Own factory for the production of pvc windows. Production of plastic windows: a peek behind the scenes of the workshop

PLASTOK opened its own production in the city of Stupino near Moscow in 1995, where on an area of 10,000 sq. meters, plastic windows are made from the German Rehau profile. How is the production plastic windows, You can watch in the video footage filmed at our factory, especially in order to understand how the production of windows is a complex and time-consuming process, despite the fact that the craftsmen work on modern and powerful German production lines"URBAN" and "HAFFNER".

Assortment of window products

We offer a full cycle of services - taking measurements, project development, manufacturing of window structures, delivery, installation and maintenance of plastic windows. Availability of modern high-tech equipment, more than 8 thousand square meters of production space, experienced designers and craftsmen production shop, reliable suppliers of components - all this enables the Plastok company to produce a wide range of high-quality window products:

window systems of classical rectangular and non-standard shapes: trapezoidal, triangular, polygonal, round and arched;
double-glazed windows various characteristics: tinted, energy-saving, multifunctional, self-cleaning, with application tempered glass or decorative film, etc.;
sliding window systems made of pvc profile for glazing balconies, loggias and verandas;
non-standard windows color solutions, Renolit films are used for manufacturing, presented in a wide range of shades from solid colors to options for imitation of various types of wood and metal.

High performance characteristics products are confirmed by certificates (including ISO 9001) and certificates. Plastok provides a five-year warranty for all manufactured products.

Stages of production of plastic windows

The production of plastic windows is a laborious process that requires strict adherence to sanitary and hygienic and technical standards. It consists of several stages:

sawing a profile at an angle of 45 ° or bending with a certain radius for non-standard systems;
profile reinforcement to strengthen the structure;
welding of finished structural elements;
installation of fittings and seals;
assembly and installation of sashes in the frame;
production of a double-glazed window and its installation with fixation with glazing beads in the sash or frame with blind glazing;
installation of handles and pads on hinges, installation of a ventilation valve and other additional options specified in the contract.

Quality control is carried out at each production stage. Manufacturing pvc windows takes from 5 days, depending on the complexity of the order and the workload of production.

Advantages of pvc windows from the manufacturer "Plastok"

A huge variety of styles and colors that can organically fit into any interior or architectural style the entire building.
High reliability and durability of PVC profile structures with a service life of 20 years. At the same time, according to the estimates of the Research Institute of Building Physics RAASN plastic structures do not lose their properties during 60 years of conditional years of operation.
High sound and heat insulation, which allow you to create comfortable conditions for work and leisure, as well as keep the heat in the room and significantly save on heating.
Availability of a special constructive solution, which prevents fogging of glasses inside the double-glazed window.
Part PVC profile lead-based stabilizers are included, which allow you to maintain the original color of products throughout the entire service life. Even after 5-10 years, plastic structures will look the same as on the day they were installed.
Plastic windows and doors are practically maintenance free. Their surface does not need to be updated or repaired - window and door structures made of PVC profiles are installed once and for a long time. The only thing that is needed is wiping with a soft sponge and detergents.
Possibility of manufacturing window and door structures custom-made - the desired shape, size and color.
The high reliability of Siegenia-Aubi anti-burglary fittings and double-glazed windows with anti-vandal film is a guarantee against unauthorized entry into the room.

Plastic windows from the manufacturer in Moscow and the Moscow region of the company "Plastok" - this is consistent high quality, European design and

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

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

In addition, having familiarized yourself with the methods of work, you can more clearly imagine the structure of the window. This, in turn, will allow you to order designs more meaningfully, understanding which element is responsible for what.

Raw Materials

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

So, what are metal-plastic windows made of?

PVC profile is the main raw material, without which, of course, no window will work. As a rule, the workshop works with several types of profile, respectively, all elements of the system must be in stock, from frames and sashes to glazing beads and additional elements.
Reinforcing profile - supplied separately, installed in plastic profile directly at the installation stage. The nomenclature of reinforcement is not so extensive, but still a dozen items (different thickness + different configurations) should be present.
Glazing - either finished double-glazed windows assembled at a separate enterprise according to the right size, or sheet glass and spacers. In the second case, the materials are delivered to a separate workshop, where glass is cut and double-glazed windows are assembled.

Accessories - in any case, they are purchased, since the process of manufacturing accessories is very complicated and time-consuming. Fitting sets are stored in a warehouse and, as necessary, are delivered to the assembly site for tying the sashes.

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

Working with a profile

Assembly preparation

I will begin the description of the window assembly process in the sequence in which the parts enter the shop and get processed. And in the first place in this list there will be a whole range of operations, which can be conditionally called the preparation of a profile for assembly.

Work is carried out in the following sequence:

First, a reinforcing profile is cut in a separate section. Steel billets are cut on a stationary circular saw either exactly to the size of the product, or - for large scale production - in increments of 50 mm. The second method is less time-consuming, while the quality of the product almost does not suffer - all the same, the fittings are made a little shorter than the plastic part of the window.
At the same time, PVC profiles for frames, sashes and imposts are cut on the sawing machine. Here, work is already underway in accordance with the task formed by the accounting department: the trimming accuracy is +/- 1 mm. Modern sawing machines allow you to set the size of the part by reading the barcode from the job sheet, which makes it possible to minimize the amount of marriage.

After trimming, PVC blanks are fed to milling machine. This device, controlled by a computer program, mills drainage holes to remove moisture from the profile cavities.
Further, the reinforcing profile and the blanks of frames and sashes are assembled in one area. Here the armir tab and its fixation are performed. To fix the metal liner, self-tapping screws with a drill are used, which are twisted either using a pneumatic screwdriver or on a special machine.
Sometimes at the same stage, strikers are installed on the frame profile, which play the role of hooks for the locking pins of the fitting mechanism.

The blanks of the impost after reinforcement and installation of strikers fall on the milling site. Here, the ends of the imposts are milled for a tight connection with the frame - according to GOST 30674-99 "Window blocks made of polyvinyl chloride profiles", the difference in the front planes should not exceed 1 mm. Mechanical connectors are inserted and fixed into the ends of the impost.
On frame profiles, holes are milled for installing a handle.

Frame and sash welding

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

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

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

After heating, the profile panels are folded and clamped in automatic clamps until the seam is completely cooled and the plastic polymerizes.

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

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

Assembly area

Frames and sashes after welding get to the assembly area. Here, the masters do most of the work with their own hands: the operations require high precision, which is difficult to ensure in automated production.

A typical algorithm includes the following operations:

Cleanup internal corners frames and sashes using a cutting tool.
Installation of mullions by marking with fastening of a mechanical connector to the frame: from the outside - using a long bolt, from the inside - using several self-tapping screws.
Installation of the stand profile on the frame. The stand profile is completed with a sealing cord made of foamed polyethylene, after which it is installed on lower part frames by snapping onto the mounts. To increase the strength, the base profile is fixed with self-tapping screws.
Installation of hinges on the frame. To fasten the hinge parts, holes are drilled in the frame (a template must be used, the configuration of the grooves in which corresponds to the configuration of the support rods at the hinge of the selected fitting system). The hinges are installed in the holes and fixed with self-tapping screws.

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

A typical instruction involves parallel strapping of the sash with fittings:

The sash after primary processing (cleaning of internal corners) enters the strapping section.
The fitting kit is adjusted in size to the dimensions of the sash. At the same time, it is trimmed on a special machine.
Fitted fittings are installed in the fitting groove, after which its individual elements are fixed with self-tapping screws.

Hanging the sash on the hinges. At the same time, transport clips are often placed on the frame to prevent damage to the fittings during transportation, and the position of the sash is adjusted using hinges.
At the same stage, the master necessarily checks how easily the sash opens and closes.

To check moving parts, the so-called "duty" handle is usually used. The handle, which will be installed on the window later, most often comes packaged and mounted directly on the object, in order to avoid damage.

Installation of additional fittings - micro-lift, micro-ventilation / step-by-step ventilation, fanlight scissors, etc.

This completes the work with the window frame. The frame with the bound sash arrives at next section where it is carried out.

Work with double-glazed windows

Production of double-glazed windows

Most of the companies involved in the production of PVC profile windows prefer to work with ready-made double-glazed windows. Those. dimensions necessary products they pass the manufacturers, and he makes the glazing to order.

But in this way the price of the product turns out to be somewhat higher, therefore, in order to save money (and to obtain additional profit), a separate workshop is created in which double-glazed windows are assembled from individual parts. The sequence of actions in this case is as follows:

Glass (ordinary sheet, energy-saving or multifunctional) is cut on special tables.
After cutting, the ends are processed with special abrasive materials - this is how small chips are removed, which can provoke the appearance of cracks.
Glass cut to size is washed to remove dust, dirt, traces of abrasive powder, handprints, etc.

After washing, drying is carried out. The best way to do this is with compressed air: its flow perfectly blows off dust particles and hairs adhering to a wet surface.
Then the distance frame is assembled. frame profile cut to size, filled with a special granular desiccant, and then connected at the corners using special adapters.
After that, the glass unit is assembled on a special table. Butyl sealant is applied to the edges of the distance frame, which provides primary fixation of the glasses.

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

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

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

Glazing area

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

The structures are installed on an inclined stand - so that the installed double-glazed windows do not fall out.
Special spacers are added to the frames and sashes, which evenly distribute the weight of the double-glazed windows.
Glazing is reinforced on the gaskets, which is fixed with the help of glazing beads.

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

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

Conclusion

Machines for the production of plastic windows are very different, and they perform a huge list of functions. But still general scheme manufacturing of such structures remains unchanged - in any case, most companies work exactly according to the algorithm described above (of course, adjusted for the characteristics of the enterprise).

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

September 30, 2016

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

Plastic windows are becoming more and more popular, which is ensured by their performance:

High mechanical strength;
Ease of care;
impact resistance sun rays and wind;
Security reliable protection by cold;
Excellent sound insulation;
Affordable cost.

Production of PVC windows- a high-tech process involving the implementation of many stages, requiring strict adherence to prescribed technical standards. Our company guarantees high quality and durability of our products.

Experienced masters of the company successfully cope with tasks of any complexity and scale. Window production in Moscow is a specialization of our company. In the course of work, professional equipment, high-quality materials, reliable components, and the latest innovative technologies are used, which contributes to obtaining high-quality products.

Over the years of work, we have established ourselves as a responsible and reliable contractor, which is confirmed by numerous positive feedback grateful clients. The production of plastic windows is carried out in accordance with the appointed time, without any delay.

Our company has more than ten years of experience in the production of plastic windows with double-glazed windows. The staff employs experienced professionals who use high-precision German technologies, in the arsenal - high-quality modern materials and equipment, which is confirmed by the relevant certificates.

The production of plastic windows is the most difficult technological process consisting of several stages. At each stage of production, all rules and technical standards are strictly observed.

At the same time, the manufacturing company takes responsibility for the reliability and durability of plastic windows.

Production of window systems taking into account your preferences

We offer big choice colors and shapes of the window to fit it into the interior and facade of any home. The company's designers are true professionals and easily navigate in various styles, from classic to hi-tech.

Not only color, but also the shape of the window can be made according to individual projects. Windows will be made exactly according to the requirements of the customer and installed on time. To achieve an impeccable result, the company's employees use modern European technologies and do not lose sight of the details.

When accepting an order, the specialist will not only take into account the wishes of the client, but also tell you how to choose the most suitable option under specific conditions

Advantages of PVC windows from the manufacturer

improved indicators of heat and sound insulation;
increased light transmittance;
environmental Safety;
wide color palette;
long service life;
reasonable prices.

Glazing of balconies and loggias

In addition to installing windows, here you can order glazing of loggias and balconies, wood-like interior decoration, installation of blinds and roller shutters. Glazing of balconies is made taking into account the purpose of the premises and the design preferences of the customer. So, you can make floor-to-ceiling glazing, tint glass and give the facade and interior space a modern look.

Regardless of the complexity and volume of the order you make, you can be sure of its impeccable execution.

Professional window installation

Design and manufacture of custom-made plastic windows are at your service: we are ready to bring any idea to life, even if it seems impossible for you.

Technicians are ready to quickly install standard structures, as well as manufacture and install windows according to individual requirements - for example, arched, round or windows in sizes that differ significantly from classical ones. In addition, the client can order one of the colors from the company's catalog and laminate window frame so that it harmoniously fits into the interior of the room.

Sale of plastic windows. Commonwealth of reasonable price and impeccable quality

Being indoors, a person sees the world through a window opening. So this is not just a light source - it is a prism of perception, a kind of "eyes" of the house, which can tell a lot about its owner. In order for them to say only what you need, choose them with love. Let them be what you want: special, exclusive, made according to your idea.

Most window manufacturing companies work with intermediaries who manufacture products at isolated and remote bases. Such incognito production makes it difficult to control the quality of goods, and the final product can be very different from the desired one. The advantageous difference of the company "Windows Master" is its own production plastic windows at a factory in Moscow. For 15 years, the company has been pleasing users with warm and cozy windows, which are produced in workshops at its own Rehau plastic window production plant. In 2007, the plant completed the installation of high-quality equipment that reduces costs to zero manual labor and allows you to process up to 300 prefabricated units per day.

Workshop of standard constructions

The Rehau PVC window factory has a department for the creation of basic window systems, which are adapted to the climatic conditions in Moscow and the Moscow region. The department is equipped with equipment from the German manufacturer SCHIRMER and ROTOX - these machines allow us to achieve high accuracy and speed of work. More than 250 people involved in production use the unique developments of Rotox. The process of the plant is automated as much as possible, and the operation is aimed at the final goal - the creation of durable translucent structures.

Aluminum structures workshop

The plant for the production of plastic windows is also equipped with a separate workshop for aluminum systems. This department has German machines SCHIRMER and ROTOX, which are designed for processing aluminum and stainless steel profiles. The aluminum systems section offers customers a variety of products - light balcony compositions, serious facade glazing, portal windows and doors. The window production process is completed on the profile receiving lines: here finished goods undergo quality control.

Custom Design Workshop

For the implementation of the most daring design ideas equipment from the department of non-standard designs is used. It is here that window systems of interesting configurations are born. During the manufacture of plastic windows, the achievements of the world brand Rehau, which develops energy-efficient systems, are used. The department is equipped with automatic German lines that allow you to create products with any bending radius. Employees of the department also make compositions of round, oval, triangular and trapezoidal shapes.

Lamination shop

The production of eurowindows is developing in accordance with popular sentiments - buyers are increasingly choosing interesting textures for the design of window systems. The plant has a special department of lamination, in which any fantasies of customers are realized - from ordinary window lamination to the creation of an imitation of expensive wood - walnut or oak. The department employs laminating machines that apply decorative films to profiles. Thanks to the launch of the lamination shop, the time for working with color designs has been reduced.

The production of plastic and aluminum windows is a complex process that requires professionalism, constant quality control and a high degree of responsibility. Therefore, following an integrated approach, you can get durable, strong and high-quality window structures.

Our window factory

The Window Alfavit company has its own plant for the production of plastic and aluminum windows, where highly qualified specialists work. The work takes place on modern equipment of the Urban and Kaban brands, which makes it possible to achieve quality work without marriage. The production is located in the Moscow region in the Sergiev Posad district. Many companies producing pvc windows are also represented in the assortment of the company. Having our own factory gives us many advantages. It's pretty low prices, we also guarantee high quality, because we ourselves control the production process. We can fulfill any individual customer order.

Plastic windows from stock

Do you need plastic windows, but the budget is strictly limited? In this case, you can contact the Window Alphabet company and buy plastic windows from the factory, the prices for which are much lower than for an individual order. Many buyers are interested in the question: why are finished PVC windows so cheap? The answer is simple - it's your own production.

Benefits of our windows

products at factory low prices
environmental friendliness according to SANPIN;
a large assortment;
production on advanced equipment;
production meets all quality standards;

Order factory plastic and aluminum windows with delivery in Moscow and to any other point of the Moscow region from our specialists. Window Alphabet saves you money, time and effort. We will make your home brighter, cozier, warmer and safer!