the glass inside the glass unit indicates gross violations committed during its production - incomplete sealing or the absence of a desiccant.

At the second stage, the first sealing layer (butyl) is applied to the end surface of the spacer frame, after connecting it. In parallel with this, automatic glass washing is carried out. After these operations, preliminary assembly of the double-glazed window is carried out: connecting the glass and the spacer frame.

At the final stage, after preliminary assembly, the glass unit enters a press, in which the space between the glass can be filled with argon. The final work of manufacturing a double-glazed window is to apply sealant to the end part of the product to provide greater tightness and rigidity.

Let's consider a more detailed technological process for the production of double-glazed windows (Fig. 1):

1. cutting glass to specified sizes

2. making a spacer frame, filling the frame with silica gel (desiccant), and assembling it.

3. applying primary sealing to the spacer frame (applying butyl)

4. assembly of double-glazed windows on automated lines

5. secondary sealing of double-glazed windows

Figure 1 - Technological process for the production of double-glazed windows

MARKETING

The main activity of the Tyagunof enterprise is the production and sale of double-glazed windows.

The purpose of these marketing studies is to study the market for double-glazed windows, as well as to determine the feasibility of their production on the basis of Tyagunof LLC.

Double-glazed windows in a single frame (frame) are an alternative to double-glazed windows in paired sashes and triple-glazed windows in separate-paired sashes used in construction.

The use of double-glazed windows when glazing window openings in residential and industrial buildings leads to a significant reduction in heat loss through the glass surface. In particular, according to calculations by the US Department of Energy, in the climatic conditions of America and Western Europe, replacing windows with conventional glazing with windows with double-glazed windows and heat-reflecting coating allows saving on heating and cooling of premises up to 50 liters of crude oil per year per 1 m 2 of energy-efficient glazing.

Advantages of double-glazed windows compared to ordinary windows:

Less noise level;

Low heat loss;

Fewer surfaces to wash;

Saving heating costs;

More advantageous box design.

Due to the obvious benefits of using double-glazed windows, in 1998 The Moscow government has introduced a decree requiring the use of only energy-efficient windows in construction. As for the whole of Russia, there is SNiP II-3-79, which indicates new requirements for thermal protection of residential premises, for which only frames with triple glazing or windows with double-glazed windows are suitable.

A double-glazed window consists of two or three sheets of flat glass connected along a contour so that a hermetically sealed chamber with a layer of dried air is formed between them. Some gases can be used instead of air (argon - most widely used as thermal insulation). The width of the glass unit is from 12 to 36 mm, which is significantly smaller compared to conventional frames.

Considering all of the above, we can assume that the double-glazed window market will be quite promising among the building materials markets. The primary consumers of double-glazed windows are construction and repair companies, the end users are customers of repairs or construction.

The price of a double-glazed window depends on the following factors:

1. number of double glazing chambers

2. type of glass used (plain transparent, tinted, low-emissivity, impact-resistant (triplex), colored, armored, etc.)

3. product dimensions

4. product shape

5. domestic/imported components (sealant, silica gel, aluminum frame, butyl glue)

6. filler used (air, argon, freon, gas mixture, vacuum)

7. Degree of line automation

8. country of origin of the line

When entering the market, the sales network can be organized through small construction and repair companies. If you establish constant contact with construction companies at a minimum level of several windows per month for each, then, subsequently, it will be possible to obtain a stable sales market.

The following equipment is used at this enterprise:

Table for automatic glass cutting model Autocut-3.2 (with tilt function) SZILANK (Hungary);

Machine for cutting spacer frame PKM 2800 CMS (Italy);

Machine for filling molecular sieve SM25 CMS (Italy);

Butyl extruder BM 7CMS (Italy);

Polysulfide extruder TMH200 CMS (Italy);

Washing line with a vertical roller press and a manual assembly stand CMS GlassMachinery (Italy);

Touch lawn filler Gasfiller S-8/3 SZILANK (Hungary);

Rotating table DTM 2x2CMS (Italy);

Refrigerator for extruder TF200 CMS (Italy).

Mission of Tyagunof LLC

We strive to be the most efficient company in Russia, to produce high-quality double-glazed windows, satisfying the needs and taking into account the interests of consumers. Through the success of the Company - to the prosperity of our employees and society.

Our values:

Focus on customer needs

Innovative production policy

Competent work of a team of professionals

Social responsibility

The main competitors in Krasnoyarsk.

OOO "Window"

(Founded in 1996. Manufacturing and installation of plastic windows. Doors. Double-glazed windows)

“We produce double-glazed windows using the most modern equipment, a glass cutting line LISEC (Austria) with computer support and a cutting accuracy of 0.1 mm, two assembly lines for double-glazed windows LISEC (Austria), OPTIFLEX (Italy) and two extruders for sealing double-glazed windows (Germany), Therefore, we guarantee high quality and long service life of double-glazed windows manufactured by us.

All double-glazed windows have been tested for thermal conductivity, strength, tightness, and environmental parameters, which is confirmed by relevant certificates. Structurally, double-glazed windows can be:

Single chamber

Double chamber

With armor and sun protection film of various colors applied to the glass inside the glass unit

Argon filled (improves thermal performance by 25%)

Using heat-reflecting Czech glass. The production time for double-glazed windows, depending on the design, is from 2 to 10 working days.”

CJSC "Siberian Glass Company"

(founded in Krasnoyarsk in 1997)

Currently, the Siberian Glass Company is a brand that unites a group of enterprises operating in the industrial glass processing market.

The structure of the group of companies includes 9 enterprises. The functions of strategic development, financial management, determination of marketing and personnel policies, coordination of the work of all enterprises of the holding are carried out by CJSC Siberian Glass Company.

Siberian Glass Company is a leader in the production of double-glazed windows in the Krasnoyarsk market of translucent structures.

The company produces double-glazed windows with aluminum spacer frame, PVC frame and thermoplastic butyl frame using innovative TPS technology.

Technical production capabilities:

TPS double glazed windows, with traditional aluminum spacer frame and PVC frame

Production capacity - up to 4,500 m2 per day

Single-chamber double-glazed windows (thickness from 14 to 36 mm)

Double-glazed windows (thickness from 24 to 60 mm)

Double-glazed windows of various geometric shapes: arch, trapezoid, triangle, circle

Double-glazed windows for structural glazing

Small and large formats (up to 3,500x2,300 mm)

Double-glazed windows are equipped with various types of glass: heat-saving, tinted, reflective, multifunctional, self-cleaning, tempered, enameled, laminated, with decorative film

Gas filling with argon and krypton.

We plan to create a personal website, which will contain all the information that interests consumers about our company.

We also plan to carry out promotions, this is the distribution of advertising leaflets, which is one of the most effective and inexpensive means aimed at promoting products.

plastic window double glazing gas filling

Production of double-glazed windows: industry analysis, detailed action plan, purchase of equipment, establishing sales and making a profit in the shortest possible time.

Most of us imagine our home as a comfortable and warm room, where neither rain nor snow is a hindrance. Whether it's wind or a blizzard, all this doesn't bother us much if we can hide behind reliable walls with high-quality sealed windows.

The last point is especially important, because, in principle, people have been able to build walls since ancient times, but there have always been problems with windows - sometimes it was leaky, sometimes you couldn’t see anything, sometimes you could hear everything a mile away. More "headache" than isolation.

However production of double glazed windows does not stand still, and today we can state that we have achieved considerable success in this

Yes, there were times when a hole in the wall was sealed with oiled paper or a specially treated bull's bladder. Now this is a thing of the past.

Modern technologies used to create equipment for the production of double-glazed windows make it possible to produce a relatively cheap, but quite high-quality product for the mass consumer.

The availability of equipment and ease of use, along with the huge demand for window replacement, have made this area a very popular business not only in Russia, but throughout the CIS.

Let's figure out how to build your own business in this area.

Production of double-glazed windows: market analysis

The production of double-glazed windows is no longer just a business, but an industry. This is not the military industry or gas production, but it is also very important because Windows surround us everywhere.

The conclusion is that someone produced and installed these windows, and therefore made money from it.

How is the situation changing on the double-glazed window market in Russia?

The glass production market in Russia is growing by an average of 8% per year. The market for the production of plastic (PVC) for double-glazed windows is also growing at a similar pace.

However, in 2016, 14.6% less double-glazed windows were produced than in 2015. However, more profits were made. More than a third of all sales of double-glazed windows come from the Central District (primarily Moscow), which is associated with the construction of the Moscow City complex and similar projects.

Russian manufacturers or foreign?

Despite the fact that many brands position themselves in Russia as foreign (“German”, for example), their production is concentrated in the Russian Federation.

The fact is that many large manufacturers of equipment for the production of double-glazed windows work according to the principle. That is, along with the equipment they receive the right to work under the umbrella brand of this manufacturer.

Therefore, it turns out that hundreds of small Russian manufacturers produce “foreign” products, in fact, being in Russia.

*Diagram of the functioning of a double-glazed window

However, working under a brand requires strict adherence to the original technology and the use of high-quality equipment for the production of double-glazed windows, which is more of a plus than a minus.

How is the market situation at the moment?

The transfer of the production of double-glazed windows to the Russian Federation from other countries has led to serious import substitution. According to the marketing agency ROIF Expert, in 2016 Russia provided itself with 98.7% of its own double-glazed windows. In total, over 3,000,000 m2 of products were produced in a year.

The development of the production of double-glazed windows in the Russian Federation has led to the fact that from an import-oriented country, Russia itself has become an exporter.

The largest sales markets were Kazakhstan, Belarus and Uzbekistan, which account for over 90% of double-glazed window exports. At the same time, imports to the Russian Federation from the EU and other countries decreased to 1-1.5% per year.

Which, however, is also a lot, given the huge volume of the domestic market - over 100,000 tons of foreign products per year worth $20-25,000,000.

What development trends are expected in the future?

There is a consolidation of enterprises in the industry against the backdrop of increased competition between players. This distorts the market, reducing prospects in one segment but expanding in another. First of all, this happens in orders for glazing of commercial real estate.

Let us illustrate this with an example from relatively recent news: one large Smolensk company producing double-glazed windows received a loan for the development of production in the amount of 135,000,000 rubles with the support of local authorities at 9.5% per annum.

The very fact of such a loan suggests that large players are betting on market expansion. Probably due to government orders before the World Cup, the need to improve cities, as well as when working on commercial real estate (business centers and shopping and entertainment centers, primarily in Moscow and St. Petersburg).

All this speaks to the following trends in the industry:

Quantity gives way to quality: The peak of installations of cheap plastic windows occurred in the mid-2000s, when old wooden windows finally became obsolete.

Now the second wave is underway - replacing already outdated first generation plastic windows with more modern and expensive ones.

The production of double-glazed windows is becoming a full-fledged industrial sector: businesses founded at the peak of the 2000s are now becoming major players, cannibalizing their less fortunate brethren.

However, turning them into large businesses makes the small business niche free again. Newbies can use this to their advantage.

Equipment for the production of double-glazed windows today: Despite the general decline in sales, the equipment is in increasing demand, because this area is one of the simplest but most profitable technology business options.

Increased production of glass and PVC against the backdrop of a decrease in the production of double-glazed windows suggests that the business is not focused on glazing residential premises, but on working with large structures in the commercial sector.

The reason is that almost all business centers are now lined with glass panels. Working in the field of glazing ordinary apartments, you won’t die of hunger either, but you shouldn’t expect super incomes in the current climate.

Production of double-glazed windows and sales of profile equipment, as well as raw materials and components for double-glazed windows, has become a branch of the economy in itself.

There are an extremely large number of such small and medium-sized industries across the country, and they all require timely deliveries.

Russian business supplies itself: Import substitution indicates that a full production cycle has been established in the Russian Federation.

His only problem is the purchase of foreign equipment. By the way, this can also be a profitable idea for business.

Summing up the market analytics section, we note that the choice of business model strongly depends on the region: work in Moscow City and the provinces are radically different.

Thus, many locate production in Smolensk, where overall business expenses are lower (salaries, utility bills). At the same time, they intend to supply products to Moscow, making a good profit (even taking into account logistics losses).

Double-glazed window - what is it?

Before moving on to the description of the business model, it is worth studying the main technical characteristics of the product itself.

So, contrary to the general stereotype, double glazing is not a window yet. Essentially, this is a box that is the basis of the window. To secure it, you also need a frame, slopes, a window sill, etc. Only everything together turns into a single system, called a window.

We dwell on this in detail because... must be aware: production of double-glazed windows and production of entire windows are not the same thing.

In the first case, your buyer will be another company or private owner who will assemble windows and install them in homes and offices.

In the second, you set up a full production and installation cycle. Then your buyer is already the end user.

The format of the business plan depends on this choice.

What does a glass unit consist of?

The simplest double-glazed window- This is a block of two glasses mounted on a special frame.

This block is hermetic or almost hermetic (there are such designs). An important component of a window in terms of noise and heat insulation is the empty space between the panes. If you add more glass, there will be more sections in the double-glazed unit.

By counting the number of voids, you can understand what type a particular window belongs to:

1. Single chamber
2. Double chamber
3. Three-chamber, etc.

In apartments, double-glazed windows are usually installed, and in offices - single-chamber. But, of course, everything depends on the needs and solvency of the customer.

At the same time, modern windows are much more complex than just a box with two glasses.

Thus, a double-glazed window includes a spacer frame that is hollow inside and a window profile. It can be plastic or metal (usually aluminum). Its task is to hold the glass and help insulate the window.

However, it is not always completely sealed. It often has special diffuse holes. There you can also find a dehumidifier that absorbs moisture. A molecular sieve is used for this.

The glass itself is also not nearly as simple as it might seem. Nowadays, a special coating of its surface is almost mandatory. And both outside and inside.

The inner part of the interglass space is covered with a moisture-absorbing composition, and the outer part is covered with a special protective film. All this improves protection not only from weather conditions, but also from physical damage.

The finished double-glazed window is attached to the window frame, and that frame is attached to the window opening. All cracks are filled with sealant (first butyl and then polysulfide).

Moreover, the sealant itself is divided into several types and types. The choice depends on whether it will be outside or inside, how elastic and durable it is, etc.

Double-glazed windows can have a specialization: anti-vandal, energy saving, sun protection, mirror, etc. All of them protect against weather conditions, but some are more effective than others.

What is needed for the production of double-glazed windows?

Having understood the features of ready-made double-glazed windows, you can think directly about the production chain: what and who do we need for double-glazed windows?

And for this we will need special units and people who will operate them.

It should be noted that modern equipment for the production of double-glazed windows is as automated as possible and does not require a large staff. Oddly enough, the larger your enterprise, the fewer people you need (in relation to the volume of products produced).

So, for the production of double-glazed windows we will need:

1. Raw materials/components from which we will make double-glazed windows.
2. The people who will assemble these double-glazed windows.
3. The equipment with which they will do this.

Components for the production of double-glazed windows

Working on a double-glazed window is reminiscent of a children's construction set - you can buy all the parts and then put them together into what you need.

The only problem is that the materials available on the market are not exactly in the form in which you will need them. For example, the glass is not cut the way you need, the aluminum profile is not divided into suitable segments, and the sealant is not ready for use at all.

This is why you need a staff: to cut everything correctly, to suit the customer’s needs, to arrange it beautifully, and to deliver the finished product where it is needed.

The basic set of components for the production of double-glazed windows is as follows:

1. Construction sheet glass - 200-450 rub./m2;
2. Spacer frame – 600-900 rub./100 m;
3. Plastic corner - 20-30 rub./100 pcs.;
4. Molecular sieve – approx. 70 rub./kg;
5. Butyl sealant in the form of a tape – 3-4 rubles/m;
6. Sealant in the form of a mixture – 200-300 rub./l.

Taking into account the consumption of materials, the cost of one double-glazed window can be 400 - 600 rubles. It all depends on how many sections are in the glass unit, what components are used - domestic or foreign, etc.

Also, the final amount is affected by how large your production is: the larger, the lower the cost of producing an individual double-glazed window.

To this should be added logistics, personnel costs and utility costs (especially electricity and water supply).

Equipment for the production of double-glazed windows and the necessary personnel

The first and most important unit in the list of equipment for the production of double-glazed windows is glass cutting table. It is highly desirable that it be semi-automatic, and for large production - fully automatic.

According to market players, an imported semi-automatic table will cost 25-30,000 euros.

You can buy a domestic version, but it has much fewer automatic functions. More production issues will depend on the operator, and this will reduce the overall speed of work and reduce the pace of production.

Plus, foreign analogues require one person at the machine, while domestic ones require at least two. But it is an order of magnitude cheaper, which means it is quite acceptable for small businesses.

In addition to this table you need washing machine already cut glass. This is another 20-25,000 euros. Plus, the machine requires the installation of special filters - this is another 1,700-3,500 euros. However, they need to be changed regularly (depending on the manufacturer).

The machine requires two operators - if one person can directly operate it, then he will need an assistant to load the glass.

However, if you intend to work on a grand scale, you can buy ready-made automated line for the assembly of double-glazed windows. It will cost 30-35,000 euros.

Requires one operator and at least one more worker to load/unload materials. It is important that the line itself will collect and even wash double-glazed windows. That is, in total it comes out cheaper and more productive than with semi-automatic equipment - there, let us remember, it came out to about 45 - 60,000 euros.

Optional equipment

Similar equipment is needed for cutting and attaching the spacer strip of the inner frame of the glass unit and the molecular sieve. It should be two devices for 5,000 and 2,300 euros respectively. They require two operators to service them.

The assembled double-glazed windows must be treated with sealant, compressed and “finished” by a specialist - check the quality of the assembly, the presence of damage, etc. For this you need a special rotating table with fasteners, and press.

The table can be semi-automatic or fully automatic. In the first case it will cost 1,500 euros, and in the second - 2,800 euros. But in the second case, you can save on the press (costs 900-1,000 euros), because it is built into the kit.

So in terms of money it comes out almost the same.

*Example of design of a workspace in the production of double-glazed windows

You will need extruder for applying two-component sealant or hot melt sealant extruder. The first option is preferable, but the second is cheaper. Their cost is 25,000 and 8,500 euros, respectively. They will require at least two people to operate them.

Additional but important equipment for the production of double-glazed windows is an industrial-type refrigeration compressor. Without it, the sealant on finished double-glazed windows will take a very long time to harden. Especially if the average daily temperature does not fall below 25 degrees, which is important for the summer period.

If you work in cool conditions, then you can do without it, although the double-glazed windows will take quite a long time to dry, which will delay the process of assembly and shipment of the finished product.

Total costs and headcount

If we convert all amounts into rubles, then the initial investment in the purchase of equipment for setting up medium-scale production will be in the range of 2-4.5 million rubles.

To service the production, at least 5-6 workers will be required (+ 100,000 rubles per month for salary alone).

As we said, the production of double-glazed windows is already a technological field of industry, which requires considerable investment and effort.

How are double-glazed windows made?

This video will help you take a look at the production and evaluate everything for yourself:

Let's sum it up: we count the income, subtract the costs from the production of double-glazed windows

Having realized what we will be working with, we can make a sketch, where we take into account all income and expenses:

• As we have already mentioned, the cost of a double-glazed window is 400-600 rubles. per 1 m2, taking into account the costs of personnel and equipment. Let's take an average of 500 rubles.
• You will sell double-glazed windows for 900 – 1,600 rubles. Let's take the average figure of 1,250 rubles.

It is believed that an average such enterprise must produce about 300 m2 of products monthly, otherwise it will be unprofitable.

It turns out that at a cost of 150,000 rubles, the revenue will be about 375,000 rubles.

• This means that your income will be about 200-250,000 rubles per month.
• With a minimum investment of 2,000,000 rubles, the payback of the business plan for the production of double-glazed windows will occur within 1-1.5 years.

Let us note a very important point - all this work requires certification and permits.

Requirements for products are specified in GOST 24866-99, which is called “Glued double-glazed windows for construction purposes.”

Production of double-glazed windows- an area in which there is nothing to do without capital and any knowledge of the industry...

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A double-glazed window is an integral part of a window. Its area occupies approximately 70% of the area of ​​the entire window structure. For this reason, the double-glazed window has a special place in the finished product: increasing thermal insulation properties, ensuring the absorption of street noise, increasing light transmittance, impact resistance, increasing resistance to wind and snow. How a double-glazed window works and what is the technology for its production will be discussed in this article.

Double-glazed window is a set (1), separated from each other by a certain distance, thus forming a sealed inter-glass space filled with dried air or other gas.

It is possible to make a double-glazed window airtight and durable through the use of two sealing circuits, for which different types of sealants are used (4.5).

The spacer frame (2) is made of an insulated aluminum profile with two rows of perforations along its entire length. A desiccant (3), the so-called silica gel, is poured into the cavity of the spacer frame, which absorbs all the moisture penetrating into the space between the glass. Thus, only dried gas remains, which serves as an excellent heat insulator.

The spacer frame in the corners is joined together using corner elements.

Double-glazed windows are divided into:

• single-chamber - two glasses with a gap between them;
• two-chamber - three glasses separated by two spaces between them, respectively.

Double-glazed windows must meet the requirements of GOST 24866-99 “Glued double-glazed windows for construction purposes.”

Basic physical characteristics of double-glazed windows

Production of double-glazed windows

The technological scheme for the production of double-glazed windows is shown in the diagram:

First of all, the glass is cut into pieces of the required size. This operation is performed by experienced glaziers on special cutting tables using a diamond glass cutter. Cut sheets of glass move along the cutting table thanks to holes on the table surface through which air is pumped. Thus, the glass “rides” on the surface of the table on an air cushion.

The finished sheets are run through a special machine. He cuts a chamfer from the ends, making the edges of the glass broken after cutting slightly rounded. This will not only protect workers from cuts in the future, but will also increase the strength of the glass and prevent the sheet from crumbling from the edges.

The glass is then sent to the oven. In the place of the cut, and mechanically this is a real break, internal stresses have accumulated, they must be relieved before inserting this glass into the frame. Otherwise it may crack.

Glass is washed using washing machines that differ in the number of brushes. For larger production volumes, assembly lines are used, which consist of washing machines and a press.

The desiccant (silica gel) is poured into the cavity of the spacer frame on a special stand.

Molecular sieves are characterized by the following specific properties:

• high adsorption;
• low dew point;
• nitrogen desorption (due to this, the glass does not deform under significant changes in ambient temperatures, with the exception of mechanical loads and damage, and also increases the service life of the glass unit).

The primary sealing layer is applied using a high-performance butyl extruder. Butyl extruders differ in butyl feed speed, loading volume, maximum and minimum width of the processed spacer frame, etc.

Then the spacer contour is glued to the glass, and another glass is installed on top. The operation is carried out on an assembly table or on an assembly line for double-glazed windows.

The assembled glass unit is subjected to pressure testing. Crimping allows you to achieve maximum impermeability and the required thickness of the glass unit.

After assembly and crimping, the glass unit is sent to a turntable, on which a secondary sealing layer is applied to the end part using a thiokol extruder. The most commonly used sealant is a two-component polysulfide sealant, Thiokol.

Assembled double-glazed windows manufactured at the enterprise must be accepted by the technical control department of the manufacturer for compliance with the requirements of the technological process and GOST 24866-99. To produce high-quality products, it is necessary to control, for example, that there is no dust and dirt inside the glass unit, that the main sealing layer is continuous, etc. Based on the results of technical control, the quality control specialist makes a conclusion about the suitability of the product and issues a passport for the batch.

After this, the double-glazed windows are dried on special stands, the design of which is designed to ensure unhindered air circulation.

Now the glass unit is ready.

Afterword

In conclusion, I would like to note the advantages of modern windows with double-glazed windows compared to windows with conventional glazing. Firstly, this is a significant reduction in heat loss, and as a consequence, heating costs. Secondly, double-glazed windows are characterized by good sound insulation. And how it was before, just remember: friends invited you to go out for a walk, without coming home to pick you up, but simply shouted out the window. And everything was heard! Thirdly, housewives will like this point; in modern windows the area of ​​available surfaces is smaller, that is, such windows are much faster to clean. So, the benefit is obvious.