Production of metal doors: technology and stages. The secret of the iron door Production of entrance metal doors machine
Modern steel door structures are not an exceptionally reliable protection of the building, but also an element of the interior and exterior. The technology for creating steel blocks is quite remarkable, which is worth considering.
Steel door blocks: necessary equipment for starting a business
Steel metal systems in turn
The main attribute of each building lies in the presence of a reliable overlap of the entrance. It is worth specifying the production process of the stages of manufacturing iron structures.
So each manufacturer is trying to make the production of steel doors more modernized, and developers in modern times use exclusively metal blocks to block the entrance to new buildings. Today, manufacturers are trying to improve not only the technical performance of systems, but the aesthetic side of the product from a design point of view in relation to the latest trends in interior stylistic fashion.
The business of manufacturing iron structures is not particularly complicated, so any entrepreneur can give life to such a production. So list necessary equipment for production purposes, it is permissible to fit into a single table:
| № | Equipment | Hardware Notes | Cost of equipment |
| Machine for cutting steel sheet (metal) | Laser or plasma can be used, since cutting on such machines occurs quickly and evenly | From $1,800.00 | |
| Metal bending press (sheet bending) | From $11,200.00 | ||
| Welding complex for finishing and spot welding | It is permissible to use conventional devices or specialized welding machines | From $1,600.00 | |
| Installation for powder coloring of products: for preparing the surface of the block for painting | It could be a special spray booth | From $980.00 | |
| Installation for powder coating of products: a compressor for painting, a painting gun and a polymerization chamber (furnace) | Instead of the polymerization step, the surface can be coated after painting with two layers of special vandal-resistant varnishes. | From $2,400.00 |
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The above list of equipment refers to the minimum required equipment. So on
Machine for the manufacture of structures
ready-made complex lines for the production of steel blocks are available on the world market, where all the machines and installations listed above are combined. Typical production lines can be fully automated or partially automated, when a human hand must be applied to a certain stage.
Such automated lines are often produced in the world by foreign manufacturers and are endowed with the following list of equipment:
- Installation of plasma cutting of metal;
- Press for bending metal sheets;
- Automatic coordinate welding of door leaves;
- Two machines for the welding process with tongs with conductors;
- Two points of the final welding process taking place in a special environment (carbon dioxide).
A typical line does not provide for a paint box, which is arranged separately. The productivity of the line is reduced to the production of 10 blocks within one hour of time, but also under the control of at least 10 people. The approximate cost of such a continuous production process in the assembled form comes down to no less than $100,000.
Workshops for the manufacture of metal structures
Workshop for the manufacture of metal structures
On the this moment steel doors are manufactured using various technologies, but in fact all of them are endowed with the same initial aspects. The main part of the production technology processes should take place in separate rooms, so the area must provide for the following workshops:
- Workshop where metal is received and raw materials are prepared;
- A workshop where metal sheets are processed and profiles are rolled;
- Workshop where the welding and assembly process takes place (production line);
- Workshop for painting products;
- Finishing and decorative shop, provided that finishing material produced on the territory of the enterprise, and not purchased in finished form;
- Assembly control shop, where the blocks are completed with locking and other mechanisms;
- Warehouses for storage finished products.
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Each of the workshops must meet special requirements regarding fire safety. So the premises should be finished (floors, walls), at least with non-combustible materials, and equipped with supply and exhaust ventilation.
Production and technological process of manufacturing steel blocks
The manufacture of iron doors in relation to technology provides for a certain sequence of production steps that are prescribed in specialized documentation (routing or technological map), where:
- Basic requirements for the initial quality of the material used;
- Rules for the transportation of raw materials and finished products, material acceptance and storage of input blocks;
- The documentation of special requirements indicates a complex technical requirements for each stage of the process;
- Methods of quality control and control are prescribed;
- Many technical conditions (production specifications) are indicated, which are compiled in accordance with the indications of GOST 31173-2003.
Main technological stages manufacturing of steel structures:
Preparation of raw materials.
At this stage, the metal material is to be sorted. The labeling of sheets is verified, the presence of deformations is checked, which appear mainly after the process of transportation or rolling. At this stage, scale and corrosion are also removed from the material. Storage of rolled metal in warehouses should be carried out on racks or sheets are stacked in piles.
Marking and cutting blanks.
The production of doors starts with the correct cutting of metal sheets relative to the templates applied to the surface using scribers and center punches.
Processing of blanks and parts.
The profile of the door frame is created on the sheet bending equipment.
Blanks for future input blocks are sawn off to eliminate burrs and irregularities. So in the process the surface layer of steel is removed in the places of cutting. Sawing can be done manually using simple files, as well as on specialized filing machines.
The processed blanks are sent to a stamping machine, on which holes of various diameters are made in the details for the needs of installation on fittings and locking systems.
Assembly process and welding work
Every owner of a house or apartment worries about their safety. Therefore, the installation of metal doors is in demand today. The construction market offers a huge selection of steel doors. But despite the competition, the business for the production of metal doors is developing successfully. Its advantage is that the process of manufacturing a metal door is simple, it does not require special knowledge, so anyone can do this business. Door metal products are divided into types according to their purpose and resistance to burglary. Distinguish: How the production process of metal doors looks like, watch the video:
You can start a metal door manufacturing business small. To do this, you will have to buy two or three garage rooms: for welding, assembly and painting of the finished product. It will not be possible to amass huge capital right away, but such a start will allow you to gain experience in entering the construction products market. By developing production, the number of equipment can be increased. Under such conditions, the business started will develop successfully. To register a business for the production of metal door structures, legal registration and (IP) or After that, you need to select a tax system by indicating the code of the classifier of economic activity (OKVED). Code 75.21 is indicated if it is planned to manufacture armored safes and, as well as fireproof cabinets and armored doors. After that, it is mandatory to issue a construction license according to SNiP 11-23-81. Without licensing, all actions taken will be illegal. To complete a full package of documentation for obtaining a license, you will need about 35,000-40,000 rubles. Plus, before starting production, you need to familiarize yourself with the requirements of GOST: Establishing the work of a workshop for the manufacture of metal doors depends on budgetary funds and the planned turnover of products. Entrepreneurs often rent workshops of inactive factories or garages to manufacture products. The premises can be separate, however, if there is a common area, it should be divided into separate areas: Certain tools will be required in the manufacture of metal doors. Commercial vehicles for business: what types can be, how and where to buy - read with recommendations. It must be understood that the number of workers depends on the volume of production. To work in the workshop for the manufacture of metal doors, you will need: Prior to starting the production process, the business owner must instruct workers. The briefing should contain issues of compliance with labor protection standards, safety precautions in the production workshop, as well as information on fire and electrical safety. The specifics of manufacturing metal doors is quite simple. The manufacturing technology of metal doors is shown in detail in this video:
Before starting a business idea for the production of metal doors, you need to think about the choice of material for the manufacture of door structures. You can make a door from different types of rolled metal products. How to return a low-quality product to the supplier and get your money back is described in detail. Cheap options involve making a frame from corners, channels or pipes. After the base is covered with sheets of steel 2 mm thick. The second technology is the manufacture of doors from finished sheets of rolled metal. It is a mistake to believe that a thick steel sheet is more reliable. The optimal sheet thickness for standard doors is 2 mm. Heavy doors cause a lot of inconvenience: because of the weight, the door hinges wear out faster and there are difficulties when opening / closing the door leaf. It will be needed in the manufacture of doors and additional elements. You should stock up on such standard fittings as locks, handles, door hinges; latches, as well as eyes, latches and locking devices. Increasing profits will only be done with the right business. To do this, you will have to hire 2-3 welders and gradually acquire the necessary special equipment. We stipulate the payment of salaries immediately: it is better to pay it according to the volume of work performed. it is recommended to calculate according to the number of manufactured doors and product quality. Earnings from the output will provide an opportunity to encourage craftsmen to work quickly, high-quality work and raise labor productivity. Undoubtedly, financial calculations can be made only after assessing the expected scale of the business. However, an approximate business plan for the manufacture of door metal products looks something like this: The calculations clearly show that the idea of establishing such a business is quite expensive. It will take time to get ahead. The payback of the project depends on the organization and the number of clients. On average, the business begins to make a profit in one and a half to two years. The main thing to do during this period is to acquire new pieces of equipment at the expense of profits. This will increase the turnover of products and ensure high quality of the product. You can set up the production of metal door products using: To organize a workshop using manual labor, you will need about 80 thousand rubles. Such a business will pay off in about 6-8 months. To set up a mini-factory, you will have to spend from 15 to 20 thousand dollars (documentation, premises, wages, raw materials, advertising campaigns, etc.). Such products are focused on a low price segment and the business will pay off in 10-12 months. Read about material incentives for staff. It will take about $150,000 to set up a factory for the production of elite doors. Rent, promotions and wages will "eat" half the amount. The rest will have to be spent on equipment. It should be borne in mind that profit from the sale of "expensive" products of such a plan is possible only when selling 80 -100 pieces. doors per month. It is difficult to break into the market of elite products, but if it succeeds, then in six months the business fully pays off. You can consider the profitability of a business using an example that is available to those who have little capital. So, in the manufacture of 3 doors daily per month (on average 21 working days), 63 units will be sold. goods. The approximate cost of the product is 12-13 thousand rubles. Estimated monthly revenue will be 63 units. X 13000 rub. = 819,100 rubles. The cost of materials will amount to 441 thousand rubles. (63 pieces X 7000 rubles). Additional expenses will take about 185 thousand rubles. (rent, utilities, advertising, taxes). In addition, additional funds can be obtained from the installation of the door. The approximate cost of installing one unit of goods is 1000-1200 rubles, and this will bring a total of 63-75 thousand rubles a month. Potential consumers of door products are those who: In the construction market, the range of door products is quite wide. However, despite the competition, it is possible to establish a good business. To do this, you need to take into account the fact that consumers pay attention not only to the strength of the door structure, but also to the stylish design. Production of metal doors: main advantages + manufacturing technology from 8 stages. Equipment for production: complex or separately + basic expenses and business profitability. Capital expenditures: from 7,340,000 rubles. It makes sense to participate in various exhibitions, put up tents with product samples in construction hypermarkets, as well as in construction markets. All this will lead to the fact that people who are currently busy with repairs will think about putting in a new door, and maybe even more than one. The costs required to open your own factory for the production of metal doors are divided into capital and monthly. It is worth considering the important fact that the first time (1-2 months) monthly expenses will not pay off with profit, so they must be taken into account when calculating the main amount of opening costs. Capital expenditures PS. The calculation takes into account the cost of the complex for production, since this is the most suitable and stable option for large-scale production. Monthly expenses There is also an option with the purchase of premises for the workshop. The amount of capital costs from this increases, but at the same time, the amount of monthly expenses decreases several times. As a result, it will bring much more benefits than renting. However, it is important to evaluate your prospects sensibly, because the benefits will be tangible only if the business quickly pays off and becomes profitable. In the case of the manufacture of economy class doors, the approximate profit will be about 1 250 000 rubles per month. It should be understood that such figures will become a reality after a few months (at best), since a sufficient volume of orders will not begin to arrive immediately. You will need to "accelerate", launch an active advertising campaign and build a customer base. Given these figures, we can conclude that the production of metal doors will pay off only in 2.5-3.5 years, with optimistic forecasts. The profitability of manufacturing specifically metal doors is much lower than that of the idea of \u200b\u200bmanufacturing ordinary ones. A novice entrepreneur should not think that a business will become successful if he does not understand the nuances of production and business promotion. Personal experience is the strongest motivator in all endeavors. How a 22-year-old guy earns up to 300,000 rubles a month in the production of metal doors - in this video: In order for the business to become even more profitable, it must be expanded from conventional production to the installation of doors. After all, the installation itself is not a particularly complicated process that does not require much time. Therefore, you can easily include it in the range of services provided by the manufacturer. This will have a positive effect on the development of door production, as it is always much more convenient for customers to do everything with one master. It will also bring additional profit, since most often the margin for such services is about 300%. On average, door installation will take 1.5 hours. This means that one installer will be able to install about 3 doors in a working day. Each installation will bring from 7,000 rubles. For a month you will get a good amount, as for additional income. In this case production of metal doors will pay off faster, and in the future it can be expanded by adding new services and products. Useful article? Don't miss out on new ones! Current idea for business. Any person who cares about their safety, by all means decides to buy entrance doors made of durable steel. The choice in favor of such structures is made by ordinary citizens and owners of commercial premises - offices, shops. The level of competition in the production of doors is quite high. But even a novice entrepreneur will be able to find a suitable niche for himself. Fortunately, customers evaluate many criteria at once - quality, reliability level, appearance. The last factor is especially important for those who live in elite houses and cottage settlements. Therefore, if an entrepreneur wants to organize a business in the production of metal doors, then he should first of all pay attention to the external characteristics of the future product. The presence of a large assortment, excellent aesthetic characteristics and an average cost will help you take your place in the market and even compete with well-known brands. And yet, customers pay great attention to the price. That is why about 80% of the market falls on budget doors with a cost of 7,500 - 8,000 rubles. This means that a metalworker who is excellent at metalworking and who decides to open a business in his garage will be able to start his own business. It is necessary at the initial stage to decide on who exactly to sell your doors to. The following categories of clients can be considered: For the commercial segment, it is better to develop your own door options, as they must have a special appearance and specific properties. The production of entrance metal doors implies the need to organize your own mini-workshop. Its area will depend on the scale of production, and they, in turn, depend on the size of the start-up capital. As a rule, start-up entrepreneurs rent premises on the territory of former factories or in hangars. A small business can get by with three working shops (metal-rolling, assembly and painting) and a warehouse for storing finished products. And a larger enterprise will require an office rental, where the company's specialists will sell doors. The production of metal doors as a business must be started only after the official registration of your own enterprise. The legal form must be chosen based on the scale of sales. A small business can be registered as an individual entrepreneur, and an LLC is suitable for a larger enterprise. At the registration stage, you must also indicate the OKVED code. In this case, the following shall apply: 75.21 - "Manufacture of armored or reinforced safes, fireproof cabinets and doors." If the company will independently deal with the installation of doors, then you can not do without additional code 25.4 - “Installation of metal building structures”. You will also need to obtain a special license. Before completing all required documents an entrepreneur needs to carefully study GOSTs 31173-2003, 23118-99 and 5089-97. Following GOST necessitates the strict fulfillment of special requirements. The production of doors is as follows: You will also need specialized equipment for the production of metal doors. Its purchase requires responsibility from the entrepreneur, because the level of productivity of the mini-workshop and the quality of finished products will depend on this. To work, you need to purchase: Some equipment can be replaced by manual labor. A fully automated workshop will cost the entrepreneur no less than 4,000,000 rubles. An important component of future success is also what kind of raw materials the entrepreneur will purchase for his production. In the manufacture entrance doors use various types of black metal. From what kind of variety the businessman chooses, it will subsequently depend on how safe the construction will turn out, what will be the cost of the door, and hence the selling price. most accessible and best option involves the use of pipe bending products (corners, channels, pipes). The frame itself is sheathed with sheet steel, the thickness of which is 2 millimeters. Doors of increased strength suggest the need to use a steel sheet with a thickness of 1.5 to 2 millimeters as the basis. The amount of start-up capital directly depends on the scale of production. A medium-sized workshop will require the following investments: Total: 4,110,000 rubles. The main costs will include rent and wage, purchase of raw materials, taxes and insurance contributions, transportation costs, utility bills. Net profit will be about 170,000 rubles per month. This means that investments can pay off in about 1.5-2 years. In this article: In order for the house to be truly a fortress, reliable metal doors should block the entrance to it - protection from uninvited guests, cold winds and street noise. Entrance doors made of durable steel are a standard requirement that every inhabitant makes today for his own home. Despite the fact that the competition in the entrance door market is quite high, you can still find a niche here: recently, the demand has grown not only for the quality and reliability of door panels, but also for spectacular appearance(especially in elite new buildings, well-guarded entrances and cottage settlements). Therefore, having thought over an interesting, stylish design and an assortment range of several models, you can enter the middle price niche on a par with branded manufacturers. However, as practice shows, the decisive factor when buying from 80% of consumers is the price. Therefore, even "garage production" - with the help of hand tools and machine tools, is quite capable of making a profit in as soon as possible which will allow you to take a step to the next stage of business development. Apply on large factories with high productivity from 200 doors/day and more. The technological process is fully automated, it takes about 2 minutes to make one door leaf. High-precision technology ensures the same geometry of the product, forming profiles, drilling holes for fittings and connecting fasteners, painting the door leaf and filling internal voids - everything happens automatically, with minimal manual intervention. The welding of the product is also automated, thanks to the use of special welding robots. Strong weld seam connections do not require additional manual cleaning and grinding. Minuses:
high price and maintenance costs (lines are made to order, the cost starts from 6 million rubles). For the full operation of such equipment, a large production area (from 1500 m 2) is required, where, in addition to the workshop itself, it is necessary to provide significant areas for storing raw materials and finished products. A set of equipment and machines for opening a partially automated production: Rice. 4 (Plasma) With this equipment, you can produce 15-20 doors per day. The required area of the premises is not less than 250 m 2 . Pros:
the cost is quite lifting for medium-sized businesses - the price of a semi-automatic line completely depends on the configuration (from 400,000 rubles). But some machines can be replaced with simpler equipment, which will significantly reduce start-up capital, but will increase the amount of manual labor and, accordingly, the cost of wages to workers. Minuses:
"human factor" less automation, the higher the number of marriages. In addition, highly skilled craftsmen, trained to work both on machines and manually, will be required to ensure the correct implementation of the production technology at all its stages. Minimum set of equipment: Pros:
minimum costs for the purchase of equipment (from 60,000 rubles) and rental of premises (60-80 m 2). Minuses:
2-3 doors a day is the maximum productivity for such equipment. Such a mini-production can only be focused on the low price segment. To avoid a large number marriage, we need specialists who can work on metal. All the main processes of steel door manufacturing technology must be carried out in separate rooms. Therefore, the production area should provide: Of the special requirements - the presence of a fire safety system, non-combustible materials for walls and floors, good ventilation. The manufacturing technology of a steel door includes a certain sequence of actions prescribed in a special document (technological or route map), indicating: Main stages technological process production of steel doors Before going to production, the metal is sorted. The marking, the presence of deformations after rolling or transportation is checked, corrosion and scale are removed. In the warehouse of raw materials and materials, rolled metal is stored stacked or on stable racks (at least 2.5 m high). Making doors starts with cutting sheet metal according to the templates applied with the help of center punches. For cutting rolled metal use: The profile for the door frame is made on bending equipment, where, under the pressure of a press, a metal plate is bent at the required angle. It can be either a standard rectangular design or an arched model. In the second case, the arcuate profile of the upper part of the door is passed through rolling machine to give the desired shape. After rolling, the profile is cut into the desired parts. The blanks are sawn off - to eliminate irregularities and burrs, the top layer of metal is removed at the cutting points. Sawdust is performed manually, with the help of files or on special sawdust machines. After processing, the blanks are sent to a stamping machine, where holes of various diameters are punched for locks and fittings in accordance with the prepared maps. The assembly of the door leaf is carried out using resistance welding, which eliminates the deformation of the leaf and ensures the absence of welding seams. The sheets are welded to the frame, a 15-20 mm indent is left on the front side, which will serve as a vestibule. In the manufacture of metal doors, a multi-seam type of welding is used. The density of the fabric structure is achieved by installing special stiffeners. Door locks are installed simultaneously with stiffeners, in places reinforced with metal plates (the so-called "technological pockets"). A non-combustible basalt slab is used between the door leafs as a seal and sound insulator (alternative options: wood, mineral wool, glass wool, polyurethane foam, polypropylene). Hinges are manually welded to the assembled door, observing the necessary gaps between the leaf and the door frame. The assembly is carried out according to several types (by marking, in conductors, by copiers) and is controlled at each stage for compliance with the geometry in order to correct the defect if necessary. After assembly, the door blank is sent for painting. The paint is applied to a cleaned, sanded and degreased surface using one of the following methods: Nitro, powder, graphite, hammer paint of various colors is used - this coating forms a good protection that protects the door from corrosion and light mechanical damage. After drying, the thickness of the applied layer is controlled and there are no visual defects - air bubbles, unpainted areas, cracks, stains. To give high wear resistance and an original decorative effect, an additional protective coating can be applied to the surface of the workpiece - molded or laminated finishing panels, which are manufactured at the enterprise by cutting (automatic or semi-automatic) according to ready-made templates or purchased in bulk. Types of skins: Inserting fittings and checking locks is done manually. To avoid the characteristic knock of metal on metal when the door is closed, to enhance heat and sound insulation, a special shock-absorbing material is glued onto the door leaf - a rubber seal made of rubber or silicone. To control the quality of the assembly and the tightness of the door leaf to the frame ready product installed on the control stand. If all requirements are met, the door is packed and sent to the finished product warehouse. There are two technologies for manufacturing steel doors: Today, the second technology is most successfully used in production, where the raw materials for the manufacture of doors are finished sheets of metal. Many believe that the thicker the steel sheet in a metal door, the better. And this is not entirely true. Too heavy doors can lead to a lot of problems, for example, difficulty in opening / closing due to heavy weight, rapid wear of hinges due to high load. Therefore, 2 mm is the upper "bar" for standard apartment doors. Each additional millimeter adds about 8 kg of weight. Required accessories: 1. It is planned to open a mini-factory for the production of steel entrance doors. Target group of consumers - construction organizations and private households. 2. For the legal registration of business, an LLC was created on the general taxation system, indicating the following types of OKVED: For the production of metal doors and the provision of services for their installation, it is necessary to issue a license in accordance with SNiP 11-23-81. The cost of processing packages of documents and obtaining a license is about 35,000 rubles. 3. The production workshop is planned to be located on 100 m 2 of non-residential leased premises. Rental price - 15,000 rubles / month. 4. Costs for the purchase of equipment - 125,000 rubles: 5. Calculation of the cost of 1 product - a metal door with a size of 2180 * 1040 mm. Total: 7081.80 rubles 6. Income from sales It is planned to manufacture and install 3 doors per day with a 21-day working day. The selling price of the product is set by the method of conducting a comparative analysis of prices on the market and is equal to 12,500 rubles. Installation cost - 1200 rubles. Projected revenue per month: 63 pieces * 13,700 rubles = 863,100 rubles / month. Material costs - 63 pieces * 7081.8 rubles = 446 153.4 rubles / month. 7. Other costs of doing business: Total: 184,449.32 rubles / month. 8. Financial results Net profit: 863,100 rubles - 446,153.4 rubles - 184,449.32 rubles = 232,497.28 rubles / month. The initial investment (equipment + license + material costs for 1 month of work + other costs) will pay off in 4 months of work.
How to start a business
Paperwork
Code 25.4 - only the installation of metal door structures is planned.Choose a room
Scheme of a metal door. Necessary equipment
We select personnel
Technological process of production
Raw material efficiency
We increase income
The production of metal doors is an efficient and profitable business. Cash costs and payback
We calculate income
Finding Clients
Approximate payback period: about 3.5 years.1. We analyze the demand for the production of metal doors
8. Costs of setting up a business
9. Profit and profitability of door production
Conclusion about metal door manufacturing business in Russia
Despite all the costs involved in organizing an enterprise of this kind, there is a chance that the production of metal doors will become very successful and will be able to bring a fairly high profit.
Enter your e-mail and receive new articles by mailMarket analysis
Features of the selection of premises
Organizational moments
Purchase of the necessary equipment
Purchase of raw materials
Financial results
Steel door production equipment
1. Automatic lines
Pros:
automated lines allow to produce 500-600 finished products per day with minimal risk getting a marriage.2. Semi-automatic lines (using manual labor)
3. Manual labor and machine tools
Workshop for the manufacture of metal doors
Technological process of production of metal doors
1. Metal preparation
2. Marking and cutting blanks
3. Processing of workpieces
4. Assembly and welding
5. Treatment with paints and varnishes
6. Sheathing with decorative elements
7. Installation of locks, fittings, quality control of the finished product
Raw materials for making steel doors
Business plan for the production of metal doors
