Manufacturing technology of a high door from MDF. Production technology of interior doors. plastic doors

Interior doors are a necessary part of residential, industrial and office premises. When choosing door panels and additional elements, you need to know how and by what rules they are made, as well as to understand the advantages and disadvantages of the materials used in the production of doors. Modern manufacturers use high-tech equipment that allows them to produce a large number of high-quality products with various types of coating and modern design.

Manufacturing technology of interior doors

Doors serve to separate the various functional parts of the room and provide sound insulation, protection from extraneous odors and excessive moisture. Methods for the manufacture of door panels and additional elements depend on the materials used in the production. The most popular doors are made of solid wood or prefabricated on a wooden frame. Glass inserts make the canvas partially transparent to light and visually expand the space of rooms or corridors.

The most complex and multi-link technological process occurs in the manufacture of doors using wooden elements. The fact is that timber that has not gone through the full cycle of pre-drying and processing is subject to warping and cracking. To avoid losses in the quality of the final product, it is necessary to pay great attention to the preliminary preparation of wood using certain technological methods. The manufacturing process of interior doors includes the following steps:

Timber (round timber) of pine species is sawn into blanks using band saws with automatic feeding of logs.
Logs are sawn into blanks of the required thickness.
The blanks are treated with high temperature and steam in drying chambers to avoid uneven drying and warping of the wood. At the end of the drying process, a mandatory moisture control is carried out.
Drying of lumber is carried out under the influence of steam and high temperature.
Dried blanks are cut into bars of a technological section and defective fragments (chips, knots, cracked and rotten areas) are removed from them, which can affect the quality of the door frame and leaf.
Defective areas are cut out of a blank cut into a beam
Then, the blanks are spliced with the help of spikes, glue and a vertical press into a shield, from which, after drying and trimming, a door leaf is obtained.
With the help of a vertical press, a panel blank of the door leaf is obtained
After sanding, the canvas is covered with three-layer veneer or MDF panels with one layer of veneer and placed in a gluing press.
At the next stage, figured decorating elements, panels or openings for glazing are cut out with a milling and engraving machine, and after assembly, the door leafs are covered with three layers of varnish with intermediate and final polishing.
Panel elements or glazing are mounted during final assembly
After the final drying, the products are packed, if necessary, supplied with fittings and sent to the consumer.

The technological sequence of manufacturing doors may be different and it depends on the material, equipment and design of the product. For example, for expensive doors made of solid wood, the use of veneer is not typical and they are made using complex CNC machines, while budget doors often use corrugated cardboard inserts and cheap laminating film.

It is important to note that under the factory conditions, fittings are usually not installed on a door with a symmetrical decor, since during installation at the consumer's, the product can open both to the left and to the right, respectively, hinges and handles are installed by installers on site.

Video: making solid wood doors

Rules and norms for the production of interior doors

Door blocks are manufactured on equipment that is located on large production areas. These premises are subject to certain requirements, as to industrial facilities, which include timber warehouses, dryers, a processing shop, a paint shop and a warehouse for finished products. Each production site is equipped according to the rules and regulations, in accordance with the technical conditions for a specific task. The main requirements for production facilities for the manufacture of doors are the following criteria:

availability of free access roads;
buildings must be provided with a stable temperature, humidity, natural and artificial lighting;
power supply, heating, ventilation, water supply and sewerage should be equipped;
the premises must be equipped with fire alarms, fire extinguishers and emergency exits;
it is necessary to ensure safe working conditions at workplaces;
paintwork areas should be isolated from the rest of the premises and provided with forced ventilation.

Personnel are required to undergo professional training and training in labor protection, fire and electrical safety, as well as to undergo unscheduled, repeated and initial briefings at the workplace.

The production room must be equipped in accordance with the standards

The main norm for the production process is technological documentation, which is based on the Technical conditions for the production of TU 5361-001-58037723-2015 "INTERIOR DOORS, PARTITIONS AND MOLDINGS TO THEM". This document sets out the requirements for the design of interior doors, the quality of the material and the coating of the front surface, as well as environmental requirements. The regulations specify the procedure for acceptance of finished products, certification and installation of a warranty period of operation.

For the buyer, it is important to have a certificate, a warranty period and the compliance of the door, frame and additional elements with the requirements of technical specifications, since this confirms the quality of the product and allows you to count on a long service life.

Current GOSTs for the production of interior doors

The technical characteristics of the doors are determined by the standards that set the general technical conditions or methods for determining the physical parameters and dimensions of the finished product. Many manufacturers create products according to non-standard sizes, but with strict observance of quality requirements. The consumer may be interested in the list of regulatory standards that manufacturers of interior doors work on, namely:

General requirements for wooden doors with a list of regulatory documents are established by GOST 6629–88, and requirements for wood products are set out in GOST 475–78.
Design options for interior doors, their types and sizes are specified in GOST 24698–81.
Requirements for extensions, fasteners and hinges are assigned by GOST 538–88.
Methods for determining sound insulation, heat transfer resistance and air permeability are regulated by GOST 26602.
The determination of the flatness of the door leaf is carried out according to the standard ST SEV 4181–83.
The reliability test methodology is set out in ST SEV 3285-81.
Impact load resistance is produced according to the method specified in ST SEV 4180-83.

Accompanying documents for finished products must contain a symbol for door panels, for example, U05195 VERSAL pat. 1014 dec/or door leaf D3 91x 230 L, which means the following door parameters:

article - U05195;
the trade name of a particular collection is VERSAL;
type of finish/color − pat. 1014 dec/oro;
product name - canvas;
product model - D3;
width and height of the canvas - 91x230;
type of opening, left − L.

Before ordering doors, it is necessary to carefully measure the doorways in order to select the required size of the frame, leaf and the required number of additional elements. For interior doors, there are standard dimensions of openings with the corresponding designation according to SNiP, and this approach makes it easier to choose a door frame according to the table.

Table: the ratio of the size of the opening to the size of the door leaf

Existing regulatory documents guarantee a high level of product quality, standardization in size and compliance with environmental requirements, in addition, the consumer can determine the compliance of the product properties declared by the manufacturer with the quality and price level.

Material for the manufacture of interior doors

In the production of interior doors and partitions, modern materials are used that are environmentally friendly, durable, lightweight and have a long service life. These include metal-plastic and glass doors, the frame for which is an aluminum profile, and the filler is plastic panels or tempered triplex glass with a matte finish. But traditional doors with a wooden frame and inserts made of glass, MDF panels and paneled elements occupy a major niche in the market. In the manufacture of such products, the following materials are used:

Defect-free pine lumber with a moisture content of not more than 8%, spliced into a tenon using glue pressing.
High density chipboard.
Natural veneer from various types of wood with a thickness of 0.6 mm.
Laminating film imitating fine wood.
Laminating film gives the doors the texture of natural wood
MDF panels of various thicknesses are used for cladding door panels and creating paneled elements.
Frosted, triplex or tempered glass is used for light-scattering and decorative inserts in the door leaf.
Corrugated cardboard is used in budget options as soundproof inserts in the canvas between the frame bars.
Corrugated cardboard is used for insulation and sound insulation of inexpensive door panels.
Wax and waterproof coatings, tinting compounds and varnishes.
Glue type "Kleiberit 303.2", MERITIN ADHESIVE D3 and others, is used for industrial gluing of fragments of leaves, door frames and additional elements.

The production of inexpensive doors is based on the use of chipboard, laminating film, corrugated cardboard and MDF, while more expensive products use solid wood with milled elements, panels and tempered glass inserts.

Six years of experience in the operation of veneered panel doors by the author of the article shows their significant reliability. But in rooms with high humidity, I would like to recommend different types of laminated doors with an additional waterproof coating. After four years of service in the bathroom on the inner veneered canvas, despite the treatment with liquid wax twice a year, whitish stains and streaks appeared from exposure to steam and condensate. There was a need for cosmetic repairs, so I had to sand the plane of the door leaf, degrease it with a solvent, cover it with a tinting compound and waterproof varnish in two layers. To a lesser extent, the same problem appeared in the laundry room, and as for the other doors, minor damage to the veneer and scratches were eliminated by gluing and treating with hard, tinted wax in various shades. After such a minor repair, the canvas, boxes and extensions acquire their original appearance and serve for more than six years. Under the conditions of suburban operation during summer residence, wooden doors covered with waterproof varnish serve more than eight years. At the same time, there is no warping and drying out in conditions of temperature changes and changes in humidity. But it should be noted that the best option for summer cottage construction are metal-plastic doors and frames that do not change properties and retain geometry under changeable weather conditions.

Equipment for the production of interior doors

The most costly production of interior doors, in terms of the amount of equipment required, is the manufacture of wood products. Factory production of metal-plastic and glass requires a large number of components and a small number of machines for cutting frames and processing glass sheets. Lumber processing is more saturated with machine tools, presses and other equipment. Consider the equipment that is used for the production of wooden doors:

Sawmills and band saws used for cutting round timber.
The sawmill allows you to get lumber of the required thickness from round timber
Thermal chambers with steam supply for drying lumber.
Industrial drying chambers allow you to bring the lumber to the required moisture level and avoid warping of the workpieces
Equipment for the production of veneer.
Tenoning machine for frame and door leaf.
Using a pneumatic press, the door leaf is glued
Circular saws and panel saws for sawing blanks to size.
Copy-milling machines with program control for decorating door panels.
Using milling machines, figured and paneled elements are produced
Grinding machines for intermediate and finishing processing of products.
Paint equipment.

The list of the production park can be expanded due to the use of various technological and design solutions in the production of interior doors and components, which has a positive effect on the consumer properties of the final product.

Video: production of interior doors

We examined some types of interior doors, production technology, as well as regulatory documents and requirements governing the production of this type. For the correct choice of doors, it is necessary to know the properties of the coating and the material from which they are made. High-quality equipment and adherence to production technology ensures resistance to external influences and a long service life of products. A wide range of design solutions allows you to give the living room an individual look and unique style.

The production of doors from wood and materials made from it is one of the most promising options for both large and small businesses. In order to open such a workshop, you will have to not only purchase a list of the necessary equipment, but also familiarize yourself with all the production nuances.

Based on the video in this article, we will discuss how the manufacture of an MDF door is carried out; consider the mechanisms by which certain technological operations are performed; and tell you what capabilities this or that machine or tool has in general.

If the company is engaged in the production of interior doors, then you should not focus it only on working with wood, or only with MDF. Moreover, most of the doors are combined: the frame is constructed from pine bars, and only then it is sheathed with sheet material. In general, for the successful sale of products, you need an extensive range covering different price ranges.

Therefore, the manufacturer must offer the buyer both cheap doors without a decorative coating, and elite ones made of natural wood, and a golden mean in the form of laminated and veneered products (see). The task is facilitated by the fact that the equipment for the production of MDF doors is also used with the same success for the manufacture of solid wood doors. Therefore, the list of machines and fixtures that we will present in the course of our article will be general.

Material preparation

Edged boards and timber used in door production must undergo a drying procedure. There are several ways to reduce wood moisture, and the easiest of them is natural.

But it takes a lot of time, so drying chambers are used in factories for this purpose. This is a stationary box with a ventilation system, in which the temperature is maintained from +40 to +100 degrees.

So:

First, when the fan is running, the lumber is heated with steam, and then the temperature is gradually brought to the desired mode. Since the design features of the drying chambers may differ, the principle of working with them is determined by the manufacturer's instructions.
Warm-up time depends on the type of wood, and the essence of drying is not only to normalize moisture, but also to relieve stress from its internal fibers. Upon reaching the required percentage of humidity, the tree is not immediately removed from the chamber, but kept in it for up to three hours. If poorly dried material is used in production, the products will be deformed.

The cost of the drying chamber depends on its capacity, and at least it is 2 million rubles. Not everyone has such tools, so some craftsmen make them with their own hands. A room is allocated for this, the surfaces of which are qualitatively insulated, steam is isolated with foil, a fan and heating elements are installed. Often, infrared film for underfloor heating is used for this purpose, as it is very economical in terms of electricity consumption.

If there is a desire, information on this topic can be easily found on the Internet. The main issue that will need to be resolved in this case is the method of loading wood into the chamber. Usually this is, as in the photo, a trolley on rails, but a forklift can also be used. And, of course, you should take care of fire safety.

Material calibration and cutting equipment

It is clear that the wood used for the manufacture of doors must be calibrated - that is, it must have clear geometric dimensions. Therefore, after drying, the lumber is processed on a four-sided planer, which is able to process the workpiece from all sides at once. When the bar passes through it, four cutters not only level the surfaces, but also reveal defective places.

Multi saw machines

A business that has a multi-blade machine at its disposal can significantly increase productivity. Such equipment allows, in order to reduce costs, to purchase not a ready-made edged board, but round wood, and saw it on your own into boards and beams.

The capabilities of this machine allow mass production of molded blanks, including from sheet and plate material: plywood, chipboard, fiberboard, MDF, furniture board.

Note! Machines with a multi-blade system are suitable for both longitudinal and transverse processing. Depending on the type of unit, up to two dozen saws can be provided in it. Their layout is standard, and is very similar to a sawmill, but unlike a multi-saw machine, several blanks cannot be made at the sawmill at the same time.

In addition, workpieces passed through a multi-saw unit are distinguished by greater geometric accuracy. All its working elements are located on the bed, and in some models there is also a material supply line, which is a roller conveyor.
The material feed unit is driven by an electric motor, and consists of shafts with spikes that ensure uniform movement of the workpieces. The sawing unit can consist of several or one shaft, on which circular saws are mounted. By the way, they can be located not only in a vertical plane, but also horizontally.

If necessary, the multi-blade machine is equipped with a milling mechanism necessary for processing the ends, as well as an installation for trimming the edges. The complete set of the machine may vary depending on the parameters of the products that you want to receive.

Trimming machines

When working with any long material, it is impossible to do without miter saws. In a small workshop, carpenters can use manual options, but for large volumes of work, a machine is needed.

Facing is a cross-cutting of wood materials, with the help of which the workpiece is given the shape of a rectangle and a workpiece of a certain length is obtained.

So:

When the company has a dryer, then one trimming machine can be installed on the site where the raw material is sorted, and the second is used for cutting the already calibrated timber or board. Such equipment has quite a lot of potential.

In addition to trimming the ends, this is the division of the workpiece into 2 parts; determination of a section with a defect, which is automatically removed during sawing; cutting blanks of a certain length. All these operations can be performed by the machine either simultaneously or sequentially. Here much depends on the configuration of the machine, its settings, as well as the task.
As in gang saws, circular saws with teeth made of hard alloys are used here. However, they have a different sharpening angle, since the wood has to be cut across the grain. A saw with the right teeth cuts through the material like clockwork, and does not tear or crumple it.

Since the cross-cutting cycle is periodic, the moving parts of the machine do not have time to heat up much, so the mechanism works properly for a long time. The only thing, for the convenience of work, the trimming machine must have a convenient device for feeding workpieces. Usually this is either a conveyor or a roller table - a roller table, the price of which, depending on the length, varies between 16,000-25,000 rubles.

So that when sawing there is no discrepancy between the required and actual dimensions of the products, all measuring instruments on the machine, as well as the stop ruler on the roller table, must be periodically checked and adjusted. To obtain the most accurate parameters, modern cross-cutting machines are equipped with optical instruments, which also need to be verified from time to time.

Panel saw

When working with sheet wood material, which is MDF, you can not do without a machine for format cutting. It cuts in a straight line or at an angle: both long-length and slab material is processed, and you can also cut a whole stack of slabs at once according to a single template.

To do this through any other machines or tools, if possible, it will take a lot of time and effort, which is simply unacceptable for the mass production of joinery. In general, production efficiency largely depends on the overall functionality of sizing machines.
All of them are professional, and are divided into three categories. The first group contains the simplest economy class models, with small dimensions, and without additional equipment with stops, rulers and clamps. Such machines can work no more than five hours in a row, and are designed for a relatively small volume - ideal for a small private workshop.

The second category includes machines of medium power, which can work a full shift (at least 8 hours), and are provided with all the necessary devices and assemblies. In particular, they can be equipped with a dust extraction device. Well, the third option is industrial machines that have the most durable design, complete set, electronic control circuit, and are able to work for two work shifts.
The basis of any machine is the frame on which all working mechanisms are mounted. The stiffer and heavier it is, the less vibration and the higher the cutting accuracy. Two saw blades are fixed on the bed. A scoring disc is located in front - it has a smaller diameter, and its function is to cut the upper (facing) layer on the workpiece.

The main disk finally cuts the material, the size of which determines the depth of cut. This arrangement of the discs allows you to make a high-quality cut, with smooth edges and without chips. The sizing machine has three working tables: one is movable, along which a full-sized MDF sheet is fed for cutting; the second support, which should support the cut off parts. The third, fixed table, on which, in fact, the saw unit is fixed, is the main one.

To cut a workpiece on such a machine, the sheet is placed on a movable table, which moves along the guides with a carriage. Using the stop, measure the desired length, and start the saw mechanism. As soon as it gains momentum, by shifting the table, the sheet is fed to the saw unit, and a fragment is cut off. From the settings in the format machine: only the depth and angle of cut.

Equipment for milling and cutting spikes

Without a milling machine, it is impossible to imagine any carpentry workshop, because cutting profiles, grooves, volumetric reliefs, large radius curved cuts, and even wood engraving are performed mechanized.

The only difference is that the milling machines used in one case or another differ somewhat in design. There are six types of removable tools, the use of which is due to the need to obtain one or another type of processing.

Thus, a wood milling machine can be considered a universal mechanism. The height of the cutter, located on a movable vertical shaft, can be adjusted. But the position of the part being processed is limited by stops and guides.

In a small workshop, you can get by with a manual milling cutter, a variant of which is presented above, but for the mass production of joinery, machines with program numerical control are used. Manufacturers offer a huge range of such equipment, which has a variety of characteristics, and is controlled by operating systems.
With a milling cutter on a vertical shaft, you can countersink, that is, get conical holes; bore them; dado. With the help of such machines, the edges of blanks are processed, frames are made. But mirror-symmetrical, or absolutely identical curly blanks: drawers, panels (see), cannot be made without a copy-type milling machine.
most often collected by spike method. Spikes on the ends of the blanks, as well as recesses for them (lugs), can only be obtained using a tenoning machine. In it, the working mechanisms are also cutters and saws. Just like other milling machines, tenoning units can be equipped with a CNC and controlled by a microprocessor.

In any case, an oval or round spike can only be made on such equipment. In addition to cutting spikes, on CNC machines, it is possible to overtake the perimeter of the door leaf, process calibrated sheet material, splice bars along the length, which is sometimes necessary for the manufacture of panel doors.

Note! In addition to the main woodworking machines mentioned above, additional equipment will also be needed in the door production, with the help of which the finished canvases and molded products are finished.

This is a hydraulic press, with the help of which the MDF door sheathing is pasted with veneer, and an edge banding machine, through which narrow strips of veneer are glued to the ends of the canvases. This includes a spray booth, and a press for gluing bars, and a surface grinder, and a packaging machine - otherwise how to transport products?

As you can see, the list of equipment is quite large, and it is clear that in order to equip a carpentry shop, you need to spend a lot of money. But do not forget this: the availability of machines and the necessary tools does not guarantee a quality result. Ultimately, it all depends on the professional competence of the people working on this equipment.

In this article:

The popularity of interior doors among the population is comparable only with plastic windows. And for the first and second demand is stable even during the economic crisis. But since interior doors perform not only a functional purpose (to open / close access to the room), but also an aesthetic one - they should look spectacular and be liked by customers.

Even if you make doors from environmentally friendly materials (for example, solid wood), but do not give the model a presentation appearance, the business is likely to be doomed to failure.

What does the consumer like? Criterias of choice

Product range– the most important solution for future production. And it should be determined taking into account consumer preferences.

The main types of interior doors:

From array

The door leaf is made from wood lamellas (an array of different species - from soft, such as pine, to hard oak and more valuable ones). The bars are spliced with glue and exposure under pressure, the canvas is sanded, calibrated and varnished, or covered with a decorative finish (for example, expensive veneer).

For premium doors, a more sophisticated technology is possible: partial tinting, mosaic splicing, inlay are used, thanks to which the door leaf turns into a real work of art.

Wooden with veneer

Doors of the middle price segment. The base is usually inexpensive wood in the form of boards fastened into a frame covered with veneer on the outside.

For voids, various fillers are used, for example, corrugated cardboard.

Laminated

When laminating, a film of various colors and textures is applied to the base frame made of chipboard or MDF. This production technology allows you to imitate various materials (and not only wood), but the wear resistance of such doors is the lowest among all types;

Plastic, aluminum and their various combinations

The combination of materials such as plastic and aluminum is used to equip non-residential premises (offices, medical, government, educational institutions).

According to manufacturers, consumer demand trends can be characterized as follows: “from cheap to expensive”. Today, veneered doors are most in demand, but with a base not from chipboard, as it was a couple of years ago, but from solid wood. Why?

The reasons are obvious:

reliability - a rather large load is placed on interior doors (especially if there is a child in the house). And a solid array always wins over a frame structure, and hardwood veneer will protect the canvas better than laminate and other film materials;
the veneer is homogeneous in structure (compared to a furniture board), so it is easy to choose the most similar doors for different rooms;
naturalness of the material;
price - the cost of doors made of inexpensive wood veneered "fits" into the category of the middle price segment (about $ 250), but they will last much longer than frame products. And if necessary, such doors can be restored.

Organizational form and distribution channels

The legal form for the business should be chosen after evaluating the potential buyer.

Here are the options:

large wholesale - construction companies and state-owned enterprises (usually, there is a tender basis, which is quite difficult for a new player in the market to win);
conclusion of contracts with networks of construction markets and specialized stores;
sales through own retail outlets;
dealer network.

In practice, an enterprise engaged in the manufacture of interior doors is rarely limited to one sales option - to increase sales, all available “channels” should be developed.

Therefore, the optimal organizational form would be a legal entity - LLC (many construction companies and supermarkets simply do not cooperate with individual entrepreneurs).

In the types of activities, you must specify the following codes:

20.30.1 Manufacture of wooden building structures and joinery;
51.53.24 Wholesale of other building materials.

A license for the production of interior doors is not required. But if you plan to provide installation as an additional service, please note that without special permission, it is allowed to install door panels only in place of existing openings. If the project provides for an extension or any other change in the opening, then an appropriate building license is required.

Technology for the production of interior doors

Let's consider the full technological cycle for the production of interior doors from solid wood with veneer veneer.

1. The production cycle begins with sawing wood (logs) on high-precision band sawmills, which ensures a minimum level of rejects.

2. After - the boards go to a special place - a drying complex equipped with chambers with mechanized loading. The drying process is completed by controlling the moisture in the material.

3. Then the board is disbanded into separate bars (lamellas) of the required section. All defects are removed from the lamellas - material with knots, irregularities that can affect the quality of the future door.

4. On a special splicing line, defect-free blanks are glued along the length into a furniture board. The strength of the door leaf is ensured by the adhesive spike connection of individual blanks. Glued beams are processed from four sides on milling machines to the required section.

5. Gluing of slats along the width, for the manufacture of canvases and individual elements of doors, is carried out in vertical presses. At the stage of this operation, the perpendicular arrangement of the fibers in adjacent bars is strictly controlled, which guarantees the high resistance of future doors to various deformations during operation.

6. To give the load-bearing structures of the door high rigidity and shape stability, the door leaf is covered with veneer, which is produced on a separate production line.

7. For the production of veneer, whole logs are used, which are pre-steamed (in a steam chamber for 3 days), and then they are centered and sanded on a bark cutter to get rid of the bark and bast layer.

8. Next step - circular trim. The log is constantly rotating, and the machine removes from it a thin layer of veneer, only 0.6 cm thick. From an average log, about 134 linear meters of veneer are obtained.

9. The veneer is then unfolded and cut into sheets. Sheets with the same fiber pattern are stacked. Of these, parts are subsequently selected for the outer lining of the door.

10. To give the door special wear resistance, three layers of veneer are used (in the economy version, they are replaced with MDF or chipboard with one layer of veneer).

To do this, glue is applied on both sides to the middle layer of the veneer sheet, and sent under a hot press. Here, at temperatures above 100 C, the middle sheet adheres tightly to the other two. After a minute and a half, the glue hardens, forming a high-strength top plywood layer for the door leaf. This finish is made from a variety of wood species (birch, oak, beech, ash and others).

11. Veneered plywood is applied to the door leaf glued from the lamellas, and placed under a cold press for 30-40 minutes until the glue dries. Further, all components of the door structure are ground and checked for compliance in order to exclude the presence of unacceptable gaps or differences in further assembly.

12. Next, the length / width of the product is measured. The door is sent to the machine, which chamfers and cuts the edges to the specified dimensions. On the next machine, the grooves for the loops are hollowed out.

13. A hole is cut out for the door handle.

14. Then, the product is polished and varnished, dried. All parts of the structure are assembled into one whole, completed with fittings, packed and sent to the warehouse.

Regulatory documents and certification of interior structures

Interior doors are not legally subject to mandatory certification, but the presence of a document confirming the quality mark and compliance with standards significantly raises the level of the manufacturer in the eyes of the buyer, forms a positive image of the company.

And in order for the doors to pass all the checks, it is necessary to adhere to the recommendations and requirements specified in:

GOST 475-78 - Wooden doors. General technical conditions;
GOST 28786-90 - Wooden doors. Method for determining resistance to climatic factors;
GOST 26602.3-99 - Window and door blocks. Method for determining sound insulation;
GOST 26602.2-99 - Window and door blocks. Methods for determining air and water permeability;
GOST 26602.1-99 - Window and door blocks. Methods for determining the resistance to heat transfer;
ST SEV 3285-81 - Wooden doors. Reliability testing methods;
ST SEV 4181-83 - Wooden doors. Method for determining flatness;
ST SEV 4180-83 - Wooden doors. Impact resistance test method

Raw materials for the manufacture of interior doors

In the production of interior wooden doors, you can use ready-made materials (furniture panels, plywood, MDF, veneer) or blanks (edged boards, solid logs). The first option greatly simplifies the technology. The second - reduces the cost and increases profits, but requires large investments. Therefore, only large factories focused on the mass production of interior doors can afford a full technological cycle.

Medium and small businesses prefer to increase their capacity using ready-made materials as raw materials. And after the payback of the initial investment and, if possible, expansion, open a separate workshop for the production of furniture panels, veneer and other materials in the immediate vicinity of the logging site.

Room for the production of interior doors

Basic requirements for the production workshop- dryness (a prerequisite for storing materials, products and working with wood), the presence of heating and all necessary communications, a three-phase network, access roads for transport.

The size of the workshop varies depending on the volume of production and the completeness of the technological cycle. If an enterprise for the production of doors from edged boards requires an area of at least 400 m 2, then for small-scale production from a finished furniture board, 100-120 m 2 will be enough.

heated warehouse for primary wood drying;
manufacturing facility;
a separate room for applying paint and varnish;
place for assembly and storage of finished products.

Estimated business plan

1. Room rental

For the production of interior doors made of natural wood (oak, pine) with veneer of various types of wood, the enterprise (LLC on the general taxation system) rented a production facility with an area of 450 m 2 .

2. Plans for production volumes

Planned production output: 800 lm/year

Ways of implementation:

through our own warehouse store;
through a network of building supermarkets;
on a contractual basis with construction contractors.

3. Capital costs

Equipment for the production of solid wood doors:

drying chamber - 35 thousand rubles;
band sawmill - 110 thousand rubles (Fig. 15);
tenon cutter for trimming lamellas and cutting tenon joints - 170 thousand rubles;
trimming press - 220 thousand rubles (Fig. 16);
pneumatic press for forming a shield - 180 thousand rubles (Fig. 17);
panel saw for sawing lumber - 200 thousand rubles;
milling and copying machine - 90 thousand rubles (Fig. 18);
grinding machine - 100 thousand rubles (Fig. 19);
auxiliary equipment (construction equipment) - 50 thousand rubles.

Total: 1,155,000 rubles.

4. Material costs for raw materials

Material costs for starting production:

oak sawlog - 50 m 3 * 6500 rubles = 325,000 rubles;
glue - 500 kg * 110 rubles = 55,000 rubles;
accessories (handles, hinges, latches) - 30,000 rubles.

Total: 410,000 rubles.

5. Salary

To ensure the production activities, it is planned to hire the following staff:

director,
accountant,
sales manager,
5 workers for machine maintenance and door assembly.

Payroll - 120 thousand rubles / month.

Payroll taxes (37.5%) - 45,000 rubles / month.

6. Calculation of the actual cost of production

Fixed costs (rub/year):

salary - 1,440,000;
taxes - 540,000;
rent - 500,000;
utilities - 60,000;
advertising - 120,000;
fixed assets depreciation - 52,750
reserve fund - 54,255.

Total: 2,767,005 rubles / year.

Material costs per 1 r.m. products:

edged board - 1/8 m 3 * 6500 rubles = 812.5 rubles;
glue - 0.4 kg / m 3 * 110 rubles / kg = 44 rubles;
frosted decorative glass - 0.3 m 2 * 1300 rubles = 390 rubles;
accessories (handles, hinges, screws, screws) - 300 rubles;
natural oak veneer 8 m 2 * 64 rubles = 512 rubles;
paint and varnish products 0.75l * 180 rubles = 135 rubles.

Total: 2193.50 RUB

Cost of production for 1 year of operation = (Fixed costs: Planned annual output) + Material costs for output

2,767,005 rubles / year: 800 m.p. + (2193.5 rubles * 800 m.p.) \u003d 1,758,258.76 rubles

7. Selling price, profit

At a cost of 1 m.p. doors at 2197.82, we calculate the sale price as follows: 2197.82 + (2197.82 * 25%) = 2747.28 rubles. Of course, the sale price is set taking into account market value and competition - this is the minimum level below which the company should not fall not to suffer losses. Annual revenue: 2747.28 rubles * 800 m.p. = 2,197,820 rubles.

Profit: 2,197,820 - 1,758,258.76 = 439,561.24 rubles / year.

8. Profitability

Product profitability \u003d (Profit: Cost) * 100% (439,561.24 rubles: 1,758,258.76 rubles) * 100% = 25%

Project payback: 3 years, 4 months.

The segment of the market for the production of interior doors will always be in demand. Good, solid interior doors will always find their buyer and give a good profit.

So, what do you need to start a business for the production of oak and other wooden interior doors from timber?

Door types

Before purchasing equipment and renting premises for the production of wooden interior doors, it is necessary to determine the range of products manufactured in the future.

Wooden doors are of the following types:

From a wooden massif of various species. Such interior doors are produced from wooden blocks of high-quality expensive wood species, which are spliced together. The resulting solid wood is sanded, calibrated and varnished in the desired shade. Mosaic splicing and toning is possible even in the bars. In such cases, the resulting array is covered with a colorless varnish. For VIP doors, whole pictures are laid out.
Veneered (veneered) doors. The production of such interior doors consists in veneering doors made of boards, solid wood or made using the technology of a wooden frame, which is filled with honeycomb cardboard, with precious wood veneer. They are in no way inferior in appearance to natural solid wood doors, but they are less durable, more capricious in operation and, if not properly maintained, will require an early restoration. The owner of the workshop for the production of wooden interior doors, when producing products of this type and providing a guarantee, must keep the veneer that matches the sold interior doors in order to eliminate deficiencies during the warranty period;
Laminated. It is an economy class door, in which a laminated film of the texture and color chosen by the customer is applied to the wooden frame. The price of such doors depends on the method of applying such a coating and its composition.

In this article, we consider the technological scheme for launching a workshop for the production of interior doors from sawn oak.

Product range

door frames;
platbands;
interior doors;
products per linear meter - door array, etc.

Sales channels

The organization does not plan to carry out independent installation of its products, finished products will be sold through such distribution channels as: 1) wholesale of interior doors to construction organizations that renovate offices, apartments, etc.; 2) retail outlets selling building materials, windows and doors; 3) construction hypermarkets and large specialized stores.

Raw materials for production

Planned raw materials for the production of interior doors:

Timber. The cost of a cubic meter of sawlogs, for example, oak, will be approximately equal to 5000-7000 rubles per cubic meter.
Glue for end splicing of beams. Such an adhesive is Kleiberit 303.2. Its consumption is 160 grams per square meter. The price for a container weighing 1 ton will be approximately 110 thousand rubles.

Equipment for the production of

You will need the following equipment for the production of interior doors:

band sawmill. You can, of course, buy ready-made boards, beams, but then the doors will come out very expensive. Price from 110-130 thousand rubles.
Drying chamber. Necessary for faster drying of wood. In general, this process will need to be approached with all seriousness, because. if you don't finish drying the wood, then the doors will warp, and this will lead to negative reviews about your products and general dissatisfaction with your customers. Who will need such products, in which cracks are then formed due to continued drying? Nobody.
Tenoning machine. About 200 thousand rubles. Designed for precise trimming, cutting mini-studs on workpieces for their subsequent splicing. Those. he makes castles.
End splicing press. From 220 thousand rubles. As a matter of fact, this press is just engaged in splicing through the ends and cuts that the previous machine made.
Pneumatic press for wooden board splicing. Thanks to him, the entire shield is formed from the previous parts received. From 200 thousand rubles.
Panel saws. 220 thousand rubles Designed for cutting lumber. They produce longitudinal, transverse, as well as sawing lumber at an angle.
Milling and copying machine. About 150 thousand rubles. Produces exact copies of wooden parts, which saves a lot of time in the production of the same type of parts.

The total cost of purchasing equipment (without a dryer) for the production of interior doors will be about 1.5 million rubles. Dryers are not sold ready-made, but are made to order. Therefore, we cannot indicate their price here, because prices vary greatly.

Production technology

The entire manufacturing technology of interior doors consists of the following production stages:

Sawing of raw materials;
Drying of blanks;
Dissolution of unedged boards;
Cutting spikes and splicing blanks;
Cut and calibration of defective places;
Glue is applied and the blanks are spliced into a wooden shield;
Calibration of canvas dimensions;
Coating grinding;
Varnishing and applying a special solution;
Final drying of the finished product.