The secret of the iron door. How To Adjust Plastic Balcony Door By Yourself Metal Door Frame Making Equipment

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 production equipment 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 case of making 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 bending 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 ensures the convenience and evenness of the finished product on the plane. 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.

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.

For organization own production at least $110,000-$150,000 is required. 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 work.

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 factory. 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.

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.
• Equipment for powder painting: 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: a plasma cutting machine, a press brake, a coordinate welding machine for door panels, 2 posts for welding with tongs with conductors, 2 posts for final welding in an 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:

1. 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;
2. Then it is bent;
3. Assembly is carried out and initial - spot welding;
4. If everything is in order, then the final finish welding is performed;
5. 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. The production uses laser and plasma machines. 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. In a fully automated production, all the necessary holes and cuts (for fittings, for glazing, etc.) are made 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.

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 the shortest possible time, which will allow you to take a step to the next stage of business development.

• GOST 31173-2003 - Steel door blocks. Specifications;
• GOST 23118-99 Steel building structures;
• GOST 5089-97 - Locks and latches for doors. Specifications.

Steel door production equipment

1. Automatic lines

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.

Pros: automated lines allow to produce 500-600 finished products per day with minimal risk getting a marriage.

Minuses: high price and the cost of maintenance (the 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.

2. Semi-automatic lines (using manual labor)

A set of equipment and machines for opening a partially automated production:

• Semi-automatic guillotine or metal cutting machine (plasma - Fig. 4, laser) - from 120,000 rubles;
• Press brake - 70,000 rubles;
• Welding machines (include spot welding, door panels, welding with tongs, final welding in a carbon dioxide environment) - from 100,000 rubles. Can be replaced by conventional welding machines;
• Painting equipment (paint gun, compressor).

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" - the less automation, the higher the number of defects. In addition, highly qualified 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.

3. Manual labor and machine tools

Minimum set of equipment:

• Bulgarian;
• mechanical guillotine for cutting metal (Fig. 5);
• milling machine;
• lathe;
• auxiliary hand tool.

Pros: minimum costs for the purchase of equipment (from 60,000 rubles) and the 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 of marriages, specialists who can work on metal are needed.

Workshop for the manufacture of metal doors

All the main processes of steel door manufacturing technology must be carried out in separate rooms. Therefore, the production area should provide:

• shop for acceptance and preparation of metal;
• workshop for processing steel sheets and rolled profiles;
• assembly and welding shop;
• paint shop;
• decorative and finishing (and if the finish is made directly at the enterprise, and not purchased from ready-made- then a separate room for the technological line for its production) (Fig. 7);
• assembly and control shop;
• finished goods warehouse.

Of the special requirements - the presence of a fire safety system, non-combustible materials for walls and floors, good ventilation.

Technological process of production of metal doors

The manufacturing technology of a steel door includes a certain sequence of actions prescribed in a special document (technological or route map), indicating:

• requirements for the quality of materials;
• rules for their transportation, storage and acceptance;
• a sequential process of converting raw materials into a steel door block, painting and assembling it;
• complex technical requirements for each process
• quality control and verification methods;
• method of transportation, storage of finished products and other specifications(TU of production), which are compiled in accordance with the requirements of GOST 31173-2003.

Main stages technological process production of steel doors

1. Metal preparation

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).

2. Marking and cutting blanks

Making doors starts with cutting sheet metal according to the templates applied with the help of center punches. For cutting rolled metal use:

• mechanical equipment (guillotine shears, presses, saws);
• oxygen method (cutting on stationary machines with gas cutting or hand cutters);
• laser, plasma cutting.

3. Processing of workpieces

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 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.

4. Assembly and welding

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 sealant 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.

5. Treatment with paints and varnishes

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:

• jet douche;
• pneumatic spraying (Fig. 13);
• spraying in an electrostatic field.

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.

6. Sheathing with decorative elements

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:

• leather, leatherette, vinyl leather;
• wooden lining;
• chipboard;
• natural wood;
• thermal film plain or with imitation of wood of various species;
• forging elements;
• veneer.

7. Installation of locks, fittings, quality control of the finished product

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.

Raw materials for making steel doors

There are two technologies for manufacturing steel doors:

• pipe-coal, using rolled pipes fastened by electric arc welding;
• profile bending - using bent rolled profiles.

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:

• locks;
• loops;
• latches/latches;
• pens;
• additional (closers, eyes, clamps, blocking devices).

Business plan for the production of metal doors

1. It is planned to open a mini-factory for the production of steel entrance doors. Target group consumers - construction organizations and private households.

2. For the legal registration of business, an LLC was created on common system taxation, indicating the following types of OKVED:

• 28.75.21 "Production of armored or reinforced safes, fireproof cabinets and doors";
• 45.25.4 "Installation of metal building structures".

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:

• guillotine crank shears NK3418A;
• sheet bending mechanism MGL-2500;
• drilling machine 2116K;
• abrasive cutting machine;
• welding machine TDM-403;
• spray gun;
• Bulgarian;
• additional equipment (hand tools, racks, exhibition stand).

5. Calculation of the cost of 1 product - a metal door with a size of 2180 * 1040 mm.

• sheet steel 2mm - 0.098 t * 31,600 rubles = 3096.80 rubles;
• insulation (mineral wool) - 0.2 m 3 * 1475 rubles = 295 rubles.
• electrodes - 4 kg * 43 rubles = 172 rubles;
• mortise lock - 820 rubles;
• loops, handle, peephole - 550 rubles;
• cutting wheels, grinding wheels - 420 rubles;
• primer - 4 l * 87 rubles = 348 rubles;
• solvent - 2l * 210 rubles = 420 rubles;
• paint - 2 kg * 460 rubles = 960 rubles.

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 determined by the method of carrying out comparative analysis market prices 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:

• rent - 15,000 rubles;
• electricity - 1200 rubles;
• depreciation of fixed assets - 5750 rubles;
• advertising - 15,000 rubles;
• staff salary (director, 5 workers and a sales manager) - 65,000 rubles;
• payroll taxes -24,375 rubles;
• income tax - 58,124.32 rubles.

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.