home » Acts » How to organize your own production of metal doors? Production of metal doors: technology and stages Production of metal doors as a business.

How to organize your own production of metal doors? Production of metal doors: technology and stages Production of metal doors as a business.

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.

Market analysis

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 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:

citizens who have just settled in a new building;
cottage buyers;
owners or landlords of offices;
citizens who inherited an apartment.

For the commercial segment, it is better to develop your own door options, as they must have a special appearance and specific properties.

Features of the selection of premises

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 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 work shops (rolling, assembly and painting) and a storage warehouse finished products. And more large enterprise will require renting an office where the company's specialists will sell doors.

Organizational moments

The production of metal doors as a business must be started only after official registration own enterprise. 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:

preparatory stage (steel sheets are checked, if damaged or deformed products are found, they are sorted out, and the slightest signs of corrosion are eliminated);
markup;
cutting;
profile processing;
construction assembly;
welding;
applying paint, varnish;
sheathing (allows you to get a beautiful and durable door);
installation of fittings, locks and rubber insulation;
checking for compliance with standards.

Purchase of the necessary equipment

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:

press brake (the most expensive equipment, the cost is not less than 800,000 rubles);
cutting machine;
welding machine;
installation for applying powder paint;
equipment for sheet surface treatment for subsequent painting;
oven (with the help of it polymerization occurs);
spray booth and a special pistol;
compressor.

Some equipment can be replaced manual labor. A fully automated workshop will cost the entrepreneur no less than 4,000,000 rubles.

Purchase of raw materials

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 different kinds black rolled 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.

Financial results

The amount of start-up capital directly depends on the scale of production. A medium-sized workshop will require the following investments:

equipment - 4,000,000 rubles;
renovation of the premises - 40,000 rubles;
obtaining permits and licenses - 40,000 rubles;
purchase of the first batch of raw materials - 30,000 rubles.

Total: 4,110,000 rubles.

The main costs will include rent and wages, the 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.

Entrance metal doors have already become an integral attribute of any apartment and premises with buildings where safety for the owners is paramount. Here we will talk about the production of metal doors, equipment and technology for their manufacture. They are very well in demand and often recently installed by the developers themselves in new apartments, because. if they do not install them, then their new owners will do it anyway.

advantage this business for the production of entrance metal doors is that the process itself is quite simple and does not require any additional knowledge from you. Therefore, any interested entrepreneur can do it.

Equipment for the production of

For the manufacture of metal entrance doors with powder coating, the following equipment is required:

Metal cutting machine. Plasma or laser is used, because. cutting them is done evenly and as quickly as possible. Price from 100,000 rubles.
Press brake. Price from 700 thousand rubles.
Welding equipment for spot and finish welding. These can be conventional devices, or welding machines. Price from 100 thousand per unit.
Powder coating equipment: complex for surface preparation before painting, spray booth (from 60 thousand rubles), polymerization oven (from 150 thousand rubles), spray gun, compressor.

This applies to machine tools, but there are also ready-made complexes (lines) for the production of metal doors that combine all these machines. They look something like this:

They come in different configurations.

The price for the line presented above is 6 million rubles. It has everything for the production of metal doors, except for the painting function, namely: plasma cutting, sheet bending press, machine for coordinate welding of door panels, 2 stations for welding with tongs with conductors, 2 stations for final welding in the environment carbon dioxide. This line is designed for 8 people with a capacity of 10 doors per hour.

Manufacturing technology

The whole manufacturing technology of entrance metal doors is very simple:

The metal is cut, and all the necessary holes for locks and eyes are made, because. if done after painting, it will cause cracking of the paint around these elements;
Then it is bent;
Assembly is carried out and initial - spot welding;
If everything is in order, then the final finish welding is performed;
After all this, the door is prepared for painting and placed in the spray booth. There it is painted through the spray gun and then placed in the polymerization oven.

You can watch the whole process in the video:

PS: don't forget about additional service, which you can provide with independent retail— installation of metal doors. She will bring you even more "penny".

Entrance doors made of metal today are in almost every apartment and in many houses. This is a sought-after product, available in the product range of many factories. The number of manufacturers is constantly growing.

Unlike an interior door, a full-fledged front door is difficult to manufacture in artisanal conditions, without the appropriate equipment. What functional parts does the equipment for the production of metal doors consist of, and at what price does it cost?

Kinds

1. Cutting machine. Used for cutting metal. In production, laser and plasma machines are used. The price of this equipment is from 200 thousand rubles.

2. Press brake. This equipment for the manufacture of doors is designed to give the metal the desired configuration. Professional machines are controlled by CNC. The cost is about 1.5 million.

3. Welding equipment for the production of doors. The metal parts of the structure (frame, sheets, stiffeners) are pinpointed during the assembly process, then welded completely. For this purpose, both professional welding machines and welding machines are used. Price from 200 thousand.

4. Completely automated production all necessary holes and cutouts (for fittings, for glazing, etc.) are performed by a jig punch press. Its price is very high, only a large factory can afford this equipment.

5. The most common option for coating the outside of the door is powder-polymer paint. For their application, a spray booth (from 120 thousand), a polymerization chamber (from 300), compressors and guns are required.

6. Equipment for the production of metal doors (ready-made lines, fully equipped with everything necessary for the manufacture of doors), cost over 10 million. Complete set of such lines:

Press brake;

Plasma either laser machine for cutting;

Equipment for welding tongs with a conductor;

Equipment for welding in carbonic environment.

This door production equipment can produce a dozen finished products per hour. Equipment for painting and other finishing is not included in the complex, it is purchased separately.

Features of the manufacture of fire doors

The main differences between fire doors and conventional door structures are resistance to open fire, high temperatures, as well as the possibility of hermetic isolation of the source of fire.

For the manufacture of such structures, refractory steels of certain grades, fire fittings and self-expanding seals are used. (Non-flammable filler of a leaf basalt wool is used not only in fire-prevention, but also in usual doors).

Equipment for the production of metal doors and the manufacturing process itself is similar to the one described above: laser cutting - bending - welding - coloring and polymerization.

Market entry key

official data on how many metal doors annually installed in Russia or at least Moscow, does not exist. However, it is not difficult to estimate the approximate capacity of this market. It is known, for example, that XXX free municipal apartments were built in the capital. At least 75% of the new settlers immediately changed the flimsy "typical" door to a solid metal one. Add here buyers of commercial housing, companies that care about, as well as residents of old houses who have decided to securely hide “everything that is acquired by overwork,” and it turns out that the Moscow market alone needs at least 50,000 doors annually.

Hundreds of enterprises of various levels are trying to make money on meeting this demand - from "garage" shops to large factories. The presence of players in such different “weight categories” is explained by the variety of market niches and a wide range of products in demand: consumers need both cheap doors and the most “fancy” ones. Such a structure of demand, in principle, makes it possible for any firm to expand and develop. Theoretically, every "soldier" is capable of becoming a "general". Even a lone artisan can grow into a head big company, gradually adding necessary equipment and increasing production capacity. But practice shows that in a market with high competition, it is better to start the path to "generals" with "lieutenants" - in our case, with the organization of a mini-factory.

Your own door factory

Experts say that more than 80% of the metal door market falls on simple products worth up to $150. To organize a mini-factory for their production, you will need at least $10,000–$15,000. This amount includes the cost of purchasing a license and renting premises, equipment, components, advertising and wages workers (in the first month of work).

The success of the business initially depends on whether it will be possible to find a suitable production facility and agree with its owner on a lease for a long time.

The mini-factory must have an area of at least 250–300 sq.m. As a rule, entrepreneurs either hangars or rent empty workshops at old "Soviet" enterprises. Variation in rental prices industrial premises very large. In Moscow, a hangar with an area of 200 sq. m. can be rented for $1700-$3000 per month. A capital building of the same area costs from $4,000.

Beginning entrepreneurs simply cannot pay so much. In this scenario, their business will be unprofitable, - says Evgeny Stepanov, Deputy General Director of Sezam.

Therefore, most firms operating in the capital's market of cheap metal doors place their production facilities in the Moscow region. Historically, most of them are concentrated in Klin.

We rent a 300-meter capital building for $1,500 a month, says Anna Savchenko, co-owner of a door company. - And some firms managed to find something similar in Klin for $500. In any case, rent here is cheaper than in Moscow. Therefore, Klin doors are cheaper than Moscow ones. And buy them better.

As for the equipment, the mandatory set includes welding machines, grinder saws, a guillotine for cutting metal, turning, milling and other machines. You can save money by buying used units.

The number of equipment, as well as the number of workers, is calculated based on the volume of output. The average welder can “weld” two or three doors per day. Thus, a company producing 300 doors per month would need at least five welders. Measurer and installer functions in small firms usually performed by one person. In addition, small producers usually do not have their own fleet. Therefore, installers have to be also drivers operating their own vehicles. Installation of one door takes 1.5-2 hours. That is, in a day, taking into account moving from client to client, one installer can complete 2-3 orders.

Finally, before starting work, a company that produces metal doors must purchase building license. It costs $800-$1000.

iron stream

In the segment of cheap metal doors, money is mainly earned due to high turnover: in order to "become profitable", you need to produce at least 200-300 products per month.

Before the 1998 crisis, this threshold was lower, says Anna Savchenko. - Then a cheap metal door cost about 1000 rubles, that is, $150. But then imported materials and components rose sharply in price following the dollar. And the proceeds from the sale of the finished door decreased to $60-70.

As a result, the income of manufacturers of cheap products began to fall. The fact is that imported components take about 30 - 40% of all costs for one such door. Another 30% is the cost of staff salaries (welders and installers, as a rule, work piecework, receiving 10-15% of the cost of the product for their work, and remuneration for dispatchers ranges from 15 rubles to 100 rubles per client). The lion's share of the rest of the revenue is "eaten up" by rent and advertising, which is indispensable in this business. And there is no way to raise the price: competition is high, customers are not rich people.

There is only one way out: to increase production and reduce the cost of production. Therefore, most entrepreneurs involved in this business invest most of their income in the purchase of new equipment. Otherwise, do not survive.

How to earn more?

More profit with lower sales volumes are received by firms engaged in the manufacture of expensive products: doors finished with laminated panels, MDF, artificial or natural veneer of valuable wood. The cost of such products is higher, but they also cost 100 - 2000% more. So, a door with an MDF finish costs $280, and an oak veneer door costs $800.

Naturally, the demand for expensive doors is much lower than for cheap ones. But, according to entrepreneurs, this business turns out to be profitable with monthly sales of 60-100 doors.

The high cost of elite products is due not only to the cost of exterior decoration. Imported locks, mostly made in Italy, cost an average of $200-$300 and crash into such doors. High quality fittings are used.

However, saving on locks and fittings is not recommended.

If you equip an elite door with penny handles, then after a while the varnish will peel off on them, - says Andrey Kukinov, president of the Sesame company. “And a cheap lock can fail quickly. And then the client has the right to make a claim, since all expensive doors are provided with a long-term guarantee. If the deficiencies are eliminated, the company will incur losses.

The cost of raw materials, components and wages of workers is about a third of the cost of an expensive door. Another significant expense item for entrepreneurs involved in expensive doors is advertising.

$10,000 for advertising

Firms involved in cheap doors, it is enough to attract customers $ 2-3 thousand per year. Companies working for more affluent citizens spend at least $10,000 on advertising. First, they have to place larger modules in the mass media. Secondly, they are advertised in all kinds of specialized publications on building design and safety. In addition, in order to attract the attention of customers, it is necessary to exhibit samples of their products in large shopping malls specializing in the sale of building materials.

A client who is ready to pay a lot of money for the door wants to see with his own eyes what he is buying, - says Alexey Kiselev, senior manager of the Valiant company. “So we have to give him that opportunity.”

Meanwhile, renting exhibition space in Moscow is not a cheap pleasure. For example, in Stroydvor, near the Voykovskaya metro station, a square meter of exhibition space costs about $70 per month. In Svoi Dom and Crocus City shopping centers - about $170 per month. As a rule, each firm has several exhibition points, each of which exhibits from 4 to 10 doors. Money for the production of exhibition samples is “frozen”, which is also noticeable. It's easy to calculate: if a firm has five showrooms, each with six doors costing $600-$1200, then the one-time cost of making them is over $20,000. Another $5,000–$15,000 needs to be spent on decorating the exposition itself.

Finally, the owner of a luxury door company needs to fork out for highly qualified ones.

Many people do not understand what is the difference between expensive and cheap doors, notes Alexey Kiselev. – A professional should be able to explain to the client that an expensive door is not only a beautiful external panel, but also effective remedy home security.

Qualified sales managers have to be specially trained so that they can talk about design features one or another door and answer any non-standard question of the client.

Big job

To expand the business of selling heavy metal doors, you can go in different ways.

Organization of own production requires at least $110,000-$150,000 Approximately half will have to be spent on the purchase of equipment. In addition to welding machines large-scale production all kinds of presses, guillotines, turning, milling and grinding machines, automatic hacksaws, as well as bending machines that allow you to bend a metal profile. Another $50,000-$70,000 will be spent on renting premises, purchasing vehicles, organizing exhibitions, advertising, and paying staff in the first months of operation.

However, even if an entrepreneur has the necessary amount, it will not be easy to enter the market of elite metal doors and gain a foothold in it, because one of the important components of success is good reputation companies. And this image is earned over the years.

Turning to a firm with extensive experience, the client is more confident that it will not disappear and that he will definitely be helped in case of a crisis - for example, if the lock jams. Customers are reluctant to use the services of novice companies, fearing to face a one-day business, to which, in which case, you can’t make any claims, - Alexey Kiselev testifies.

If the entrepreneur is not ready to invest a lot of money in organizing his own production of expensive doors, he can become a dealer of some large plant. Then he will have to spend money only on renting an office and exhibition space, on staff salaries and advertising.

For example, in Moscow and 52 other regions of Russia, firms representing the Yoshkar-Ola plant "Guardian" successfully operate. This brand is already "promoted" on the market, and doors from Yoshkar-Ola are popular with consumers. However, there are difficulties with obtaining an "entrance ticket" to the market. The fact is that a businessman can create a new representative office of the Guardian only if he manages to negotiate with dealers already working in a particular city.

This policy is explained by the fact that the appearance of each new dealer entails an outflow of customers from other long-established firms, - says CEO official representation of the plant "Guardian" in Moscow Dmitry Radchenko. - It is possible to conclude a cooperation agreement with the plant only in those cities where there are no official representatives yet. Or where existing dealer firms are unable to meet demand.

So, entrepreneurs who want to trade "foreign" products will have to attend to the search for untapped markets.

A lone handicraft will not get rich

You can make simple cheap doors even in a car garage. You can deliver them to customers in a regular "passenger car". $500 is enough to buy a minimum set of tools. A Consumables cost $30-40 per item.

For a month, the master can manufacture and install 5-10 doors, - says Sergey Beltsev, who used to be engaged in this business. - It takes a couple of days to go to the customer to measure the doorway and directly to the manufacture of the door. Another day - for its installation and for the purchase of materials for the implementation of the following orders. In parallel with this, you need to search for customers, and this is the main headache.

The largest influx of customers is provided by advertising in the Extra-M newspaper. It does not hurt to scatter leaflets in the mailboxes. Some individuals manage to negotiate the "outbidding" of customers with dispatchers working for firms. Including advertising costs, a private trader making 10 doors a month can earn $200-$300. This salary is comparable to the salary of skilled craftsmen working in firms that produce metal doors. Therefore, it is not surprising that many individuals prefer to move to such enterprises as welders or installers.

To produce high-quality metal doors, modern installations and tools are needed. Workshops for the production of such products may differ in equipment depending on the types of box construction and the finish of the canvases. But many of them will have most of the same equipment for the production of metal doors. Here are the main machines and devices used in this process.

Cutting and milling

The process of creating a metal door begins with marking the steel elements in order to final result had parameters exactly corresponding to the ordered sizes. Next, cutting of iron sheets for linen and solid-bent boxes is carried out. This is done using hydraulic shears.

The huge machine has a powerful base plate for positioning the workpiece. On such a table there is an extreme point along which the cut is carried out. The sheet of iron is laid out in such a way that the marking line exactly falls on this edge. Metal cutting is performed by a movable hard alloy plate driven by hydraulic power. The movement of the mechanism provides two cylinders at the edges of the installation. Such equipment is capable of cutting up to 10 mm thickness, which makes it possible to obtain smooth edges and high accuracy.

Equipment for the manufacture of metal entrance doors, in the case of a box from a profile, includes cutting machines with a large disk of abrasive rotating on high speed. This allows you to quickly cut blanks for vertical and horizontal beams, as well as future stiffeners. The final fitting and deburring is done with small grinders and grinding wheels.

Companies specializing in finishing metal fabric with MDF panels always have cutting machines for wood and milling equipment for pattern selection and relief creation. This gives a variety of surface designs and expands the design options for the sash.

Bending equipment and dies

Companies for the production of metal doors from a curved profile use sheet benders. These are large vertical machines with a matrix of 90 degrees and a counterpart, which is smoothly supplied by hydraulic cylinders. When the sheet of iron is marked, it is inserted into the gap between the working surfaces of the machine strictly along the lines and the bend is launched. The equipment allows to produce:

door frames;
stiffening rib;
solid canvases with bends;
internal frames.

The presence of this machine makes it possible to perform bends and create structures with three, four or more corners, depending on the production and technical needs. Similar in principle of operation, equipment for the manufacture of metal doors, but with stamping dies, allows you to extrude a pattern on the surface of the leaf.

Drilling and turning

For the manufacture of standard holes for locks in the canvas and additional plates, drilling machines are used, which allow changing the working part in the cartridge and obtaining various diameters for locking mechanisms. The adjustment of the alignment of the crossbar and the counterpart in the finished product is carried out locally with a hand drill.
Most companies buy web attachment loops from third-party manufacturers. Other firms prefer to manufacture such units on their own and have for this lathe and a set of cutters for external and internal grooves of canopies.

Welding and forging

All manipulations with blanks are carried out on supports or tables made of thick iron. This provides comfort and evenness. finished product on surface. Adjustment and reduction of cracks is performed with clamps and clamps. Next, the welding work begins.

Equipment for the production of entrance metal doors for suturing can be in the form of:

welding inverter for coated electrodes;
semiautomatic device with continuously moving wire in an inert gas environment;
pincers with contact welding.

Any of these devices is capable of applying high-quality durable seams, but the difference lies in the speed of work and the magnitude of deformations from overheating of the metal, which requires subsequent processing and straightening.

Forged elements on the doors are created by heating steel bars in a forge or gas equipment, and subsequent processing on an anvil with various tools. This gives beautiful patterns in the form of leaves, curls and other objects that decorate and enhance the protection of the canvas.

Sanding and painting

The finished product must be processed to perfection. Sanding machines with sandpaper flap discs help with this. Rotation at high speeds allows you to remove small bumps, welding spatter and burrs. After that, the door is processed. This can be done with an airbrush, in the case of applying paints and varnishes, or by powder spraying. The latter is produced in a special chamber where the metal is heated and granulated powder is fed onto it, baked on the surface.

The company "Pantera" uses the most advanced equipment in the manufacture of metal doors, which gives high strength, evenness and beauty of the product. All products are tested and have a certificate.