Production of plastic windows. Russian factories for the production of windows. Reinforcing steel insert

The production of plastic windows is a complex process that should ultimately give a high-quality result - a window structure with good hydro, heat and sound insulating properties.

VEKA strictly adheres to the requirements of Russian and international manufacturing standards, which guarantees high quality products. German technologies and equipment are used in the production of VEKA PVC windows.

Making a window consists of many operations. But in a simplistic way, there are several steps:

1. PVC profile production.
2. Making a window frame.
3. Assembly of components into a single product.

See how PVC profiles are manufactured and windows are assembled at the factory:

Materials for the production of plastic windows

The main materials and components necessary for the manufacture of metal-plastic windows:

• granulated or powdered polyvinyl chloride for the manufacture of a profile;
• steel profile for reinforcement;
• sealant;
• accessories and additional equipment (blinds, etc.);
• double-glazed windows.

The production of plastic windows is based on the use of one of the oldest man-made materials - polyvinyl chloride. It was obtained in the laboratory in 1835 by the chemist Regnault.

However, the polymerization product of vinyl chloride, PVC, began to be widely used in industry only in the 1930s. And the manufacture of PVC windows did begin in the post-war years.

The use of polyvinyl chloride for the production of windows allows the production of window profiles of various shapes. At the same time, all of them are distinguished by low thermal conductivity, high chemical resistance, environmental friendliness, ease of processing, good energy-saving properties and resistance to climatic influences.

Production stages

The production of a PVC profile and the assembly of the structure is preceded by an inconspicuous, but very important stage - design. Design engineers create drawings and diagrams of future windows, in which:

• draw the design to the millimeter;
• provide mechanisms to ensure the safety of the window;
• select fittings and accessories for noise, hydro, thermal insulation;
• design the placement of a heater, an opening mechanism, a metal profile that reinforces the structure, etc.

STAGE I: extrusion

The profile for windows is obtained by continuous extrusion of a PVC mass heated to 80-120 ° C through an extruder. In the die (part of the extruder for molding a product from a molten material), the softened material acquires the shape, size, and wall thickness provided for by the project.

It is very important to maintain the temperature regime when the mass is heated and the already elongated profile is cooled. Failure to comply with it leads to distortion of the finished product and marriage. After cooling, the PVC profile enters the marking line. Here it is pasted over with a protective film.

STAGE II: cutting and storage

After the marking line, the PVC profile is fed to the cutting line. An automated saw cuts it into pieces that are convenient for storage and transportation, the finished profile is placed on special pallets. After that, the blanks go to the warehouse, from where they are sent to different cities to window manufacturers.

Companies such as VEKA produce only the profile itself. VEKA production is located at factories in the Moscow region and Novosibirsk. And partner factories in different cities make window structures directly, embedding reinforcing inserts, fittings, double-glazed windows into the PVC profile.

STAGE III: PVC profile cutting

A standard PVC profile is cut into blanks on a high-precision machine. The CNC of the machine allows you to maintain the design dimensions of the future window up to tenths of a millimeter. Also on automated machines, technological holes for fittings, etc. are made in the profile.

STAGE IV: reinforcement

To strengthen the window structure, reinforcing inserts made of galvanized steel must be installed inside the plastic profile. Reinforcement is cut with circular or band saws for metal. Reinforcing liners are needed in order to protect the window from deformation caused by temperature changes.

STAGE V: welding and seam processing

In the process of welding profile blanks, the profile at the joints is heated up to 240 °C. Immediately, the surfaces to be welded are firmly pressed against each other. The production of metal-plastic windows is a complex process, and the quality of welding has become an important indicator of the reliability of the window design. Therefore, after welding, the seam undergoes a separate test.

From the welding machines, the design enters the machining center, which automatically cleans the weld and transfers the product to the assembly area, where the fittings are installed.

STAGE VI: installation of insulation, fittings

If the impost was not welded into the structure at the welding stage, then at this stage it is fixed using mechanical fastening.

A seal is installed - it is inserted into the grooves and coated with a special molecular adhesive. Holes are drilled in the profile to equalize the pressure in the internal cavity.

After that, in accordance with the customer's order, fittings are installed that ensure the mobility of the window sashes, locks, hinges, etc.

VII STAGE: installation of a double-glazed window

At this stage, the metal-plastic window enters the glazing stand. Here a double-glazed window is installed in it, fixing it with a glazing bead.

Linings are preliminarily placed under the double-glazed window, which exclude unwanted stresses in the glass. They also serve as stoppers when squeezing the window sash in case of a possible break-in.

VIII STAGE: warehousing and shipping

After the QCD inspector checks the quality of the finished plastic window, the product leaves the production shop and goes to the warehouse to go to the customer from there.

Quality checking

In order for the window to last for a long time, not only the profile itself must be of high quality, but also all stages of creating the structure. Literally everything affects the quality: maintaining the temperature in the workshop, the materials used, the qualifications of the employees, the technical condition of the cutting machines. Therefore, VEKA conducts a detailed audit of its partners so that the windows are truly made to last for centuries.

Thus, to check the quality of the extrusion process, all VEKA mother and daughter plants are monitored. The data is sent to the central office of VEKA AG in Sendenhorst. Raw materials and finished products are checked directly at the factories by our own laboratories and quality departments.

Why are some PVC windows more expensive than others?

PVC profile for the production of plastic windows is manufactured at VEKA factories and there is no doubt about its quality.

But why, then, in different companies, similar windows can differ greatly in cost?

Much depends on what the manufacturer equips the window with - cheap fittings, low-quality insulation, "forgets" to put a reinforcing insert, lining, or saves on double-glazed windows. We advise you to read

The production of PVC profile windows consists of several stages and is carried out on a new generation of technological equipment. For the most critical processes today, CNC machines are used, thanks to which it is possible to achieve high precision cutting and assembly. In the production of windows, both format-cutting centers and machines for milling, cutting glazing beads, welding parts and cleaning corner joints are involved. The manufacture of window structures is always carried out in a strictly defined sequence, and this article will tell you about all the main stages of production.

Measurement of plastic windows

The manufacturing process always begins with a measurement, and this procedure cannot be isolated from all other stages. It is recommended, since only a specialist knows all the nuances of this process. When customers decide to independently determine the dimensions of windows, they make standard errors, due to which the sizes of windows and openings do not match up or down. Both options are bad because they provoke:

• the need to perform additional work to adapt openings before installing windows with the wrong dimensions;
• depressurization of structures along the perimeter of the assembly seam;
• deformation of sashes and frames;
• depressurization of a double-glazed window.

In some cases, with incorrectly determined sizes, new windows have to be ordered. If the dimensions were provided by the client, all work is carried out at his expense.

Drawing up a specification

Today, the determination of the dimensions of parts and their quantity is carried out on computers using special software - no one makes manual calculations with a calculator. After the transfer of the documentation by the measurer, the designer enters all the necessary data into the computer, and the program calculates the dimensions of frames, sashes, double-glazed windows and each component separately. Then this information is electronically transmitted to the workshops for the production of double-glazed windows and window or door blocks.
Some window manufacturers may order double-glazed windows from companies that specialize only in the production of these products. However, the essence of the technological process does not change depending on where exactly these window elements will be manufactured.

Double-glazed window production

This stage of window manufacturing is also partially automated. All large and medium-sized enterprises for the production of double-glazed windows today use CNC centers for glass cutting. Moreover, in some cases, automation has affected not only the cutting procedure, but also the assembly of finished products. The whole production process of double-glazed windows is as follows:

When the sealant goes through a full polymerization cycle, which takes from 3 to 12 hours, the double-glazed window is ready for transportation to the workshop where the main production of plastic windows is carried out.

Production of window and door blocks from PVC profiles

This process consists of several stages - cutting, milling, reinforcement, welding (fusion), grinding of connecting seams, integration of imposts and tying with fittings. After that, the design of window or door blocks can be considered actually finished. It remains only to insert double-glazed windows into the light openings of the wings.

Preparation of PVC profiles

This stage includes several procedures. To prepare the profiles for the assembly of window structures, three operations are sequentially performed with them:

1. Cutting - according to the specification that came from the computer in the design department to the CNC machine in the workshop, PVC profiles are cut at an angle of 45 degrees.


2. Milling - during this stage, small holes are cut in certain areas of some parts. Such a procedure is necessary to create drainage channels in the designs of door and window blocks.


3. Reinforcement - according to the dimensions of the already cut profiles, steel liners are cut, which are inserted into the internal chambers and fixed with metal screws. This significantly increases the rigidity of plastic parts.

After completing the above measures, the profiles are considered ready for assembly into frames and sashes. These steps are carried out on welding and stripping machines.

Assembly of windows and doors

The optimal result, which ensures high strength and precision of the joints, is achieved by simultaneously connecting all the joints of the frame or sash. That is, all 4 corner joints must be made at once. This can only be achieved with automated equipment. Fusion of profiles is carried out at high temperature and pressure. If you violate the optimal welding mode, the quality of the seams will be unsatisfactory.

To achieve the desired parameters, special Teflon elements are lowered into strictly fixed gaps between PVC profile parts, which melt the plastic. After reaching the desired temperature, the plates with non-stick coating quickly rise, and all parts are simultaneously pressed against each other and held until the plastic is completely solidified. Before proceeding to the next step, the machine independently checks the strength of the connecting seams.

Cleaning corner joints

Since the melted plastic is partially squeezed out when joining PVC parts, the joints after fusion of the profiles look very rough. It seems that the frames and sashes are covered with wide scars at the corners. To give the structures a normal look, all the plastic that has come out is removed using a special milling machine. On this equipment, not only excess polyvinyl chloride is removed from the joints, but also reduced seams are polished. Thanks to this procedure, frames and sashes made of PVC profiles acquire a presentable appearance.
If a laminated profile is used for the manufacture of windows, after welding and cleaning the seams, narrow white stripes appear at the corner joints. This technological flaw is eliminated by painting over the joints with special markers, the color of which matches the color of the decorative film.

Not so long ago, a production technology appeared on the market that makes welding seams invisible to the naked eye.

Milling and mullion integration

Imposts are inserted into ready-made structures. To perform the integration of mullions, they must be adapted to the shape of the profiles. This procedure is performed using a special milling cutter that removes excess plastic. After fitting, imposts are either fastened with corners and self-tapping screws, or welded into the main structure.

Installation of sash opening systems

Mounting of fittings is carried out on special stands. If such equipment is not available, the harness is attached manually using templates. Together with the installation of the main fittings, the strikers are fastened from the inside of the light openings and the handles for controlling the opening systems are fixed, which are connected to the locking mechanism of the fittings.

Fixing the sealing circuits

To fix the seals in the profiles, special grooves are provided. The greater the number of circuits, the higher the level of tightness of the windows. As a result, it is recommended to use systems in which their number is at least three pieces. Sealing contours of various shapes are inserted into the grooves on both frames and sashes, after which the window or door units are ready for the final stages of assembly.

Hanging sashes

Elements of the opening mechanism (hinges) are available both on the frame and on the sashes. Thanks to this, when performing the hanging procedure, you just need to insert the sashes into the light openings and fix the fittings.

Installation of double-glazed windows

Before performing this procedure, it is necessary to wipe the seals and glasses, and also remove the remnants of the smeared sealant, if any. The inside of frames and sashes must be free of dust and other debris. Double-glazed windows are inserted into the skylights after fixing the straightening plates, after which they are fixed with the help of clamping beads. These operations are performed manually and in a strictly defined sequence. Sometimes double-glazed windows are inserted into the openings already at the facility during

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 allows us to achieve high-quality work without the absence of 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. These are quite low prices, we also guarantee high quality, because we control the production process ourselves. 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-made plastic and aluminum windows with delivery in Moscow and to any other point in the Moscow region from our specialists. Window Alphabet saves you money, time and effort. We will make your home brighter, cozier, warmer and safer!

The Okna R company is one of the leaders in the production of plastic windows in Moscow and the Moscow region, for more than 15 years it has been providing a full cycle of services: we design and manufacture window, balcony and door structures, deliver them to the glazing facility, professional installation, warranty service and repair of any complexity.

In the production of window structures, the priorities for us are the high quality of finished products and an affordable price.

Equipping the plastic window factory with the latest European equipment, using only proven components from well-known brands for the production (Rehau profiles, Lisec and Guardian Industries double-glazed windows, Maco and Fornax fittings), as well as compliance with GOST requirements and strict control at every stage - guarantee the high quality of our products .

At Windows R, you can:

• purchase standard plastic windows of standard sizes or order the manufacture of non-standard designs according to individual sketches and sizes;
• not limited to ordering only white windows, we offer window lamination with Renolit colored films for various types of wood or metal;
• order windows with the required set of characteristics by choosing a double-glazed window with energy-saving, triplex, multifunctional or colored glass.

The range of products and services of the Okna R company is not limited to the production and installation of PVC windows, we also manufacture aluminum windows for glazing balconies and loggias, professional turnkey finishing of these premises, production of plastic doors for various purposes (entrance, interior, office and balcony ), manufacture and installation of blinds and roller blinds.

For dealers and construction companies, we provide an excellent opportunity to order wholesale plastic windows and other products on mutually beneficial terms.

Plastic window assembly process

1. Profile cutting. From a six-meter Rehau profile, blanks of window frames are cut at an angle to the required dimensions. In the manufacture of non-standard window structures, the profile is bent to a certain radius.
2. Reinforcement. Next, the plastic profile is reinforced to increase the rigidity and strength of the final product.
3. Seam welding. Thanks to the assembly on automatic equipment, four corners of the structure are welded at the same time, which makes it possible to avoid defects and distortions during production.
4. Construction assembly. According to the exact marking, fittings are mounted and a sealant is installed in special grooves. After that, a double-glazed window is fixed in the window frame with the help of glazing beads.
5. Order picking. At the final stage of production, the linings on the hinges, window handles, supply valves and other accessories prescribed in the contract are installed.

Depending on the workload of production lines and the complexity of designs, the production of plastic windows takes from 5 to 10 days.

There are several reasons why it is profitable to order plastic windows from the Prosvet Windows company. One of them is our own production base. Today, the buyer seeks to choose not just plastic windows, the prices of which correspond to certain characteristics. He needs to get first-class quality, a high level of service and warranty from the manufacturer. We can offer all this.

Long-term cooperation with the German concern REHAU allows us to manufacture high-quality plastic windows and sell them at the best prices. Manufacture of products takes place on modern equipment, taking into account all innovative technologies. Moreover, the company has developed its own certification system. And now each of our clients is sure that when ordering REHAU PVC windows, he is completely insured against fakes.

The production process begins with computer processing of the data obtained during the measurement - the type of window, its dimensions, color, type of double-glazed window and other additional characteristics. The whole complex of works on the production of PVC windows is fully controlled. Before delivery to the site, the products are carefully checked by the Technical Control Department.

Why own production is beneficial?

The impeccable quality of the product, in which we are confident, is achieved. And we guarantee it to all customers who purchase plastic windows. The price pleases, the service is improving, the quality is growing - aren't these signs of a successful company?

Why own production is interesting?

The range of manufactured products is increasing every year. Treating work as creativity is a great motivation for all our employees. We know how to make beautiful and high-quality windows and, importantly, we get real pleasure from the result.

Why own production helps?

Each customer is always primarily interested in the timing of the production of PVC windows. We respect our customers, so we produce windows quickly and on time. Our customers do not depend on anyone - from the production base, high-quality windows are delivered immediately to the objects, bypassing the warehouses of intermediary firms. This saves time and allows you to work quite mobile.

The production of plastic windows by the company "Windows Prosvet" is:

• Use of German REHAU profiles. We are official representatives of this brand and have a license to produce REHAU window profiles in Russia.
• Large-scale production: more than 4000 square meters of finished products per month!
• Huge selection. We are always happy to offer various options for plastic windows and balcony blocks and fully ensure the installation of structures.

These advantages allow our products to win over competitors not only in quality, but also in all other indicators. We have our own production at our disposal, to which we devote all our strength every day so that our customers have the opportunity to buy only the best PVC windows of genuine German quality!