PVC window manufacture: where to start and how to succeed

Today we more and more often choose PVC windows (also called simply plastic windows) instead of wooden ones, and therefore this is a very popular product that can bring high income through a properly built business. Below we will describe in detail what equipment you need for the efficient manufacture of PVC windows. This is a complex process that requires several types of machines because each has its own functional purpose and is suitable for a certain type of work. We will also consider different methods for the manufacture of PVC windows with recommendations on which devices to use in the process.

How PVC windows are made

The manufacture of PVC windows can be divided into several main stages: preparation, channel milling, profile joining and frame milling.

First, the necessary size blanks are made from PVC sheets and a supporting metal profile. It is especially important to pay attention to the precision of the cut, which plays a key role in production. Now grooves should be made on the inside of the edge.

Then comes the most crucial moment - the connection of the already cut profiles. The metal inner profile is securely fixed and both parts are connected with self-tapping screws. But the window still has to be closed somehow, so now we need to make slots for the lock and handle. Then it is time for the installation of vertical and horizontal dividers. These dividers are called mullions and they are fixed in the grooves with connectors after milling the edges of the frame.

How to choose a manufacturing location

The more the better - this is the rule when you are choosing a manufacturing location for windows. You will need a space of at least 150 square meters and with 3-meter spacious ceilings. Connecting to a three-phase 380 V power grid is also a prerequisite for the operation of most machines and equipment.

Try not to overlook a perfectly working ventilation system, since production requires melting of polyvinyl chloride during welding, and this process is accompanied by the evaporation of substances harmful to people.

What equipment do you need?

It is wise to be prepared for the fact that the manufacture requires considerable investments. It is not worth trying to save a few bucks here, although for some positions, not the key ones, already used machines can be purchased. The price tag for each device will differ depending on the built-in functionality. So, for example, if you want to equip the most automated production with the latest machines, then the cost can go up to half a million dollars. 

What exactly do you need to buy? You will need equipment from 3 categories: pneumatics and machine tools, optional equipment and hand tools. We'll explain later why none of these categories can be skipped.

Pneumatics and machine tools
PVC profiles are cut using a mitre saw, in production usually two are needed at once: one for plastic windows and the other for metal frames. Such saws can be divided into the following types:
- table saws;
- stationary saws;
- single-head saws for cutting impost and bay windows and a two-head version for cutting metal frames and sashes.

What profile size should you take? Sizes vary, but a 6.5-meter length is ideal because it keeps waste to a minimum.

For large-scale production, a band saw is used instead of a mitre saw, because it can be used to produce many profiles in parallel, significantly speeding up the process.

Part of the manufacturing is the formation of drainage grooves to drain moisture, therefore, a drainage machine will always be among the necessary equipment. In the beginning, you can get by with a hand tool, but on a scale, a full-fledged stationary version is required.

Then the question of attaching the profile to the frame itself arises - here you need a screwdriver. It is not critical which type to choose: you can use both a stationary version and a manual device. Naturally, the first one guarantees high speed and the best quality in large-scale production.

A copy milling machine is required to cut the holes in which the handle and lock will be attached. The bench machine can also be used in conjunction with a drill, which will be used to form a triple hole for the handle. A pneumatic clamp and a three-spindle head will help bring production to a new level and, in general, greatly simplify the workflow.

The window frame is assembled from different parts of the profile using a welding machine. The machine can be purchased as a single-head device for small-size manufacture and, respectively, a two-head device for a constantly growing workshop. The equipment is very easy to use because it automatically welds the profiles at the specified angle.

The next step is to clean the weld bead. This will require a pneumatic deburring machine or a three-sided stripping machine in the case of large-scale manufacture. The face surfaces will be carefully finished with knives and an auxiliary cutter. There are also manual units for working with the frame angle.

As you might guess, in the production of windows, there is a tool for each task. So for cutting glazing beads, there are specially designed saws, which are divided into the following subspecies: for automatic control, for manual control and stationary.

A glazing stand is necessary at the last stage, when the operation of the window is checked and the fittings are adjusted. If you have purchased a stand with the possibility of vertical lifting, then during inspection the window can be fixed at the required height, which is very convenient.

Optional equipment

Above, we have considered only the main units required for work. But no less important are the auxiliary tools. This could include the following equipment:
- pneumatics (milling drills and screwdrivers);
- compressor (depends on the volume of the workshop and the compressed air consumed) and main filters;
- tables, 2-10 pieces according to the size of the workshop;
- racks for placing finished windows, materials, double-glazed windows;
- carts for transporting materials and products.

From the hand tool category, you will need hammers, shovels, rollers for rolling the seal and many other small tools.

Staff selection

This point is no less important than the choice of equipment. After all, awkward hands or a lack of experience can lead to the breakdown of valuable machines, production defects or even an accident. The workforce includes both machine tool workers and a team of engineers, operators, sales managers, advertising specialists and marketers that are essential to successfully position your product in the market. High-quality equipment needs fine-tuning and adjustment, so such specialists will also greatly help production.

Technological processes

The quality of the final product is based on the quality of the raw material, in this case the PVC profile. Next comes high-tech equipment and proper material processing. The production of a metal-plastic window itself can be divided into the following stages:
- cutting the plastic profile according to the necessary requirements;
- hardening with a reinforcing profile;
- connection of profiles;
- milling - creating holes to remove moisture using a cutter;
- installation of fittings;
- welding and cleaning of seams;
- glass installation and fixing with aluminium;
- pressing as the final stage of production.

Manufacturing costs

Any manufacturing costs can be divided into 2 main groups: basic costs, which include renting a place, purchasing equipment, regularly purchased materials, staff salaries and utilities, and additional costs such as license registration, advertising and taxes.

Now that we have decided on the main points for the production of PVC windows, it is worth thinking about how exactly to sell the product on the market.

How to find your buyer

Individuals, property owners, construction companies - these are your potential clients. To get them interested, you need to strike a balance between low cost and quality product. And then the product will sell itself: metal-plastic windows are comfortable and serve for a very long time, perfectly retain heat and insulation. Considering that active construction is underway in all cities, the PVC window market is also constantly growing.

Although windows can be divided only into laminated and white in appearance, they differ in quality very significantly, so if you do not save on equipment and specialists, you can occupy a niche of a luxury product on the market. The models differ in the number of leaves: there can be from one to four leaves. But for this you do not have to buy different equipment, you simply configure the existing one as you need it. Windows can be custom-made or produced by a single template for large projects, it all depends on your client.

This is briefly about the manufacture of PVC windows, and the most important thing for it is high-quality equipment because it will become the basis for the prosperity of your future business.