Stages of production of double-glazed windows for window structures. Production of plastic windows: let's take a peek behind the scenes of the workshop. Technology for the production of double-glazed windows.

To manufacture double-glazed windows for windows, it is necessary to purchase expensive equipment and properly set up the production process. But if you do everything correctly, you will be able to make a good profit in the shortest possible time. This type of business is promising and relevant. Therefore, enterprises specializing in this matter are increasingly being opened.

Types of double-glazed windows

A double-glazed window is a translucent structure that is installed in a special profile.

Advantages of double glazed windows

It can be found not only in windows, but also in doors, shop windows, and facade systems. There are several types of double-glazed windows:

single-chamber - low cost, but not energy-efficient designs;
two-chamber – do not allow heat to pass through, do not fog up and do not freeze when the air temperature drops significantly;
three-chamber – characterized by increased energy efficiency;
with the “spy” system – equipped with mirrored glass, which limits the visibility of those inside the building from the outside of the building;
shockproof - capable of withstanding significant loads, therefore they are installed in offices, shops, and residential buildings on the ground floor.

Necessary raw materials and supplies

To organize the production of double-glazed windows for PVC windows, it is necessary to prepare some materials. First of all, it is glass in the form of sheets. Their maximum length is 3 m and their weight is 90 kg.

In addition to sheet glass, to establish the production process, it is necessary to prepare other varieties of this material - reinforced, patterned, painted, impact-resistant, etc. Also, each glass unit contains certain fillers.

Distance frame

The distance frame ensures the same distance between the glasses.

It can be made from the following materials:

metal-plastic;
aluminum;
galvanized steel;
fiberglass.

The width of the spacer frame is strictly controlled by GOST and is usually 8-36 mm. Depending on the manufacturing technology used, this element can be formed by bending and have one connecting node. It is possible to produce a spacer frame from 4 separate elements.

Corners

Angles are designed to connect straight frame parts. They are made from various materials - plastic, zinc, steel. The main thing is that this element ensures the durability of the glass unit structure in all directions.

Molecular sieve

It is an absorbent material designed to absorb excess moisture. The molecular sieve significantly increases the service life of double-glazed windows installed on windows.

Materials of this type are used for primary and secondary sealing of double-glazed windows. They prevent moisture from the environment from penetrating into the structure.

Decorative elements

Decorative elements give the finished product exclusivity. The aesthetic qualities of double-glazed windows are also significantly improved. Glass tinting can be used to give it a specific color. A popular solution is to install decorative frames. They can be shaped like a cross-shaped binding, recreating the shape of a circle, polygon, or arch.

Production of double-glazed windows for plastic windows

Double-glazed window production technology

The technology for producing double-glazed windows involves several successive stages, each of which is performed on special equipment.

Cutting the canvas

The sheet glass is placed on a specially equipped cutting table. After carrying out the entire complex of preparatory work, the workpiece is cut into parts of the required size. This technological operation can be carried out manually with a carbide cutter or automatically. In the latter case, high precision of manufactured parts and excellent labor productivity are ensured.

Washing

The cut blanks are placed on a special inclined plane. They are cleaned by spraying water or a special chemical composition. After washing, stains remain on the glass, which can be removed with a piece of soft cloth. Usually cotton or suede is used. You can dry the surface using a stream of warm air.

To facilitate this operation, professional equipment is used. The washing machine is capable of not only cleaning the fabric, but also drying it with air.

This stage of work must be carefully monitored. The presence of even a small amount of moisture on the workpieces leads to insufficient sealing of the glass unit. Therefore, it is recommended that window glass undergo several drying stages.

Preparing the spacer

In double-glazed windows, a spacer frame is installed between the two panes. Before installation, it goes through a preparatory stage, which includes cleaning from contamination, anti-corrosion treatment and drying. All these processes most often occur in parallel with sheet parts in a special machine.

After this, the spacer frame is cut into pieces of the required length. The individual elements are connected to each other using corners and filled with absorbent. When using the "warm edge" technology, the frame is formed from a flexible material. This eliminates the presence of connections that are “cold bridges” in the glass unit design.

Internal sealing of glass unit

To ensure a tight fit of the spacer frame to the glass, it is treated with butyl on both sides. A special butyl sealing tape can be secured.

Formation of double-glazed windows

After installing all the sheets, the structure is sent for gluing, which is carried out on a special press.

It can be either manual or pneumatic with roller feed.

Final stage of production

The finished structure is filled from the inside with special gas - carbon dioxide, argon, special mixtures. For complete sealing, all joints are treated with silicone or polyurethane-based sealant. After this, the finished products are packaged and delivered to the final consumer.

Business profitability

When organizing a business for the production of double-glazed windows, the following investments will be required:

rent of premises – 120 rubles/sq.m. m;
equipment – 3.5-4 million rubles;
workers' salary - 75 thousand rubles. per month;
purchase of materials – 1 million rubles. per month.

During production per month 1100 sq. m of double-glazed windows in the end you can get about 250,000 rubles. net profit. Production profitability will be 22%.

In order for modern windows to have excellent performance, the production of double-glazed windows must be carried out in strict accordance with technological standards. The main requirement for these products is absolute tightness. However, in addition to this, there are a number of equally important criteria - stability of shape, sound and heat insulation declared by the manufacturer, as well as the absence of condensation on the inside of the glass. This result can only be achieved if all standards are met during the production process.

Terminology nuances

The technology for manufacturing double-glazed windows for windows made of plastic, eurobeam and aluminum is the same. As a result, there is no separate production of wooden double-glazed windows and their other types. In addition, this term itself contains a semantic error that can be misleading. After all, there are no wooden parts in any double-glazed windows, and in this case we are talking about the manufacture of double-glazed windows for wooden windows.

To produce these elements of window structures, the following are used:

various types of glass;
metal or plastic spacers;
sealants;
inert gas;
moisture absorber;
decorative elements - fusing, polymers, beveli and broaches;
energy-saving and soundproofing coatings.

For the manufacture of heated double-glazed windows, additional materials and special technologies are used. Read more about this on OknaTrade.

Stages of manufacturing double-glazed windows

Thanks to the automation of some stages of this process, it was possible to achieve higher quality and reduce the production time of double-glazed windows. The entire production procedure consists of 7 stages:

cutting glass;
cutting spacers – spacer frames;
glass washing;
applying sealant;
polishing glass edges;
primary assembly;
final sealing.

After completing all of the above processes, the double-glazed windows are ready for integration into window frames.

Glass cutting

One of the main and most important procedures is glass cutting. Moreover, in this process, not only accuracy is important, but also preserving the structure of the material being cut, as well as ensuring smooth fracture edges. The fact is that during the cutting process, microcracks form on the glass, which have the ability to “self-heal” quite quickly. As a result of this feature, if you hesitate, you can cause a defect, therefore, with high-quality cutting, the break should be made immediately after the cut.

Today this process is fully automated, so manufacturers of double-glazed windows have managed to improve quality. Cutting is carried out on special format-cutting machines with CNC and special air cushions for sheets of glass. In addition, to prevent chipping, the cutting line is immediately and automatically treated with a low-viscosity lubricating fluid. Thanks to this, the process of “self-healing” of glass significantly slows down, and it is possible to achieve perfectly even breaks without chips.

Preparing spacers

Simultaneously with the glass cutting process, preparation is carried out, the types of which can be found in the review on OknaTrade. Since spacer frames are made by pre-cutting profiles and then assembling them into a solid frame or by bending, the preparatory procedure may differ depending on the choice of spacer profile. During assembly, a molecular sieve - special absorbing granules - is poured into the internal cavities of the spacers. There are a number of requirements for this material:

the ability to absorb exclusively moisture and inertness to other substances contained in the air;
a suitable diameter of granules that will not allow them to spill out of the holes in the spacer frame.

The production of double-glazed windows at this stage is carried out taking into account that the glass does not fog up from the inside during the operation of the windows. During this process, it is important to correctly determine the “dew point”, so that the correct amount of moisture absorber will be selected.

When ordering double-glazed windows, it is recommended to give preference to models made from spacer frames with a thermal break. The use of such spacers allows you to eliminate “cold bridges” in this area of the window structure.

Glass washing

Washing of already cut glass is carried out in a special chamber using demineralized water. The entire procedure is performed without the use of detergents. All contaminants are removed from the surface of the glass using special brushes with bristles of strictly defined hardness. This technology allows you to thoroughly clean all surfaces without scratching the glass.

Applying sealant

This seemingly simple procedure is of fundamental importance - if the technology for its implementation is violated, there is a high risk of depressurization of the double-glazed window. Butyl-based compositions are applied to the surface of spacers using automatic or manual methods. In this case, the second option is allowed only if the production of double-glazed windows is not of a mass nature. During the application process, it is fundamentally important that the sealant layer is uniform throughout and amounts to 3 mm.

Glass grinding

Before performing direct installation, in order to reduce the likelihood of destruction of the newly assembled structure, the glass is ground around the perimeter. This event improves adhesion and provides insurance for the time it takes for the sealant to harden.

Primary assembly

At this stage, the glass is connected to the spacer frames, to which sealant has previously been applied. It is very important that the binder composition after assembly is exclusively black. After all, the presence of white spots on the sealant means that it was touched by hands or the glass was not washed properly. This negatively affects the quality of the connecting seam. To avoid such situations, workers wear gloves and keep the glass clean. After assembly, the structures are placed under a special press, where under pressure the butyl coating penetrates the structure of the silicate mass and ensures a reliable connection.

Double-glazed windows with white spots in places where glass and spacer frames are glued together are not suitable for installation and operation. The use of such products can lead to a rapid reduction in the energy efficiency of windows and the level of sound absorption.

Final stage

The production of double-glazed windows for windows ends with the stage of applying a second layer of sealant to the side parts of the structure. The procedure is performed in a temperature range of 16-25°C with air humidity not exceeding 50%. Thiokol, silicone or polyurethane sealants can be used as a secondary layer. Thanks to this stage, the safety of the primary geometry of double-glazed windows is ensured throughout their entire warranty period.

Double-glazed windows have long been popular because they create a comfortable microclimate and silence inside the house. And why? The dimensions of the individual elements of the package are verified, and together with the geometric rigor of the profile, this ensures the required quality of plastic windows.

What is a double glazed window?

It is often mistakenly referred to as an entire window made of plastic. This is not true. A double-glazed window is part of it; it is a chamber that is sealed and cannot be disassembled. The main role of the window package is to resist heat transfer from the house to the street and vice versa. The simplest and most economical design is single-chamber. It is formed by two glasses. They are separated to be at a fixed distance from each other, with a spacer frame around the perimeter. It has perforations, that is, small holes facing the inside of the chamber. Inside the frame are silica gel granules or molecular sieves. They play the role of dehumidifiers for air or other gases (inert) located in the chamber. Butyl is used to adhere the glass to the frame and provide primary sealing. A secondary polysulfide seal gives the joint strength when inserted into plastic profiles. Here's what it all looks like in the photo:

Classification

If you do not take into account the name of the manufacturer and the plastic profile for the window used by it, then the classification is simple. Double-glazed windows are divided into (see photo):

single-chamber;
two-chamber;
products with three chambers.

Single-chamber has a width of 12-36 mm and consists of two glasses. The two-chamber one has three glasses and, accordingly, two spacer frames. The width of such double-glazed windows is 24-64 mm. In southern latitudes, one camera is enough. In moderate areas it is worth thinking about two, in northern regions three is acceptable. It is also advisable to choose products with two chambers for windows in houses near airports, highways and noisy industries, given the increased noise of such structures.

Features of glass unit design elements

Manufacturing a double-glazed window is a painstaking and precise job, so certain requirements are imposed on its individual elements.

It is worth considering them separately.

Distance frame. The most commonly used materials for its production are galvanized steel and aluminum. They are reliable, durable; In addition, aluminum weighs little. But these are metals, and they will act as “cold bridges” in the window design. Therefore, intensive development is underway to create plastic* frames, and they do not even need perforations: the desiccant is introduced into the thermoplastic, which by extrusion (extrusion) creates the required gap between the glasses. When making frames with perforations for the holes, it is necessary to choose a diameter such that the desiccant cannot spill out through them during transportation.
Dehumidifiers. They are needed to remove molecular water between the glasses. After all, moist air promotes heat transfer, and the room will cool faster. And although different dehumidifiers have different dew points, this is not so important: their task is to absorb moisture when assembling the bag, since after sealing it no longer enters the chamber.
Sealants. Double sealing prevents moisture from penetrating inside the bag. This creates resistance to heat transfer, since dry gases conduct heat poorly. Butyl as a primary sealant is good because it creates moisture resistance with a minimum joint width. This allows you to maintain the ideal geometry of the package.
Glass. Any type of glass can be used. Which one to choose? Depends on what additional qualities the consumer needs. Tempered, triplex and reinforced glass, as well as sun control and patterned glass, are rarely used. More expensive are photochromic glasses, which can change color, and smart glasses, which change transparency. If the glass is not energy-saving, then it does not have any effect on heat transfer resistance. It weighs more than all the other elements of the package combined.

When you bring the flame of a lighter to special glasses, it is reflected in both, but with an offset and a different shade of the flame!

Stages of creating double-glazed windows

The very first step is cutting the glass. It is produced according to standard sizes, but the customer can specify their own sizes, because the current standard windows do not coincide with those produced previously. The glass in them can be transparent, transmitting up to 95% of daylight. Sheet transparent glass is marked M with a digital index from 0 to 8. M0 is an ideal canvas, but for double-glazed windows you can also choose M1.

For aesthetics and to protect the room from prying eyes, decorative glass and film coverings are also used. Functional glass can have increased strength, energy-saving or self-cleaning coating, protection from solar heat or ultraviolet radiation - there is plenty to choose from.

At the second stage, the glass is washed with demineralized water. This is done by a special brushing machine. The task of this stage is to ensure ideal adhesion of the sealant and glass, so dust, grease, and microparticles remaining after cutting must be washed off.

The third stage is fastening the spacers into a spacer frame and applying the first sealant to it.

At the fourth stage, the bags are assembled directly, that is, the glass is connected with a sealant to the frame, after which the product is put under the press for a few seconds. The bags are ready, all that remains is to secure them with secondary sealant in plastic profiles.

It is worth adding that a conversation about what a double-glazed window consists of will be incomplete without mentioning that you can choose to replace the air with argon, krypton or xenon in the package chambers. They improve the technical characteristics of the product, but not for long.

Reduced fuel consumption thanks to double glazed windows

In a city apartment, words about saving fuel sound a little abstract, but for a country house the owner will consider everything thoroughly. It is advisable to install energy-saving glass here. Their surface is coated either with metal oxides (k-technology) or alternating silver and dielectrics AlN, BiO, TiO2 (i-technology). These surfaces reflect the heat of the room back from the glass, and the same happens with the air outside. This action resists heat transfer to “nowhere”. After all, a significant part of the heat no longer escapes through cold windows. And this share was 40-50%.

You can further reduce heat loss, and at the same time improve the sound insulation qualities of double-glazed windows for windows. To do this, the air in them is replaced with an inert gas. Moreover, with ordinary glass, the heat transfer resistance in this case decreases by only 3-5%, and with energy-saving glass - by 30. It becomes almost twice as warm (40% + 30% = 70%). How much fuel is saved thanks to this!

Energy-saving glass does not sweat and does not “cry”!

Sound insulation level

Thanks to the air or gas layer in the glass unit, the resistance not only to heat transfer, but also to the propagation of sound increases. Even a single-chamber double-glazed window reduces noise by 34 dB. You can calculate: if a truck “growls” at 70 dB, then single-pane windows reduce its noise to 36 dB. For comparison, noise in a library is rated at 30, and 35 is normal human speech. It is clear that as the number of cameras increases, the sound almost completely disappears (see photo).

Marking of double-glazed windows

It characterizes the type of glass and the dimensions of the distance between them, as well as the number of cameras. The letter M denotes ordinary glass, the number in front of the letter is the thickness of the glass, and behind it is the brand of glass. The number delimited by hyphens indicates the distance between the glasses of the package. The number of these numbers indicates how many cameras there are in a given double-glazed window.

For example, marking 6M1-20-6M1 gives the following information: a double-chamber double-glazed window filled with air, consisting of six-millimeter glasses with a distance between them of 20 mm. If the chamber was filled with argon, the marking would look like this: 6M1-20Ar-6M1. With a different type of glass, instead of M there would be a different letter indicating the type of glass: F - float glass, PI - having a heat-reflecting film, and so on.

Resistance to the penetration of noise from the street and heat transfer between the street and the room is the main function of a double-glazed window that composes a window.

I like

On all modern automated lines for the production of double-glazed windows, several sections can be allocated, corresponding to different stages of the technological process.

Glass cutting

At the first stage, glass is cut to standard sizes.

Modern cutting tables are highly mechanized devices in which the movement of the cutter is controlled by a computer according to a program specified by the operator from the keyboard. Some tables are equipped with a special cutting optimization program that allows you to reduce waste to 5% or less.

The glass moves across the table surface on an air cushion created by a large number of holes on the table surface.

Breaking of glass after a cut is carried out by special rods rising from the surface of the table.

When a cutting tool passes over the surface of the glass, a small groove with microcracks is formed on the glass. When broken along this groove, the glass breaks. In order to obtain an even cut, the break must be made quickly enough after creating the groove. This is due to the so-called “glass self-healing” effect after microcracks are created. The resulting microcracks seem to begin to stick together spontaneously, and breaking the glass in this case is much more difficult. In order to avoid such phenomena, a special cutting fluid is used, which has low viscosity and good wetting properties. It penetrates into microcracks and prevents the glass from self-healing.

Cutting spacers and filling molecular sieve

In parallel with glass cutting, spacer frames are cut to the dimensions of a given glass unit and the frame of the glass unit is pre-assembled using corners and connecting inserts.

For high-quality cutting of spacer frames, special saws are used, equipped with a circular saw mechanism, a workpiece clamping mechanism and roller conveyors for feeding and measuring workpieces.

Simultaneously with assembly, the spacer frames are filled with a molecular sieve (desiccant), which adsorbs moisture from the inter-glass space of the glass unit.

By using a dehumidifier, the air inside the glass unit is almost completely dehydrated, and thus eliminates the possibility of condensation between the glass panes throughout the entire range of normal operating temperatures.

Backfilling is done using special sealed structures, which are one of the mandatory elements of the equipment complex for the production of double-glazed windows.

Glass washing

At the next stage of manufacturing double-glazed windows, the glass is washed with demineralized water (with a conductivity of less than 20 µim/cm) in a brush washing machine.

Glass with a soft low-emissivity coating should be washed only with specially designed brushes that have a certain bristle stiffness.

Washing is a responsible operation that largely determines the durability of a double-glazed window, the good sealing of which is based on the ideal adhesion of the sealant to the glass.

Hand washing (wiping) glass is not recommended, especially with the use of detergents. After manual washing, a film of grease or other substances remains on the surface of the glass, invisible to the eye, but leading to peeling of the sealant and, accordingly, depressurization.

Butyl application

At stage III, polyisobutylene sealant is applied to the pre-prepared frame of the double-glazed window from the spacer frame.

Butyl sealant is applied at a temperature of 120-140 "With a width of approximately 3-4 mm using a butyl extruder. The layer must be uniform, without breaks, at least 3 mm wide, especially in corners and joints. Additionally, in the corners, sealant is applied along the connecting cracks.

For small production volumes or repairs, which is an exceptional case, the initial sealing of double-glazed windows can be carried out manually. In this case, the sealing layer is applied in the form of a thin self-adhesive butyl tape.

Pre-assembly of double-glazed windows

At stage IV, the pre-assembly of the double-glazed window is carried out. At this stage, the washed glass is connected to the spacer frame using a pre-applied butyl sealant.

After this, the structure is sent to the press so that the sealant is placed in the pores of the glass.

Application of secondary sealant

At the final stage of manufacturing a double-glazed window, using automatic equipment or manually, it is applied to the end surface of the double-glazed window.

In this article:

To open a glass business, you need impressive investments and massive volumes of orders (it’s not for nothing that in Russia there are no more than 2 dozen factories producing flat glass). But there is an alternative option with a very obvious and popular sales area - the production of double-glazed windows for wooden and metal-plastic windows.

Choosing a business direction

Most window manufacturing companies are small businesses, limiting themselves to the assembly and installation of finished products. And although logic dictates that having your own glass line will significantly reduce the cost of windows, manufacturers, in most cases, still prefer to buy ready-made double-glazed windows. Why? It all depends on production volumes.

Options for organizing the production of double-glazed windows:

Manual assembly (up to 50 double-glazed windows/day)
Automated or semi-automated production line (100-1500 double-glazed windows/day).

The cost of hand-made and purchased double-glazed windows is almost the same, because manual technology requires the use of expensive raw materials. And when an automated line operates, “manual” materials are replaced with professional, cheaper analogues for mass production - for example, liquid butyl is used instead of butyl cord.

Therefore, manual assembly of double-glazed windows most often becomes a “backup” option to prevent the failure of large orders due to the high (usually seasonal) workload of the supplier and frequent violations of delivery deadlines. Or when orders are not regular and large in volume, and the supplier of double-glazed windows is located geographically far away.

An automated line (fully or partially), as practical experience confirms, will be appropriate for established sales of products of at least 1000 m 2 /month.

Legal registration

The organizational form of the future business should be chosen with an eye on purchasing partners. The main sales market for double-glazed windows– companies producing and installing windows, which can be both legal entities and individuals. From the point of view of cost optimization, it is most profitable to register an individual entrepreneur - both taxation is lower and accounting is simpler.

For the production of double-glazed windows, the following OKVED is indicated:

26.12 Forming and processing of sheet glass.
If you plan not only production for your own needs, but also sale to third parties, you must add: 51.53.23 Wholesale trade in glazing materials;
52.46.3 Retail trade in glazing materials.

Double-glazed windows are subject to mandatory certification; finished products must comply with:

GOST R 54175-2010 (replaces GOST 24866-99) - Glued glass units for construction purposes. Technical conditions;
GOST R 54174-2010 - Glued double-glazed windows. Rules and methods for ensuring product quality;
GOST R 54173-2010 - Glued double-glazed windows. Methods for determining the physical characteristics of sealing layers;
GOST R 54172-2010 - Glued double-glazed windows. Durability assessment method.

Please note that certification takes about 3 months (that’s how long durability tests take). To undergo the “procedure”, you need to provide sanitary and epidemiological reports on sealants and absorbents, technical production regulations, certificates of personnel completion of training, certificates for equipment, and samples of marking.

Raw materials and supplies used in the production of double-glazed windows

The standard raw material for the manufacture of double-glazed windows is sheets of glass up to 3 m long and weighing about 90 kg. In addition to sheet glass, patterned, reinforced, impact-resistant, fire-resistant, painted and other types of glass are used in the production of double-glazed windows.

GOST 111-2001 Sheet glass. Technical conditions.
GOST R 54171-2010 Multilayer glass. Technical conditions.
GOST R 54169-2010 Sheet glass, dyed in the mass. General technical conditions.
GOST R 54170-2010 Colorless sheet glass. Technical conditions.
GOST R 54162-2010 Tempered glass. Technical conditions.

"Fillers" of a double-glazed window:

1) Distance frame - a hollow aluminum, metal-plastic, fiberglass or galvanized steel strip, which is designed to maintain the same distance between the glasses. The distance between the glasses depends on the width of the spacer frame - according to GOST R 54175-2010, this figure should be in the range of 8-36mm.

Depending on the manufacturing technology, spacer frames can be made by bending and closed on one connector, or assembled from four straight sections fastened with 4 connecting corners;

2) Corners– elements made of plastic, steel or cast zinc for fastening straight frame cuts. The choice of material for the corner is not important - the main thing is that it ensures the mechanical stability of the frame structure;

3) Molecular sieve– absorbent material that absorbs excess moisture inside the glass unit;

4) Various sealants for primary and secondary sealing, which must meet the requirements of GOST R 54173-2010 “Glued double-glazed windows. Methods for determining the physical characteristics of sealing layers."

To give the windows exclusivity and the façade of the building individuality, various coatings and tinting are used for glass. But the most popular solution today is decorative frames placed inside a double-glazed window, which can have the shape of a cross-shaped frame (like French windows) or depict a more complex figure (double circle, polygon, arch).

It is necessary to take into account that double-glazed windows are products with a long warranty service (from 5 years). If a defect is detected, the glass unit will have to be replaced.

Technological process for the production of double-glazed windows

1. Cut

A sheet of glass is placed on a cutting table, where it is cut according to specified parameters into blanks for the future double-glazed window. Depending on the technological equipment of the production, cutting can be done manually with a sharp carbide cutter, or automatically. Naturally, when the machine operates, the cutting accuracy is much better and productivity is higher.

2. Washing

The cut pieces are placed on a special inclined stand and cleaned using a spray bottle with glass cleaning liquid or plain water. After washing, the window should be wiped dry with a cotton/suede cloth or dried with warm air. This is a prerequisite for high-quality adhesion of the sealant - on a damp and insufficiently clean surface, sealing will be incomplete, and in places of contamination, moisture can penetrate inside the glass unit.

The process can be accelerated by using a washing machine, in which all cleaning and drying processes are performed automatically using water and compressed air.

3. Preparing the spacer

To form a single-chamber double-glazed window, you need two glasses and a spacer frame placed between them. The cleanliness of the spacer bar is subject to the same requirements as for glass. That is, it must be pre-cleaned from dirt, corrosive substances and possible moisture (usually, the process is carried out simultaneously with glass washing).

According to standard technology, the bar is cut into sections of the required length, taking into account that the perimeter of the glass will always be greater than the perimeter of the frame. These sections are attached with corners and filled with absorbent. The “warm edge” technology uses a flexible spacer frame that does not require preliminary manipulations with cutting.

4. Internal sealing

For fastening to glass, the spacer strip is covered on both sides with internal sealant - butyl tape (attached manually) or molten butyl, which is applied using extruder. According to the standard, the depth of the primary layer of sealant should not be less than 4 mm, and the overall depth of the sealing coating should be from 9 mm. These parameters are established by the technological documentation and depend on the type of sealant used.

The use of a butyl extruder ensures not only speed, but also high strength of internal sealing, since before application to the frame butyl is heated to 120-160C, which creates optimal conditions for the “adhesion” of the sealant.

Two holes with a plug are made in the bar. One is for gas injection, the second is for air outlet.

5. Formation of a double-glazed window

The second glass “covers” the frame, the glass unit forms a single structure, which is sent to the press for gluing. This can be a manual press, the pressure of which is regulated by valves, or a pneumatic one, with a roller feed.

The production of two- and three-chamber double-glazed windows follows the same algorithm - a strip is again attached to the second glass, sealed and covered with a third glass. The process is repeated depending on the structural type of the window.

6. Gas filling

Through a specially left hole, the glass unit is filled from the inside with gas (carbon dioxide, xenon, argon or various mixtures). At this stage, it is important to regulate the flow rate - if the pressure is high, the air from inside the double-glazed window will not escape through the second hole, but will mix with the gas.

7. External sealing

The finished glass unit is treated with silicone or polyurethane sealant. The easiest way to apply sealant is with a mixing device with cartridges. The minimum thickness of external sealant for structures filled with argon is 5 mm, with dry air - 3 mm.

8. Packaging of finished products

Finished double-glazed windows are installed vertically on stands with an inclination of 5-7 degrees to the vertical to prevent tipping. This position is necessary to prevent further compression of butyl. If you store a glass unit in a horizontal position, there is a high probability of butyl compression and loss of sealing qualities.

Cork/polymer gaskets are placed between the glass units to protect the surface from damage during transportation or storage. After complete polymerization (3-12 hours - depending on the temperature in the workshop and the properties of the sealant), the products are ready for shipment.

According to GOST R 54175-2010, each double-glazed window must be marked. The marking is applied to the glass in the lower left corner or on the spacer frame and contains the trademark/name of the manufacturer, date of manufacture, and formula of the glass unit.

Business plan for an enterprise for the production of double-glazed windows

1. Room

To open a production workshop, a premises with an area of 300 m 2 was rented. Rental price per month – 120 rubles/m2.

The premises meet all the requirements of GOST R 54175-2010 for a workshop for the production of double-glazed windows:

divided into a warehouse for consumables, finished products and a workshop where the equipment is located;
the temperature regime is observed +16 - +24C;
humidity level does not exceed 50%;
has water connection and heating;
complies with fire safety standards in accordance with GOST 12.1.004-91 “System of occupational safety standards. Fire safety. General requirements.”Additionally, lighting sources were installed in the glass washing area and above the cutting table.

2. Form of organization

Since the main buyers are individual entrepreneurs producing PVC windows, it was decided to register the business as an individual entrepreneur using the simplified tax system of 6%.

3. Capital investments

Equipment was purchased - a technological line produced by Fimtec (Germany), with a capacity of up to 350 double-glazed windows/shift.

Equipment:

cutting kit (unit for straight cutting + table 2.3 * 3.3 m) – 400,000 rubles;
washing machine – 978,000 rubles;
filter for water purification – 95,000 rubles;
semi-automatic assembly line with a roller press – RUB 1,025,800;
saw for cutting the spacer frame – 135,500 rubles;
apparatus for filling the frame with absorbent – 44,000 rubles;
manual bending unit for rounding the frame – 46,650 rubles;
butyl extruder – RUB 767,800;
table for sealing double-glazed windows (rotating) – RUB 147,160;
compressed air dryer – 67,400 rubles;
pneumatic kit – 44,000 rubles;
small package of tools (glass gauge, ruler with suction cups, manual glass cutter, angle, compass up to 2000mm, suction cup with 2 heads) – RUB 30,000.
Total: RUB 3,781,310

4. Staff

It is planned to hire a technologist and 5 general workers to service the line. The wage fund will be 75,000 rubles/month.

5. Shop productivity and profit

It is planned to work in one 8-hour shift, with an output rate of 50 m 2.

Total for the month: 50m2 * 22 work shifts = 1100m2.

Sales price of finished products – 1350 rub/m2

Profit: 1350 rubles/m2 * 1100m2 = 1,485,000 rubles/month.

6. Calculation of material costs

To produce 1 m 2 of single-chamber double-glazed windows you will need: - sheet glass 4 mm thick - 2.5 m 2 * 320 rubles/m 2 = 800 rubles;
aluminum spacer frame PROFIL GLAS, 11.5 mm – 4 m.p. * 7.61/1 m.p. = 30.44 rubles;
plastic corners 4 pcs. * 23.81/ 100 pcs. = 0.95 rub;
butyl Fenzi – 20 gr. * 214.71/1 kg. = 4.30 rub;
secondary sealant – 228 ml. * 210.3/l = 47.95 rub;
molecular sieve – 160 gr. * 65.80/1 kg. = 10.53 rub.

Total: 894.17 rub.

The cost of a window depends not only on its size, but also on the width of the spacer frame

Material costs will be: 1100 m 2 /month * 894.17 rubles = 983,587 rubles / month.

7. Production costs

rent – 36,000 rubles/month;
Payroll – 75,000 rubles/month;
social contributions (37.5%) – 28,125 rubles/month;
electricity 85 kW/day * 22 work shifts * 3 rubles = 5,610 rubles/month;
USN (income tax) - 89,100 rubles/month;
rental of a Gazelle car with a pyramid installation and driver services – 6,000 rubles/month;
material costs – 983,587 rubles/month.

Total: 1,223,422 rubles/month.

8. Evaluation of financial results

Net profit: 1,485,000 - 1,223,422 = 261,578 rubles/month.

Production profitability:(RUB 261,578: (RUB 983,587/month * 12 months)) * 100% = 22%.

Return on initial investment: RUB 3,781,310: RUB 261,578/month = 1 year 3 months.