Equipment for the production of painted MDF facades. Production of furniture facades: a plan for starting a business. Facades from MDF

The appearance of the product and its final cost depend on the furniture facade. Wherein, given fact is taken into account regardless of the fact that the details of the facade occupy only a quarter of the object itself. The technology of production from the array itself is quite complex and requires the use of many resources.

Filling

Drying the wood is always the first step in processing. To dry all lumber intended for the manufacture of furniture frame and facade, you need to use a special furniture facades from an array.

This technological process is necessary in order to regulate the moisture content of the material, leading it to optimal rate. If the moisture content of the tree is approximately 10 percent, this will remove internal stress. The use of a special chamber is essential, since the presence of cracks and other defects will depend on the quality of drying.

After the material is prepared properly, the production of furniture panels begins.
The finished material must be cut (trimmed) taking into account the desired characteristics of length and width. If there are areas with marriage, they should be removed immediately. To carry out this process, use machines for the production of solid wood facades.
After that, the workpieces need to be spliced along the length and calibrated.
The next step is gluing the shields.

When it is planned to manufacture a frame-paneled facade, you need to cut the canvas to make blanks for the main part of the facade. After this action, the entire perimeter of the canvas should be processed. Often used for this purpose production technology of curved facades from solid wood. This action is commonly called profiling, it allows you to achieve a perfectly even geometric shape of the product.

Frame

The next step will be the binding of the facade. The beginning of this process is the calibration, for the implementation of which, you need. In simpler terms, the main task of this manipulation will be to achieve the same size of different strips and to profil the edges of the workpieces. They will need to be cut transversely and brought to the specified parameters.

For processing curved surfaces, a milling tool is required. machine for making furniture facades. Thanks to the development modern technologies, at the moment it is possible to create cutters of any shape and size, that is, any pattern that gives an aesthetic look to the frame. To facilitate the subsequent assembly of the product, using machines for furniture facades you need to cut the counter profile.

Assembly

After all the elements are prepared for further work, you need to assemble the product. TSolid wood facade manufacturing technology quite simple, along the perimeter of the frame there are special grooves into which you need to insert a panel or other material. Customers often choose lattices or glass; a stained-glass window will also look beautiful. It is now popular to use facades created like blinds, as this allows you to create an optimal exchange of air flows in the cabinet.

This material appeared as a result of the development of the dry method for the production of fiberboard and the improvement of the technologies used for this. Medium-density fiber boards have a developed surface of wood fibers and a shortened pressing cycle. Due to the participation of binders in the interfiber interaction, MDF is highly durable. MDF facades, which are made by cutting wood fiber boards, milling and applying film or paint, are widely used for the production of furniture, flooring, wall paneling in rooms.

Although chipboard materials are significantly cheaper than MDF, nevertheless, the latter are in higher demand due to certain advantages. First of all, medium-density fiber boards are moisture resistant, retain their shape well under temperature fluctuations and are resistant to mechanical stress. They are environmentally friendly material. Thanks to these qualities, MDF is ideal for the manufacture of furniture (primarily for kitchens). It is widely believed that MDF boards even surpass natural wood in terms of moisture resistance and their mechanical characteristics. In addition, unlike the latter material, they are resistant to various fungi and microorganisms, which means they are safe and hygienic. The cost of this material is also of great importance. Products made of MDF are 60-70% cheaper than similar products made of solid wood and almost two times cheaper than solid lumber. MDF boards can be processed in almost any way and faced with MDF laminate, natural or synthetic veneer, resin film, PVC film. For all these reasons, they have become the most common and sought-after facade material.

Types of MDF boards differ for various reasons: for use (furniture, floor coverings, interior doors, dropped ceilings, Wall panels etc.), by type of coating (painting, PVC film, paper-resin film, veneer, etc.), by the presence of inserts (lattices, glass, etc.), by shape (flat, curved, etc.).

So, to organize your own production of MDF facades, you will need a room with an area of about 100 square meters. meters. It must be clean (with a ventilation system) and heated (the temperature in it must not fall below 15 degrees Celsius). The raw materials for the manufacture of facades are MDF boards, facing material(PVC film is the most common) and adhesive composition.

The production process of MDF facades consists of several key stages. First, the slab for the facade is cut using a panel saw. The workpieces must be highly accurate, free of defects (chips, cracks, etc.). At the next stage, a given pattern and a three-dimensional profile are applied to the plane and ends of the blanks for the furniture facade, which is created on a milling table using a milling machine. Modern equipment allows us to produce profiles of almost any complexity. Then the parts are polished using a vibratory grinder. Production waste is removed with a vacuum cleaner, and a compressor is used to blow the facades after grinding and before application. Before cladding, the facade surface must be carefully prepared and cleaned.

There are several most common cladding technologies in the production of furniture facades. Lamination is a process MDF facings paper-resin films under the influence of temperature and pressure. The porous surface of the paper contains melamine resin, which polymerizes and penetrates the MDF structure at the capillary level, resulting in a uniform surface layer that is durable, waterproof and resistant to high temperatures. Laminating is the process of facing MDF with fully cured paper-resin films with preliminary application to the base board. adhesive composition. In this case, the film is glued to the MDF, which simplifies the cladding process (compared, for example, with lamination). In the manufacture of facades, which should have the highest protective and wear-resistant properties, post-forming technology is used, which is the process of facing chipboard with layered laminates or high-pressure plastics.

Also, MDF facades are covered with plastic, film or enamel, veneered with natural veneer.

Most often, PVC film is used for facade cladding, as it is simpler and can significantly reduce the cost of the finished product. In this case, glue is also applied to the surface of the plate - in two layers when exposed to high temperatures (up to 80 degrees Celsius), and the material is allowed to dry for 30 minutes. Then a PVC film is applied to it, which is preheated. After cladding, the facade is sent under the press, and then the excess is removed from it.

To organize the production of MDF facades, special equipment is required. It includes: a panel saw (depending on the model, its price can be 200-250 thousand rubles), a copy-milling table (30 thousand rubles), milling machine(350 thousand rubles), vibration grinder (1.5-2 thousand rubles), industrial vacuum cleaner (10 thousand rubles), piston compressor (5-7 thousand rubles), airbrush (5 thousand rubles), vacuum press (150-170 thousand rubles). The performance of this equipment, which can be operated by one specialist, will be about 20-25 square meters. meters per shift and about 100 sq. meters of facades per week. Monthly output can be 400-450 sq. meters. With an increase in the number of production workers to three people, productivity also increases significantly. Since the production process of MDF facades involves human participation, the quality finished products directly depends both on the quality of the materials used for its production, and on the qualifications of the worker.

The number of facade productions in our country is increasing every year. But most of them cannot boast of high-quality products, as they use the cheapest MDF boards and low-grade films for the manufacture of facades. At the same time, trends in this market indicate that buyers prefer quality products and are willing to pay more for them. Therefore, experts advise to bet on the optimal ratio of price and quality and not to strive to reduce the cost of production at any cost through the use of low-quality raw materials.

The total cost of opening the production of MDF facades is about 1.5 million rubles. This amount includes the purchase of basic and additional equipment, its delivery and installation (about 1 million rubles in total), rent and preparation of premises for production, purchase of a batch of raw materials for a month of work (200 thousand rubles), business registration, and other current expenses .

The market for such products is very wide. This includes various construction and renovation companies, furniture stores and even individuals who often order MDF facades directly from the manufacturer. The wholesale cost of one square MDF facade is about 1000 rubles. The profitability of such production reaches 28%. The payback of the project is estimated at 6-8 months.

In the USA, where marketing is considered a sacred science, almost a religion, they are convinced that housewives are the driving force behind any business. “In American families, a man formally manages the household budget, but in reality it is a woman,” ironically marketing specialist Williams Scott from Philadelphia. - The concepts of many companies take this fact into account, focusing either on neutral models or models with a feminine touch. See how American kitchen furniture companies are thriving.”

Indeed, in the West, new houses and apartments have already been exhibited since kitchen sets However, in the secondary market, pre-sale preparation of real estate includes the renewal of furniture facades, primarily in kitchens. “Family women first go to the kitchen, then to the children's rooms, then to the bathrooms, and only then to the bedroom,” explains sales manager Eric Bormann in Germany. “Single women or just married women in conversations are interested in the bedroom, but they still go to the kitchen first.”

May with big share the likelihood of asserting that similar predilections dominate in Russia. "Demand kitchen facades housewives will provide, - the expert of the startup community, Ph.D., is convinced. n. Associate Professor Igor Malyugin. - At the same time, this entrepreneurship is far from being as simple as it seems. It has pitfalls that many startups have crashed on.” We decided to talk about what an entrepreneur who took over needs to know.

There are many materials for kitchen facades. Of particular interest are the facades made of solid wood. This is a classic kitchen sets, at the same time, the high cost of this production, primarily due to high cost high-quality source material, sharply narrows consumer qualities. “The price of kitchen sets with solid wood facades can start from one hundred thousand rubles,” states Igor Malyugin. - A piece production of facades under the order can raise the price even higher. In addition, standard facades, even the simplest country-style ones, require special painting.” Of course, such production can only be successful if demand is stable.

Dull facades made of chipboard, which until recently were the main material for kitchen sets in our country, are a thing of the past. MDF is being replaced with PVC films as a coating, as well as wood and glass. The lot of laminated chipboard is economy class kitchens with low added value. “For small businesses, this material will not provide the necessary level of profitability,” says Anton Yaroshenko, an entrepreneur from the Volga region. - Given the low production volumes and the level of manual labor, as a rule, characteristic of small firms, production should be built on the basis of modern technologies - this is MDF with PVC film. According to the expert, the high aesthetic and operational properties of such facades guarantee a decent level of profitability. However, when starting the production of such facades, one should decide on the technology for applying PVC films on MDF boards.

The king of facades - postforming

The choice of one or another facade production technology predetermines the starting costs. For example, softforming, until recently the most popular technology among furniture makers, is leaving the stage and giving way to postforming. “The reason lies in the relative simplicity of the production of high-quality facades by this method,” businessman Sergey Samokhvalov is convinced. “All it takes is a press, a cutting machine and a facing machine.”

At the same time, the entrance ticket to this business is expensive. For information: membrane press ORMA(Italy) costs 67,600 euros and focuses on high-quality Japanese film. The Chinese clone of this press costs already 15 thousand euros. Meanwhile, high-quality and at the same time inexpensive presses are produced in Russia for covering furniture facades of MDF and other similar products with PVC films and natural veneer, for example, a mini-press with pneumatic lifting of the desktop for radius facades Maxim DIP, which can be bought for 230 thousand rubles.

By the way, there are craftsmen who claim that it is possible to organize the production of furniture facades for almost a penny. “For several years I worked in one of the divisions of a furniture manufacturing company,” Anatoly Komarov shares his experience at the New Ideas in Furniture Manufacturing business forum. - Specifically, he was engaged in the manufacture of facades for cabinet furniture, in particular, kitchen furniture. The firm has collapsed. But the work remains." According to the entrepreneur, they later made a home-made installation for, in which “an aluminum tire is heated, post-formed plastic is bent on it. They made countertops, kitchen facades, bar counters. Non-standard products. Enclosures for speakers. Branded installations cost more than $ 10,000. We spent about 30 thousand rubles on installation and worked for almost two years.

Thus, for the production of facades from MDF with PVC film, a cutting machine and a press are required. Actually, you can cut the plates manually, using a power tool. The lion's share of spending at the start will go to the press. At the same time, powder coating of MDF facades can be used, however, for this method it is necessary to have special equipment.

“We cut facade blanks on a panel saw,” Anatoly Komarov shares his experience. - Semicircular chamfers were removed with a milling cutter. The skin was polished. On some facades, some patterns were made with a finger cutter according to the template. At first they tried to paint with enamels, like how cars paint. Terrible headache. There is such a bad concept -
swelling of fibers on MDF. When covered with primer, polished to a shine. You start to paint - as small needles rise. And with powder coating it turned out ... at the plant, where there was a line for powder coating of metal parts. Painted on all sides in one coat. The trick was in the fastening - how to fasten the door so that there are no traces left.

“On the whole, it's a worthy cause,” Anton Yaroshenko is convinced. - Now, of course, if you have experience, you can set up this production inexpensively, say, for five hundred thousand in very small areas. It will easily take several months to debug the technology so that there is no further marriage. If you manage to establish a stable sales, for example, through building materials stores, then you can make good money.”

Before deciding to create your own production of facades, you need to get a clear idea not only about one-time investments in equipment, but also to understand what costs will be required for the production of the product itself.

This article provides only an approximate calculation of the cost of production of MDF film facades on thermal vacuum and milling equipment "Maxim". The authors do not claim the completeness and accuracy of the economic study. This is rather a reference summary that will help beginners quickly understand the specifics of manufacturing furniture facades.
In your region, prices, wage levels may differ from those used in this calculation. In addition, it should be noted that the article was written in the already distant 2011. Therefore, you can calculate the order of profitability and payback time yourself, based on your own current figures.
Don't forget also about taxes, rent industrial premises and interest on loans and leases. In addition, of course, there are consumables, such as circular saws, end mills, grinding sponges, etc. It should also be noted that these figures relate to the manufacture of flat facades, the production of radius facades using curved-glued technology has its own characteristics and their cost somewhat higher. Also, the presses themselves for the manufacture of curved facades with a lifting table are structurally more complex and more expensive than conventional ones. However, the retail cost of curved facades is many times higher than the prices of ordinary ones, therefore, the financial attractiveness of their production is higher.

So, the main items of variable costs of the cost of MDF film facades are as follows:

MDF sheet 16 mm laminated one-sided 2800x2070mm 2100 rub. (5.8 sq. m -10% waste = 5.2 sq. m)
- 400 rubles. / sq. m Significantly reducing the cost of facades allows the use of ordinary non-laminated MDF, the reverse side of which is laminated (lined with texture papers) using a membrane-vacuum press "Maxim DIP-2514" in the color of the PVC film on the front side of the facade. Both the most inexpensive finishing materials and more expensive materials impregnated with formaldehyde resins that do not require final finishing. In addition, film facades, the reverse side of which is covered with textured lamination to match the facade, are sold more expensive than ordinary ones with white reverse side:
MDF sheet 16 mm 2440*1830 mm 795 rub. (4.46 sq. m -10% waste = 4 sq. m) - 200 rubles/sq. m MDF sheet 10 mm 2440*1830 mm 550 rub. (4.46 sq. m -10% waste = 4 sq. m) - 138 rubles/sq. m
PVC decorative matte film - 60-65 rubles/sq. m(in December 2014 it was already 140-225 rubles/sq.m.)
Decorative PVC film gloss - 100-120 rubles / sq. m (in December 2014 it was already 260-390 rubles/sq.m.) depending on the manufacturer and film effects (3D effect, metallic, etc.) the price may be slightly higher, but the price of facades also increases in proportion)
One bookmark in a press with desktop dimensions of 2500 * 1400 mm is 3.5 square meters. m PVC film. The real output in the product from one tab is usually 1.7-2.2 sq. m. That is, for 1 square. m of the finished product is spent from 1.6 to 2.0 square meters. m of decorative film
Thus, the consumption of PVC film:
Matte: 104-140 rubles / sq. m
Glossy: 160-240 rubles / sq. m
Glue 20-35 rubles / sq. m
Wages 70-100 (120) rubles/sq. m(formatting and milling MDF, applying glue, sanding, film lining)
Energy consumed by Maxim presses for a full cycle of heating and vacuuming in the structure of the cost of MDF furniture facades is actually not as significant as other factors - 0.1-0.6 kW / h * 3.00 rubles. \u003d 0.30-1.80 rubles / sq. m

Total cost square meter finished product
cannot exceed ( in 2011 prices):

Matt facades: 594-695 rubles.
Glossy facades: 650-795 rub. The cost of manufacturing a square meter of MDF door linings is correspondingly lower, the real yield of finished products is higher, as well as the production speed.

The actual performance of the Maxim DIP-2514 thermo-vacuum press when laminating kitchen doors with a decorative film can be 60-100 square meters. m of finished MDF facades per shift.

When laminating door linings with extensions and cashing, the yield of products will be even greater. One door lining with preparation, laying out is covered with a film in just a matter of seconds. That is why in the manufacture of film MDF overlays on steel doors The greatest efficiency is shown by two-table membrane-vacuum presses.

Average wholesale prices for facades in the European part of Russia:

Matt facades: 1300 rubles.
Glossy facades: 1750 rubles.

Thus, with a full load of hot vacuum press per shift you can get a profit (excluding overhead costs) not less than:

For one shift:

Matt facades: from (1300 - 695) 60 sq. m = 36.300 rubles.
before (1300 - 594) 100 sq. m = 70.600 rubles.
Glossy facades: from (1750 - 795) 60 sq. m = 57.300 rubles.
before (1750 - 650) 100 sq. m = 111.000 rubles.

Per month (22 working days):

Matt facades: 798.600 - 1.553.200 rubles.
Glossy facades: 1.260.600 - 2.442.000 rubles.

Prices for decorative films, MDF, adhesives have, of course, increased significantly over the past years, however, retail and wholesale prices for finished furniture facades lined with PVC film have also increased. That's why facade production remains an equally profitable and attractive activity.

To organize the production of MDF film facades, it is necessary to separate the area for applying glue, drying, grinding and pressing the facades from the area where the facades are formatted and milled, in such a way as to completely exclude dust from entering the air. The quality of the lined surface of the facade depends on this. To speed up production, it is extremely important to organize a quick and convenient supply of workpieces from one zone to the next.

1. Workpiece formatting area (panel saw) - 7x4m (28 sq.m)
2. Milling zone (copy-milling machine - 3x3m) + (cleaning tables - 5x5m) = (25 sq. M)
3. Glue application area - 3x3m, preferably 4x4m (16 sqm)
4. Drying zone for blanks - 2x2m, preferably 4x4m (16 sqm)
5. Pressing zone - 7x3m, it is desirable to have two cutting tables in this zone (finishing, removing shagreen, blowing with compressed air) 7x4m (28 sq. m)

Manufacturing technology of MDF facades is increasingly considered by furniture manufacturers as a promising, strategically significant, innovative direction for the development of an enterprise in the most difficult competitive environment. MDF furniture according to their own quality characteristics in many ways superior to the same products made of chipboard, metal, plastic or natural wood. And it's hard to argue with that.

The main materials used for the manufacture of MDF facades are MDF board itself, PVC film for vacuum pressing, glue and sometimes, for lining the back of the furniture facade, laminating paper is used.

MDF board for facades

MDF stands for Medium Density Fibreboard, and is made by hot pressing fine wood fibers treated with binders.

MDF board, used in the manufacture of furniture, has one of the most important qualities - ease of processing. This allows, without excessive effort, to give workpieces a variety of shapes and freely work with surface relief using a conventional set of sawing, milling and grinding tool available in almost every furniture manufacturer. Actually, MDF production facades is possible even in garage conditions, "on the knee".

PVC film for MDF facades

PVC film for cladding furniture facades MDF is made from a synthetic substance, hard polyvinyl chloride. When heated to a certain temperature, it becomes plastic, under the influence of vacuum tightly fits the MDF facade blank, repeating its relief, and when cooled, it retains its shape.

Thanks to the huge variety color solutions, shades, patterns, embossing and textures, PVC film for MDF facades is able to imitate virtually any natural or artificial material, whether it be wood or stone, metal or fabric, leather or fantasy abstraction and other, other, other design ideas.

Besides , PVC film, used for cladding MDF facades, has many other positive qualities:

It has a high degree of resistance to mechanical and chemical damage.
Does not fade under the influence of ultraviolet radiation.
It does not age, as it is based on the polymer polyvinyl chloride (PVC).
Easily cleaned with household products from stains and dirt.
As a rule, it has a low cost, especially PVC film from a Korean manufacturer.

Characteristics of MDF facades in PVC film

First of all, it should be noted the widest choice for the implementation of design ideas. The ability to give the MDF facade any shape, create an intricate relief on its surface, and imitate a huge variety of materials, allows you to meet the most incredible requirements of a fastidious customer.
Along with high quality and excellent appearance MDF facades have a relatively low prime cost production. On the one hand, this is due to the low cost of the main materials: MDF furniture board and PVC film. On the other hand, there is the possibility of partial or complete automation of production.
The manufacturing technology of MDF facades is so simple that even a start-up enterprise with limited opportunities for additional capital investments can master it. To start the production of MDF facades in PVC film, you only need to purchase membrane vacuum press. The rest of the necessary equipment, as a rule, is available from each furniture manufacturer.
Due to its fibrous structure, MDF holds furniture fittings better, does not dry out over time and does not lose its qualities.
The resistance of MDF to moisture makes it possible to produce MDF kitchen fronts, as well as bathroom furniture.
Environmental Safety. The production technology of MDF facades does not provide for the use of materials hazardous to health. And the level of formaldehyde emission from MDF boards is comparable in safety to natural wood.

Of course, MDF facades in PVC film also have a number of disadvantages. First of all, it is worth noting the weak resistance to high temperatures. For example, on kitchen cabinets, the heat from the stove heats the facades, the adhesive layer softens, and the film begins to peel off and curl.

Production of furniture facades: a plan for starting a business

Most often this is caused by low-quality glue or incorrectly selected pressing mode in the manufacture of facades.

Another disadvantage of facades in the film, upon closer examination, is the presence of irregularities and shagreen on the surface. The fact is that when applying glue to MDF, barely noticeable villi can rise. In the process of vacuum cladding, the PVC film copies the relief of the facade, including them.

Painting MDF facades

The disadvantages of MDF facades in PVC film are absolutely not characteristic of painted facades. On the one hand, the paint layer is able to withstand much more high temperatures than film. On the other hand, after painting, the facades undergo a grinding and polishing procedure, so they have an almost mirror-like surface. It is these basic qualities that painted MDF facades have won the trust of the consumer.

To diversify the range of furniture production with painted MDF facades, significant additional capital investments will not be required, since the equipment used to prepare MDF blanks for cladding in film and for painting is identical. One aspect worth highlighting here. technological process- laboriousness. But there are other pluses and gifts in this case. Painting, grinding and polishing MDF facades require a significant amount of skilled labor, which increases their cost by an order of magnitude.

However, the main advantage of film facades over “paint” is the ability to imitate a variety of natural and artificial materials. Thus, the use of MDF facades in PVC film in the manufacture of furniture for the kitchen, bedroom, hallway or office will always be profitable, beautiful and in demand. So, manufacturing technology MDF facades in the future, it should be mastered by every furniture manufacturer developing its enterprise.

The relevance of the production of MDF facades is justified by the regular demand for these products. Despite the high price compared to chipboard materials, medium-density furniture fronts emit less toxic substances and have greater strength, which makes them so popular in the market for quality building products. In Russia, the need for MDF is more than 200,000 cubic meters per year.

MDF facades are construction material medium-density for furniture and paneling, which is made by cutting fibreboard, milling and applying a film or painting.

From English MDF - Medium Density Fiberboard - medium density fiberboard.

Range

by application (furniture, interior doors);
by type of coating (PVC film, painting, etc.);
by type of milling (embossed, 3D);
by inserts (stained-glass window, lattice, glass);
in shape (curved, curved, flat).

In addition to facades, MDF is made of:

floor coverings;
Wall panels;
dropped ceilings;
molded products;
decorative items, etc.

Sales market

Organization of production

The production of MDF facades requires the work of 1-3 specialists.

Production of MDF furniture facades as a business

Square necessary premises is 100 sq.m. The pressing room should be free of dust and the temperature should be maintained at a level of at least 15 degrees. The raw materials for production are MDF boards, PVC film and glue.

Necessary equipment

Feasibility study

Capital expenditures

Equipment - 0.8 million rubles.
Additional equipment - 0.1 million rubles.
Delivery and installation - 0.2 million rubles.
Preparation of the premises - 0.2 million rubles.
Inventory for 2 months - 0.3 million rubles.
Business registration and other expenses - 0.1 million rubles.

Total start-up costs: 1 700 000 rubles.

Calculation of revenue when working 2 people

* Business profitability is indicated according to the expert opinion of the author of the article.

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