Technology for the production of interior doors MDF in a cold way. Production of mdf doors - factory of painted doors demfa. Materials for creating wooden doors

The production of doors from wood and materials made from it is one of the most promising options for both large and small businesses. In order to open such a workshop, you will have to not only purchase a list of the necessary equipment, but also familiarize yourself with all the production nuances.

Based on the video in this article, we will discuss how the manufacture of an MDF door is carried out; consider the mechanisms by which certain technological operations are performed; and tell you what capabilities this or that machine or tool has in general.

If the company is engaged in the production of interior doors, then you should not focus it only on working with wood, or only with MDF. Moreover, most of the doors are combined: the frame is constructed from pine bars, and only then it is sheathed with sheet material. In general, for the successful sale of products, you need an extensive range covering different price ranges.

Therefore, the manufacturer must offer the buyer cheap doors without decorative coating, and elite, made of natural wood, and the golden mean in the form of laminated and veneered products (see). Facilitating the task is the fact that the equipment for MDF production doors, with the same success is used for the manufacture of solid wood doors. Therefore, the list of machines and fixtures that we will present in the course of our article will be general.

Material preparation

Edged boards and timber used in door production must undergo a drying procedure. There are several ways to reduce wood moisture, and the easiest of them is natural.

But it takes a lot of time, so drying chambers are used in factories for this purpose. This is a stationary box with a ventilation system, in which the temperature is maintained from +40 to +100 degrees.

So:

• First, when the fan is running, the lumber is heated with steam, and then the temperature is gradually brought to the desired mode. Because design features drying chambers may differ, the principle of working with them is determined by the manufacturer's instructions.
• Warm-up time depends on the type of wood, and the essence of drying is not only to normalize moisture, but also to relieve stress from its internal fibers. Upon reaching the required percentage of humidity, the tree is not immediately removed from the chamber, but kept in it for up to three hours. If poorly dried material is used in production, the products will be deformed.

• The cost of the drying chamber depends on its capacity, and at least it is 2 million rubles. Not everyone has such tools, so some craftsmen make them with their own hands. A room is allocated for this, the surfaces of which are qualitatively insulated, steam is isolated with foil, a fan and heating elements are installed. Often, infrared film for underfloor heating is used for this purpose, as it is very economical in terms of electricity consumption.

If there is a desire, information on this topic can be easily found on the Internet. The main issue that will need to be resolved in this case is the method of loading wood into the chamber. Usually this is, as in the photo, a trolley on rails, but a forklift can also be used. And, of course, you should take care of fire safety.

Material calibration and cutting equipment

It is clear that the wood used for the manufacture of doors must be calibrated - that is, it must have clear geometric dimensions. Therefore, after drying, the lumber is processed on a four-sided planer, which is able to process the workpiece from all sides at once. When the bar passes through it, four cutters not only level the surfaces, but also reveal defective places.

Multi saw machines

A business that has a multi-blade machine at its disposal can significantly increase productivity. Such equipment allows, in order to reduce costs, to purchase not a ready-made edged board, but round wood, and saw it yourself into a board and a bar.

The capabilities of this machine make it possible to mass-produce molded blanks, including from sheet and plate material: plywood, chipboard, fiberboard, MDF, furniture board.

Note! Machines with a multi-blade system are suitable for both longitudinal and transverse processing. Depending on the type of unit, up to two dozen saws can be provided in it. Their layout is standard, and is very similar to a sawmill, but unlike a multi-saw machine, several blanks cannot be made at the sawmill at the same time.

• In addition, workpieces passed through a multi-saw unit are distinguished by greater geometric accuracy. All its working elements are located on the frame, and in some models there is also a material supply line, which is a roller conveyor.
• The material feed unit is driven by an electric motor, and consists of shafts with spikes that ensure uniform movement of the workpieces. The sawing unit can consist of several or one shaft, on which circular saws are mounted. By the way, they can be located not only in a vertical plane, but also horizontally.

If necessary, the multi-blade machine is equipped with a milling mechanism necessary for processing the ends, as well as an installation for trimming the edges. The complete set of the machine may vary depending on the parameters of the products that you want to receive.

Trimming machines

When working with any long material, it is impossible to do without miter saws. In a small workshop, carpenters can use and manual options, but for large volumes of work you need a machine.

Facing is a cross-cutting of wood materials, with the help of which the workpiece is given the shape of a rectangle and a workpiece of a certain length is obtained.

So:

• When the company has a dryer, then one trimming machine can be installed on the site where the raw material is sorted, and the second is used for cutting the already calibrated timber or board. Such equipment has quite a lot of potential.

• In addition to trimming the ends, this is the division of the workpiece into 2 parts; determination of a section with a defect, which is automatically removed during sawing; cutting blanks of a certain length. All these operations can be performed by the machine either simultaneously or sequentially. Here much depends on the configuration of the machine, its settings, as well as the task.
• As in gang saws, circular saws with teeth made of hard alloys are used here. However, they have a different sharpening angle, since the wood has to be cut across the grain. A saw with the right teeth cuts through the material like clockwork, and does not tear or crumple it.

• Since the cross-cutting cycle is periodic, the moving parts of the machine do not have time to heat up much, so the mechanism works properly. long time. The only thing, for the convenience of work, the trimming machine must have convenient fixture for supplying blanks. Usually this is either a conveyor or a roller table - a roller table, the price of which, depending on the length, varies between 16,000-25,000 rubles.

So that when sawing there is no discrepancy between the required and actual dimensions of the products, all measuring instruments on the machine, as well as the stop ruler on the roller table, must be periodically checked and adjusted. To obtain the most accurate parameters, modern cross-cutting machines are equipped with optical instruments, which also need to be verified from time to time.

Panel saw

When working with sheet wood material, which is MDF, you can not do without a machine for format cutting. It cuts in a straight line or at an angle: both long-length and slab material is processed, and you can also cut a whole stack of slabs at once according to a single template.

• To do this through any other machines or tools, if possible, it will take a lot of time and effort, which is simply unacceptable for the mass production of joinery. In general, production efficiency largely depends on the overall functionality of sizing machines.
• All of them are professional, and are divided into three categories. The first group contains the most simple models economy class, with small dimensions, and without additional equipment with stops, rulers and clamps. Such machines can work no more than five hours in a row, and are designed for a relatively small volume - perfect option for a small private workshop.

• The second category includes machines of medium power, which can work a full shift (at least 8 hours), and are provided with all the necessary devices and assemblies. In particular, they can be equipped with a dust extraction device. Well, the third option is industrial machines that have the most durable design, complete set, electronic control circuit, and are able to work for two work shifts.
• The basis of any machine is the frame on which all working mechanisms are mounted. The stiffer and heavier it is, the less vibration and the higher the cutting accuracy. Two saw blade. A scoring disc is located in front - it has a smaller diameter, and its function is to cut the upper (facing) layer on the workpiece.

• The main disk finally cuts the material, the size of which determines the depth of cut. This arrangement of the discs allows you to make a high-quality cut, with smooth edges and without chips. The sizing machine has three working tables: one is movable, along which a full-sized MDF sheet is fed for cutting; the second support, which should support the cut off parts. The third, fixed table, on which, in fact, the saw unit is fixed, is the main one.

To cut a workpiece on such a machine, the sheet is placed on a movable table, which moves along the guides with a carriage. Using the stop, measure the desired length, and start the saw mechanism. As soon as it gains momentum, by shifting the table, the sheet is fed to the saw unit, and a fragment is cut off. From the settings in the format machine: only the depth and angle of cut.

Equipment for milling and cutting spikes

Without a milling machine, it is impossible to imagine any carpentry workshop, because cutting profiles, grooves, three-dimensional reliefs, large radius curved cuts, and even wood engraving are performed mechanized.

The only difference is that the milling machines used in one case or another differ somewhat in design. There are six types of removable tools, the use of which is due to the need to obtain one or another type of processing.

• Thus, a wood milling machine can be considered a universal mechanism. The height of the cutter, located on a movable vertical shaft, can be adjusted. But the position of the part being processed is limited by stops and guides.

• In a small workshop, you can do manual router, a variant of which is presented above, but for the mass production of joinery, machines with program numerical control are used. Manufacturers offer a huge range of such equipment, which has a variety of characteristics, and is controlled by operating systems.
• With a milling cutter on a vertical shaft, you can countersink, that is, get conical holes; bore them; dado. With the help of such machines, the edges of blanks are processed, frames are made. But mirror-symmetrical, or absolutely identical curly blanks: drawers, panels (see), cannot be made without a copy-type milling machine.
• most often collected by spike method. Spikes on the ends of the blanks, as well as recesses for them (lugs), can only be obtained using a tenoning machine. In it, the working mechanisms are also cutters and saws. Just like the others milling machines, tenoning units can be equipped with CNC, and controlled by a microprocessor.

• In any case, an oval or round spike can only be made on such equipment. In addition to cutting spikes, on CNC machines, it is possible to overtake the perimeter of the door leaf, process calibrated sheet material, splice bars along the length, which is sometimes necessary for the manufacture of panel doors.

Note! In addition to the main woodworking machines mentioned above, additional equipment will also be needed in the door production, with the help of which the finished canvases and molded products are finished.

• This is a hydraulic press, with the help of which the veneer is pasted over the MDF door paneling, and edge banding machine, through which narrow strips of veneer are glued to the ends of the canvases. This includes a spray booth, and a press for gluing bars, and a surface grinder, and a packaging machine - otherwise how to transport products?

As you can see, the list of equipment is quite large, and it is clear that in order to equip a carpentry shop, you need to spend a lot of money. But do not forget this: the availability of machine tools and necessary tools does not guarantee a quality result. Ultimately, it all depends on the professional competence of the people working on this equipment.

Interior veneered door of our production- this is a door leaf of a frame design, made using natural wood, medium density fibreboard (MDF) and restructured veneer (fine-line), adhesive and paint materials, glass, fasteners and other materials and products that meet the requirements of standards and specifications.

For door production lumber of coniferous wood "pine" with a moisture content of 7 ± 1% is used. To achieve the desired wood moisture content, the company has built and operates a drying complex, consisting of an autonomous boiler room, four drying chambers with front loading with a capacity of 50 m 3 each. The drying complex is equipped automated system drying process control. The drying chambers are equipped with reversible fans, humidification systems, wood and air humidity control sensors, and an air conditioning system. Dried lumber is unloaded into the cooling room, where it cools for 48 hours to relieve internal stresses.

The resulting material is used to form the frame of the door leaf.

Door block design

The sheets are made up of:

• frame (bars of coniferous wood);
• honeycomb filling (strips of special cardboard glued together in the form of honeycombs and placed on edge);
• inserts for the tie-in of the lock (bars of coniferous wood);
• frame cladding (MDF veneered with natural veneer);
• internal frame - "double-glazed window" from MDF (for canvases under glazing)

Unglazed (deaf) canvases are made with only one outer frame. Glazed doors have an internal frame corresponding to the size of the inserted glass and slatted filling.

MDF (MDF-medium-density fiberboard) is a sheet material produced from wood species under environmentally friendly conditions by dry hot pressing, with an increased density of 850 kg/m. cube

In MDF, the developed surface of wood fibers and the reduced pressing cycle are effectively combined with strength due to the participation of binders in the interfiber interaction. The production technology of MDF doors eliminates the use of unhealthy epoxy resins and phenol.

This type of semi-finished product is highly environmentally friendly, and also has excellent characteristics of compactness, fiber adhesion, and dimensional stability over a long period of time.

The use of this material in door production allows to acquire the properties of excellent planarity of the web surfaces, surface hardness and impact resistance.

honeycomb core - This is a high-tech material used to form the frame of the structure. Honeycombs got their name due to their geometric similarity to honeycombs. The main task of the material is to fill the space between the two skins. By placing a honeycomb core between the skins, the rigidity of the structure actually increases by a factor of 100 or more - this is the effect of the separation of the carrier layers. Thus, honeycombs placed between the skins do not particularly burden the structure, because they are light, but they guarantee strength. Honeycomb filler is currently the most promising material for the manufacture of ultralight and durable structures for various purposes.

Filling the door leaf using cardboard honeycombs:

1. timber frame (solid);
2. facing panel;
3. honeycomb filling.

Door construction with honeycomb filling significantly lightens the weight of the web, which reduces the load on the loops, has good heat and sound insulating properties, and also avoids warping of the web during operation.

natural veneer- These are thin slices of natural wood that have the color and texture of wood. The undeniable advantage of such material in door production is that it preserves the natural pattern of wood, which cannot be conveyed by any modern technological tricks. In addition, natural veneer is durable, it does not peel off and does not dry out, because it is glued to the MDF base.

The veneering of the surface with veneer and the assembly of the canvas frame are carried out by hot pressing. Next, the door leaf is formatted to size in length and width, followed by gluing the ends with veneer.

To create an individual profile for each model, milling is carried out according to the contour specified by the template. The processing process is personal for each type of canvas.

Each door leaf is processed by manual grinding of the surface with abrasive materials. To obtain the smoothest possible surface, our specialists have developed a step-by-step system for processing the door leaf with a grinding tool with varying degrees of graininess.

Finishing of a covering is made by experts of the highest category manually by paints and varnishes of the Swedish production "Becker Acroma". This two component alkyd varnish on an organic basis has a high covering power due to the high content of dry residue and forms a strong and, at the same time, elastic film on the surface of the product. In addition to the decorative function, the lacquer coating performs a protective role - it prevents the leaf from swelling at too high humidity in the room and protects the door structure from drying out at low humidity.

And besides, do not forget that the varnish also gives the surface of veneered doors a more beautiful appearance. Only after varnishing the final color of the wood appears.

On door production a system for identifying the performers of operations has been introduced, which allows minimizing the number of defective products and identifying a specific contractor that allows a violation of the technological process. Marking is made on the upper and lower edge of the door leaf. Each product undergoes strict quality control. Frosted Bronze glass is installed in the door leafs under the glazing, which gives the door its individuality and completeness. Glazing is made with the help of elastic gaskets in the amount of six pieces, which eliminates the oscillation of the glass and ensures its clear fixation. Thanks to this glazing technology, the glass can be easily removed and reinstalled.

All door leafs are packaged in corrugated cardboard around the perimeter and polyethylene packaging, which allows us to protect our products from external influences. All our products must be completed with a passport for the product, with detailed description warranty obligations and recommendations for storage and operation.

Box beam manufacturing technology

Applicable materials:

• lumber: pine, humidity 8±1%;
• MDF - 10 mm;
• c. natural veneer.

Manufacturing technology. The base of the boxed timber is made from dry lumber using the butt splicing method. When splicing lumber, wood defects are removed: knots according to the tolerance standard, cracks, blue stain, rot, etc. Glued blanks are profiled to a given size on four-sided planers. MDF is cut into a given size on a format-cutting center. The use of this machine provides the necessary geometry of the workpiece. The MDF strip is glued to the hot melt adhesive on the automatic molding line. The resulting "rough workpiece" is processed on four-sided planing machines, after which natural veneer is glued onto the workpiece on an automatic line for facing molded products. The veneered box beam enters the painting shop. Where is the final finishing of products: grinding, priming and top coat varnish.

Manufacturing technology of the platband and additional strip

The platband is made of profiled MDF blanks wrapped in fine-line veneer and having a paintwork identical to the door leaf. Packed in polyethylene. The additional element is made of MDF blanks and lined with the appropriate veneer. Packed in polyethylene.

Production of interior doors

Interior doors are a necessary part of residential, industrial and office premises. When choosing door panels and additional elements, you need to know how and according to what rules they are made, as well as to understand the advantages and disadvantages of the materials used in the production of doors. Modern manufacturers use high-tech equipment that allows you to produce a large number of high quality products with various types of coating and modern design.

Manufacturing technology of interior doors

Doors serve to separate the various functional parts of the room and provide sound insulation, protection from extraneous odors and excessive moisture. Methods for the manufacture of door panels and additional elements depend on the materials used in the production. The most popular doors are made of solid wood or prefabricated on a wooden frame. Glass inserts make the canvas partially transparent to light and visually expand the space of rooms or corridors.

The most complex and multi-link technological process occurs in the manufacture of doors using wooden elements. The fact is that timber that has not gone through the full cycle of pre-drying and processing is subject to warping and cracking. In order to avoid losses in the quality of the final product, great care must be taken preliminary preparation wood using certain technological methods. The manufacturing process of interior doors includes the following steps:

Timber (round timber) of pine species is sawn into blanks using band saws with automatic feeding logs.

Logs are sawn into blanks of the required thickness.

Drying of lumber is carried out under the influence of steam and high temperature.

Defective areas are cut out of a blank cut into a beam

With the help of a vertical press, a panel blank of the door leaf is obtained

Panel elements or glazing are mounted during final assembly

The technological sequence of manufacturing doors may be different and it depends on the material, equipment and design of the product. For example, expensive solid wood doors do not typically use veneer and are manufactured using complex CNC machines, while budget doors often use corrugated board inserts and cheap laminating film.

It is important to note that in the factory, fittings are usually not installed on a door with a symmetrical decor, since during installation at the consumer's, the product can open both to the left and to the right, respectively, the hinges and handles are installed by installers on site.

Video: making solid wood doors

Rules and norms for the production of interior doors

Door blocks are manufactured on equipment that is located on large production areas. These premises are subject to certain requirements, as to industrial facilities, which include timber warehouses, dryers, a processing shop, a paint shop and a warehouse for finished products. Each production site is equipped according to the rules and regulations, in accordance with the technical conditions for a specific task. The main requirements for production premises for the manufacture of doors are the following criteria:

• availability of free access roads;
• buildings must be provided with a stable temperature, humidity, natural and artificial lighting;
• power supply, heating, ventilation, water supply and sewerage should be equipped;
• rooms should be equipped fire alarm, fire extinguishing equipment and emergency exits;
• workplaces need to provide safe conditions labor;
• paintwork areas should be isolated from the rest of the premises and provided with forced ventilation.

Personnel are required to undergo professional training and training in labor protection, fire and electrical safety standards, as well as undergo unscheduled, repeated and initial briefings at the workplace.

The production room must be equipped in accordance with the standards

The main norm for the production process is technological documentation, which is based on the Technical conditions for the production of TU 5361-001-58037723-2015 "INTERIOR DOORS, PARTITIONS AND MOLDINGS TO THEM". This document sets out the requirements for the design of interior doors, the quality of the material and the coating of the front surface, as well as environmental requirements. The regulations specify the procedure for acceptance of finished products, certification and installation of a warranty period of operation.

For the buyer, it is important to have a certificate, a warranty period and the compliance of the door, frame and additional elements with the requirements of technical specifications, since this confirms the quality of the product and allows you to count on a long service life.

Current GOSTs for the production of interior doors

The technical characteristics of the doors are determined by the standards that set the general technical conditions or methods for determining the physical parameters and dimensions of the finished product. Many manufacturers create products according to non-standard sizes, but with strict observance of quality requirements. The consumer may be interested in the list of regulatory standards that manufacturers of interior doors work on, namely:

1. General requirements for wooden doors with a list of regulatory documents are established by GOST 6629–88, and requirements for wood products are set out in GOST 475–78.
2. Design options for interior doors, their types and sizes are specified in GOST 24698–81.
3. supplement requirements, fasteners and loops are assigned GOST 538–88.
4. Methods for determining sound insulation, heat transfer resistance and air permeability are regulated by GOST 26602.
5. The determination of the flatness of the door leaf is carried out according to the standard ST SEV 4181–83.
6. The reliability test methodology is set out in ST SEV 3285-81.
7. Impact load resistance is produced according to the method specified in ST SEV 4180–83.

IN accompanying documents for finished products, there must be a symbol for door leaves, for example, U05195 VERSAL pat. 1014 dec/or door leaf D3 91x 230 L, which means the following door parameters:

• article - U05195;
• the trade name of a particular collection is VERSAL;
• type of finish/color − pat. 1014 dec/oro;
• product name - canvas;
• product model - D3;
• width and height of the canvas - 91x230;
• type of opening, left − L.

Before ordering doors, it is necessary to carefully measure the doorways in order to select the required size of the frame, leaf and the required number of additional elements. For interior doors, there are standard dimensions of openings with the corresponding designation according to SNiP, and this approach makes it easier to choose a door frame according to the table.

Table: the ratio of the size of the opening to the size of the door leaf

Existing regulatory documents guarantee a high level of product quality, standardization in size and compliance with environmental requirements, in addition, the consumer can determine the compliance of the product properties declared by the manufacturer with the quality and price level.

Material for the manufacture of interior doors

In the production of interior doors and partitions are used modern materials, which are environmentally friendly, durable, light weight and long term operation. These include plastic and glass doors, for which the framework is aluminum profile, and the placeholder - plastic panels or tempered triplex glass with matte finish. But traditional doors with a wooden frame and inserts made of glass, MDF panels and paneled elements occupy a major niche in the market. In the manufacture of such products, the following materials are used:

1. Defect-free pine lumber with a moisture content of not more than 8%, spliced ​​into a tenon using glue pressing.
2. High density chipboard.
3. Natural veneer from various types of wood with a thickness of 0.6 mm.
4. Laminating film imitating fine wood.

Laminating film gives the doors the texture of natural wood

Corrugated cardboard is used for insulation and sound insulation of inexpensive door panels.

The production of inexpensive doors is based on the use of chipboard, laminating film, corrugated board and MDF, while more expensive products use solid wood with milled elements, panels and tempered glass inserts.

Six years of operating experience by the author of the article veneered panel doors shows their great reliability. But in rooms with high humidity, I would like to recommend different kinds laminated doors with an additional waterproof coating. After four years of service in the bathroom on the inner veneered canvas, despite the treatment with liquid wax twice a year, whitish stains and streaks appeared from exposure to steam and condensate. There was a need for cosmetic repairs, so I had to sand the plane of the door leaf, degrease it with a solvent, cover it with a tinting compound and waterproof varnish in two layers. To a lesser extent, the same problem appeared in the laundry room, and as for the other doors, minor damage to the veneer and scratches were eliminated by gluing and treating with hard, tinted wax in various shades. After such minor repairs canvases, boxes and extensions acquire their original appearance and serve for more than six years. Under the conditions of suburban operation during summer residence, wooden doors covered with waterproof varnish serve more than eight years. At the same time, there is no warping and drying out in conditions of temperature changes and changes in humidity. But it should be noted that the best option for summer cottage construction are metal-plastic doors and frames that do not change their properties and retain their geometry under changeable weather conditions.

Equipment for the production of interior doors

The most costly production of interior doors, in terms of the amount of equipment required, is the manufacture of wood products. Factory production of metal-plastic and glass requires a large number of components and a small number of machines for cutting frames and processing glass sheets. Lumber processing is more saturated with machine tools, presses and other equipment. Consider the equipment that is used for the production of wooden doors:

Sawmills and band saws used for cutting round timber.

The sawmill allows you to get lumber of the required thickness from round timber

Industrial drying chambers allow you to bring the lumber to the required moisture level and avoid warping of the workpieces

The machine is designed for cutting spikes on wooden blanks.

Using a pneumatic press, the door leaf is glued

Using milling machines, figured and paneled elements are produced

The list of the production park can be expanded due to the use of various technological and design solutions in the production process of interior doors and components, which has a positive effect on the consumer properties of the final product.

Video: production of interior doors

We examined some types of interior doors, production technology, as well as regulatory documents and requirements governing the production of this type. For the correct choice of doors, it is necessary to know the properties of the coating and the material from which they are made. Quality equipment and compliance with the production technology ensures resistance to external influences and a long service life of products. A wide range of design solutions allows you to give the living room an individual look and unique style.

Manufacturing technology of MDF doors

In modern construction, the MDF board has confidently taken one of the leading positions among the materials for the manufacture of furniture, interior partitions, platbands, door blocks and canvases. This material is a medium-density natural sawdust board. The manufacture of MDF consists in the steam treatment under pressure of pre-ground sawdust. After the end of this stage of production, the wood is rubbed to the state of fibers similar to the felt disks of a defibrer, the formation of a “carpet” from them, its pressing, drying and grinding.

As a result, the plate is quite dense and homogeneous. Its main advantages are

There is not a single building material that does not have flaws. As for MDF, it is worth noting the fact that the integrity of the MDF structure, if it is seriously damaged, cannot be restored and must be replaced. In addition, you can count on the long service life of MDF furniture or doors only if the material is made in full accordance with the technological requirements and properly dried.

Key differences in decorative door trim

Painted MDF doors

When using this type of decorative door finish, enamels and paints can be used that have good spreadability and elasticity of the resulting protective coating. Thus, it is possible to provide the product with a beautiful appearance, as well as a sufficiently high resistance to external influences (chemical and physical). Factory coloring can be done by automatic equipment or by hand.

Veneered materials

The process of veneering (or veneering) of the material consists in gluing on base surface MDF is a decorative layer of veneer made from precious woods of one or more species. As a result, the resulting design takes on the appearance of a product from an array, at the same time, it is deprived of all the disadvantages associated with the use of solid wood: they become

Laminated MDF doors

Lamination technology consists in applying under pressure to the front surface of the plate MDF films PVC. Depending on the selected finishing material it is possible to achieve completely different decorative effects: the product can become glossy or matte, imitating the texture of natural stone or a certain type of wood. In addition to the decorative qualities of the resulting surface, it is possible to provide increased wear resistance and antistatic properties. The laminated door does not burn out on the sun, is not susceptible to influence of chemicals.

Milling

Very widespread (especially in the manufacture of door panels and furniture facades) is the milling of the material - its relief finish, which provides great opportunities for new design solutions. To perform such tasks in factories, special machine tools with program control are used.

MDF doors and 3D technologies

Relatively new technology, which has already become in great demand, are embossed 3D MDF doors. Their canvases are voluminous veneered surfaces with preserved natural wood texture. Today, this is the most expensive version of the MDF door of all those listed, but the high cost in this case is entirely based on the complexity of the technology and the low prevalence of enterprises for their manufacture.

Such production takes place in several stages:

1. a project for the design of the canvas is being developed (using computer technology, a sketch of the drawing is created),
2. a 3D surface is made: the whole process is aimed at giving the source material a given relief using special equipment (in some cases, the finishing is done manually by craftsmen);
3. finishing cladding consists in applying a special coating that protects the MDF board from mechanical and chemical damage, direct exposure to ultraviolet radiation (in this case, the surface can be given any texture, including fluorescent or "metallic").

MDF doors: manufacturing technology

Interior doors are never completely made of MDF panels. When using the standard version of the lightweight web design, it includes:

Controversial environmental friendliness of the material

Very often, the real “stumbling block” in choosing MDF doors is the question of their environmental safety. There has always been a lot of controversy about this. But if we consider this issue objectively, there are simply no grounds for fear in this case. The material is made from woodworking waste, but at the same time it remains the same wood that is used for the manufacture of solid wood products, but subjected to grinding, high pressure, steam heating, pressing.

In the production process, such chemical substances as paraffin and formaldehyde resin, which has low toxicity. To bind all components, manufacturers use lignin, which is released independently during the heating of wood. For the manufacture of MDF, there is simply no need to use phenol or epoxy resins, the fumes of which are hazardous to health. Therefore, there are absolutely no reasons to be afraid of installing MDF doors.

How to open a workshop for the production of interior doors

The popularity of interior doors among the population is comparable only with plastic windows. And for the first and second demand is stable even during the economic crisis. But since interior doors perform not only a functional purpose (to open / close access to the room), but also an aesthetic one - they should look spectacular and be liked by customers.

Even if you make doors from environmentally friendly materials (for example, solid wood), but do not give the model a presentation appearance, the business is likely to be doomed to failure.

What does the consumer like? Criterias of choice

Product range– the most important solution for future production. And it should be determined taking into account consumer preferences.

The main types of interior doors:

From array

The door leaf is made from wood lamellas (an array of different species - from soft, such as pine, to hard oak and more valuable ones). The bars are spliced ​​with glue and exposure under pressure, the canvas is sanded, calibrated and varnished, or coated decorative trim(for example, veneer of expensive breeds).

For premium doors, a more sophisticated technology is possible: partial tinting, mosaic splicing, inlay are used, thanks to which the door leaf turns into a real work of art.

Wooden with veneer

Doors of the middle price segment. The base is usually inexpensive wood in the form of boards fastened into a frame covered with veneer on the outside.

For voids use various fillers such as corrugated board.

Laminated

When laminating, a film of various colors and textures is applied to the base frame made of chipboard or MDF. This production technology allows you to simulate various materials(and not only wood), but the wear resistance of such doors is the lowest among all types;

Plastic, aluminum and their various combinations

The combination of materials such as plastic and aluminum is used to equip non-residential premises (offices, medical, government, educational institutions).

According to manufacturers, consumer demand trends can be characterized as follows: “from cheap to expensive”. Today, veneered doors are most in demand, but with a base not from chipboard, as it was a couple of years ago, but from solid wood. Why?

The reasons are obvious:

• reliability - a rather large load is placed on interior doors (especially if there is a child in the house). And the whole array always wins over frame structure, and hardwood veneer will protect the canvas better than laminate and other film materials;
• the veneer is homogeneous in structure (compared to a furniture board), so it is easy to choose the most similar doors for different rooms;
• naturalness of the material;
• price - the cost of doors made of inexpensive wood veneered "fits" into the category of the middle price segment (about $ 250), but they will last much longer than frame products. And if necessary, such doors can be restored.

Organizational form and distribution channels

The legal form for the business should be chosen after evaluating the potential buyer.

Here are the options:

• large wholesale - construction companies and state-owned enterprises (usually, there is a tender basis, which is quite difficult for a new player in the market to win);
• conclusion of contracts with networks of construction markets and specialized stores;
• sales through own retail outlets;
• dealer network.

In practice, an enterprise engaged in the manufacture of interior doors is rarely limited to one sales option - to increase sales, all available “channels” should be developed.

Therefore, the optimal organizational form would be a legal entity - LLC (many construction companies and supermarkets simply do not cooperate with individual entrepreneurs).

In the types of activities, you must specify the following codes:

• 20.30.1 Manufacture of wooden building structures and joinery;
• 51.53.24 Wholesale of other building materials.

A license for the production of interior doors is not required. But if you plan to provide installation as an additional service, please note that without special permission, it is allowed to install door panels only in place of existing openings. If the project provides for an extension or any other change in the opening, then an appropriate building license is required.

Technology for the production of interior doors

Let's consider the full technological cycle for the production of interior doors from solid wood with veneer veneer.

1. The production cycle begins with sawing wood (logs) on high-precision band sawmills, which ensures a minimum level of rejects.

2. After - the boards go to a special place - a drying complex equipped with chambers with mechanized loading. The drying process is completed by controlling the moisture in the material.

3. Then the board is disbanded into separate bars (lamellas) of the required section. All defects are removed from the lamellas - material with knots, irregularities that can affect the quality of the future door.

4. On a special splicing line, defect-free blanks are glued along the length into a furniture board. The strength of the door leaf is ensured by the adhesive spike connection individual blanks. Glued beams are processed from four sides on milling machines to the required section.

5. Gluing of slats along the width, for the manufacture of canvases and individual elements of doors, is carried out in vertical presses. At the stage of this operation, the perpendicular arrangement of the fibers in adjacent bars is strictly controlled, which guarantees the high resistance of future doors to various deformations during operation.

6. To give the load-bearing structures of the door high rigidity and form stability, the door leaf is covered with veneer, which is produced on a separate production line.

7. For the production of veneer, whole logs are used, which are pre-steamed (in a steam chamber for 3 days), and then they are centered and sanded on a bark trimmer to get rid of the bark and bast layer.

8. Next step - circular trim. The log is constantly rotating, and the machine removes from it a thin layer of veneer, only 0.6 cm thick. From an average log, about 134 linear meters of veneer are obtained.

9. The veneer is then unfolded and cut into sheets. Sheets with the same fiber pattern are stacked. Of these, parts are subsequently selected for the outer lining of the door.

10. To give the door special wear resistance, three layers of veneer are used (in the economy version, they are replaced with MDF or chipboard with one layer of veneer).

To do this, glue is applied on both sides to the middle layer of the veneer sheet, and sent under a hot press. Here, at temperatures above 100 C, the middle sheet adheres tightly to the other two. After one and a half minutes, the glue hardens, forming a high-strength top layer plywood for the door leaf. This finish is made from a variety of wood species (birch, oak, beech, ash and others).

11. Veneered plywood is applied to the door leaf glued from the lamellas, and placed under a cold press for 30-40 minutes until the glue dries. Further, all components of the door structure are ground and checked for compliance in order to exclude the presence of unacceptable gaps or differences in further assembly.

12. Next, the length / width of the product is measured. The door is sent to the machine, which chamfers and cuts the edges to the specified dimensions. On the next machine, the grooves for the loops are hollowed out.

13. A hole is cut out for the door handle.

14. Then, the product is polished and varnished, dried. All parts of the structure are assembled into one whole, completed with fittings, packed and sent to the warehouse.

Regulatory documents and certification of interior structures

Interior doors are not legally subject to mandatory certification, but the presence of a document confirming the quality mark and compliance with standards significantly raises the level of the manufacturer in the eyes of the buyer, forms a positive image of the company.

And in order for the doors to pass all the checks, it is necessary to adhere to the recommendations and requirements specified in:

• GOST 475-78 - Wooden doors. General technical conditions;
• GOST 28786-90: Wooden doors. Method for determining resistance to climatic factors;
• GOST 26602.3-99: Window and door blocks. Method for determining sound insulation;
• GOST 26602.2-99: Window and door blocks. Methods for determining air and water permeability;
• GOST 26602.1-99: Window and door blocks. Methods for determining the resistance to heat transfer;
• ST SEV 3285-81: Wooden doors. Reliability testing methods;
• ST SEV 4181-83: Wooden doors. Method for determining flatness;
• ST SEV 4180-83: Wooden doors. Impact resistance test method

Raw materials for the manufacture of interior doors

In the production of interior wooden doors, you can use finished materials(furniture board, plywood, MDF, veneer) or blanks (edged board, solid logs). The first option greatly simplifies the technology. The second - reduces the cost and increases profits, but requires large investments. Therefore, only large factories focused on the mass production of interior doors can afford a full technological cycle.

Medium and small businesses prefer to increase their capacity using ready-made materials as raw materials. And after the payback of the initial investment and, if possible, expansion, open a separate workshop for the production of furniture panels, veneer and other materials in the immediate vicinity of the logging site.

Room for the production of interior doors

Basic requirements for the production workshop- dryness (a prerequisite for storing materials, products and working with wood), the presence of heating and all necessary communications, three-phase network, access roads for transport.

The size of the workshop varies depending on the volume of production and the completeness of the technological cycle. If an enterprise for the manufacture of doors from edged boards requires an area of ​​​​at least 400 m 2, then for small-scale production from a finished furniture board, 100-120 m 2 will be enough.

• heated warehouse for primary wood drying;
• manufacturing facility;
• a separate room for applying paint and varnish;
• place for assembly and storage of finished products.

Estimated business plan

1. Room rental

For the production of interior doors made of natural wood (oak, pine) with veneer of various types of wood, the enterprise (LLC on the general taxation system) rented a production facility with an area of ​​450 m 2 .

2. Plans for production volumes

Planned production output: 800 lm/year

Ways of implementation:

• through our own warehouse store;
• through a network of building supermarkets;
• on a contractual basis with construction contractors.

3. Capital costs

Equipment for the production of solid wood doors:

• drying chamber - 35 thousand rubles;
• band sawmill - 110 thousand rubles (Fig. 15);
• tenon cutter for trimming lamellas and cutting tenon joints - 170 thousand rubles;
• trimming press - 220 thousand rubles (Fig. 16);
• pneumatic press for forming a shield - 180 thousand rubles (Fig. 17);
• panel saw for sawing lumber - 200 thousand rubles;
• milling and copying machine - 90 thousand rubles (Fig. 18);
• grinding machine - 100 thousand rubles (Fig. 19);
• auxiliary equipment (construction equipment) - 50 thousand rubles.

Equipment for the production of MDF doors

The production of doors from wood and materials made from it is one of the most promising options - for both large and small businesses. In order to open such a workshop, you will have to not only purchase a list of the necessary equipment, but also familiarize yourself with all the production nuances.

Based on the video in this article, we will discuss how the manufacture of an MDF door is carried out; consider the mechanisms by which certain technological operations are performed; and tell you what capabilities this or that machine or tool has in general.

To get quality products

If the company is engaged in the production of interior doors, then you should not focus it only on working with wood, or only with MDF. Moreover, most of the doors are combined: the frame is constructed from pine bars, and only then it is sheathed with sheet material. In general, for the successful sale of products, you need an extensive range covering different price ranges.

Therefore, the manufacturer should offer the buyer both cheap doors without decorative coating, and elite ones made of natural wood, and the golden mean in the form of laminated and veneered products (see Veneered doors: what it is and how it is done). The task is facilitated by the fact that the equipment for the production of MDF doors is also used with the same success for the manufacture of solid wood doors. Therefore, the list of machines and fixtures that we will present in the course of our article will be general.

Material preparation

Edged boards and timber used in door production must undergo a drying procedure. There are several ways to reduce wood moisture, and the easiest of them is natural.

But it takes a lot of time, so drying chambers are used in factories for this purpose. This is a stationary box with a ventilation system, in which the temperature is maintained from +40 to +100 degrees.

• First, when the fan is running, the lumber is heated with steam, and then the temperature is gradually brought to the desired mode. Since the design features of the drying chambers may differ, the principle of working with them is determined by the manufacturer's instructions.
• Warm-up time depends on the type of wood, and the essence of drying is not only to normalize moisture, but also to relieve stress from its internal fibers. Upon reaching the required percentage of humidity, the tree is not immediately removed from the chamber, but kept in it for up to three hours. If poorly dried material is used in production, the products will be deformed.

• The cost of the drying chamber depends on its capacity, and at least it is 2 million rubles. Not everyone has such tools, so some craftsmen make them with their own hands. A room is allocated for this, the surfaces of which are qualitatively insulated, steam is isolated with foil, a fan and heating elements are installed. Often, infrared film for underfloor heating is used for this purpose, as it is very economical in terms of electricity consumption.

If there is a desire, information on this topic can be easily found on the Internet. The main issue that will need to be resolved in this case is the method of loading wood into the chamber. Usually this is, as in the photo, a trolley on rails, but a forklift can also be used. And, of course, you should take care of fire safety.

Material calibration and cutting equipment

It is clear that the wood used for the manufacture of doors must be calibrated - that is, it must have clear geometric dimensions. Therefore, after drying, the lumber is processed on a four-sided planer, which is able to process the workpiece from all sides at once. When the bar passes through it, four cutters not only level the surfaces, but also reveal defective places.

Multi saw machines

A business that has a multi-blade machine at its disposal can significantly increase productivity. Such equipment allows, in order to reduce costs, to purchase not a ready-made edged board, but round wood, and saw it on your own into boards and beams.

The capabilities of this machine make it possible to mass-produce molded blanks, including from sheet and plate material: plywood, chipboard, fiberboard, MDF, furniture board.

Note! Machines with a multi-blade system are suitable for both longitudinal and transverse processing. Depending on the type of unit, up to two dozen saws can be provided in it. Their layout is standard, and is very similar to a sawmill, but unlike a multi-saw machine, several blanks cannot be made at the sawmill at the same time.

• In addition, workpieces passed through a multi-saw unit are distinguished by greater geometric accuracy. All its working elements are located on the frame, and in some models there is also a material supply line, which is a roller conveyor.
• The material feed unit is driven by an electric motor, and consists of shafts with spikes that ensure uniform movement of the workpieces. The sawing unit can consist of several or one shaft, on which circular saws are mounted. By the way, they can be located not only in a vertical plane, but also horizontally.

If necessary, the multi-blade machine is equipped with a milling mechanism necessary for processing the ends, as well as an installation for trimming the edges. The complete set of the machine may vary depending on the parameters of the products that you want to receive.

Trimming machines

When working with any long material, it is impossible to do without miter saws. In a small workshop, carpenters can use manual options, but for large volumes of work, a machine is needed.

Facing is a cross-cutting of wood materials, with the help of which the workpiece is given the shape of a rectangle and a workpiece of a certain length is obtained.

• When the company has a dryer, then one trimming machine can be installed on the site where the raw material is sorted, and the second is used for cutting the already calibrated timber or board. Such equipment has quite a lot of potential.

• In addition to trimming the ends, this is the division of the workpiece into 2 parts; determination of a section with a defect, which is automatically removed during sawing; cutting blanks of a certain length. All these operations can be performed by the machine either simultaneously or sequentially. Here much depends on the configuration of the machine, its settings, as well as the task.
• As in gang saws, circular saws with teeth made of hard alloys are used here. However, they have a different sharpening angle, since the wood has to be cut across the grain. A saw with the right teeth cuts through the material like clockwork, and does not tear or crumple it.

• Since the cross-cutting cycle is periodic, the moving parts of the machine do not have time to heat up much, so the mechanism works properly for a long time. The only thing, for the convenience of work, the trimming machine must have a convenient device for feeding workpieces. Usually this is either a conveyor or a roller table - a roller table, the price of which, depending on the length, varies between 16,000-25,000 rubles.

So that when sawing there is no discrepancy between the required and actual dimensions of the products, all measuring instruments on the machine, as well as the stop ruler on the roller table, must be periodically checked and adjusted. To obtain the most accurate parameters, modern cross-cutting machines are equipped with optical instruments, which also need to be verified from time to time.

Panel saw

When working with sheet wood material, which is MDF, you can not do without a machine for format cutting. It cuts in a straight line or at an angle: both long-length and slab material is processed, and you can also cut a whole stack of slabs at once according to a single template.

• To do this through any other machines or tools, if possible, it will take a lot of time and effort, which is simply unacceptable for the mass production of joinery. In general, production efficiency largely depends on the overall functionality of sizing machines.
• All of them are professional, and are divided into three categories. The first group contains the simplest economy class models, with small dimensions, and without additional equipment with stops, rulers and clamps. Such machines can work no more than five hours in a row, and are designed for a relatively small volume - ideal for a small private workshop.

• The second category includes machines of medium power, which can work a full shift (at least 8 hours), and are provided with all the necessary devices and assemblies. In particular, they can be equipped with a dust extraction device. Well, the third option is industrial machines that have the most durable design, complete set, electronic control circuit, and are able to work for two work shifts.
• The basis of any machine is the frame on which all working mechanisms are mounted. The stiffer and heavier it is, the less vibration and the higher the cutting accuracy. Two saw blades are fixed on the bed. A scoring disc is located in front - it has a smaller diameter, and its function is to cut the upper (facing) layer on the workpiece.

• The main disk finally cuts the material, the size of which determines the depth of cut. This arrangement of the discs allows you to make a high-quality cut, with smooth edges and without chips. The sizing machine has three working tables: one is movable, along which a full-sized MDF sheet is fed for cutting; the second support, which should support the cut off parts. The third, fixed table, on which, in fact, the saw unit is fixed, is the main one.

To cut a workpiece on such a machine, the sheet is placed on a movable table, which moves along the guides with a carriage. Using the stop, measure the desired length, and start the saw mechanism. As soon as it gains momentum, by shifting the table, the sheet is fed to the saw unit, and a fragment is cut off. From the settings in the format machine: only the depth and angle of cut.

Equipment for milling and cutting spikes

Without a milling machine, it is impossible to imagine any carpentry workshop, because cutting profiles, grooves, three-dimensional reliefs, large radius curved cuts, and even wood engraving are performed mechanized.

The only difference is that the milling machines used in one case or another differ somewhat in design. There are six types of removable tools, the use of which is due to the need to obtain one or another type of processing.

• Thus, a wood milling machine can be considered a universal mechanism. The height of the cutter, located on a movable vertical shaft, can be adjusted. But the position of the part being processed is limited by stops and guides.

• In a small workshop, you can get by with a manual milling cutter, a variant of which is presented above, but for the mass production of joinery, machines with program numerical control are used. Manufacturers offer a huge range of such equipment, which has a variety of characteristics, and is controlled by operating systems.
• With a milling cutter on a vertical shaft, you can countersink, that is, get conical holes; bore them; dado. With the help of such machines, the edges of blanks are processed, frames are made. But mirror-symmetrical, or absolutely identical curly blanks: drawers, panels (see. Door panel: how to make and install), it is impossible to make without a copy-type milling machine.
• The door frame is most often assembled with a spiked method. Spikes on the ends of the blanks, as well as recesses for them (lugs), can only be obtained using a tenoning machine. In it, the working mechanisms are also cutters and saws. Just like other milling machines, tenoning units can be equipped with a CNC and controlled by a microprocessor.

• In any case, an oval or round spike can only be made on such equipment. In addition to cutting spikes, on CNC machines, it is possible to overtake the perimeter of the door leaf, process calibrated sheet material, splice bars along the length, which is sometimes necessary for the manufacture of panel doors.

Note! In addition to the main woodworking machines mentioned above, additional equipment will also be needed in the door production, with the help of which the finished canvases and molded products are finished.

• This is a hydraulic press, with the help of which the MDF door paneling is pasted with veneer, and an edge banding machine, through which narrow strips of veneer are glued to the ends of the canvases. This includes a spray booth, and a press for gluing bars, and a surface grinder, and a packaging machine - otherwise how to transport products?

As you can see, the list of equipment is quite large, and it is clear that in order to equip a carpentry shop, you need to spend a lot of money. But do not forget this: the availability of machines and the necessary tools does not guarantee a quality result. Ultimately, it all depends on the professional competence of the people working on this equipment.

Interior doors are a necessary part of residential, industrial and office premises. When choosing door panels and additional elements, you need to know how and according to what rules they are made, as well as to understand the advantages and disadvantages of the materials used in the production of doors. Modern manufacturers use high-tech equipment that allows them to produce a large number of high-quality products with various types of coating and modern design.

Manufacturing technology of interior doors

Doors serve to separate the various functional parts of the room and provide sound insulation, protection from extraneous odors and excessive moisture. Methods for the manufacture of door panels and additional elements depend on the materials used in the production. The most popular doors are made of solid wood or prefabricated on a wooden frame. Glass inserts make the canvas partially transparent to light and visually expand the space of rooms or corridors.

The most complex and multi-link technological process occurs in the manufacture of doors using wooden elements. The fact is that timber that has not gone through the full cycle of pre-drying and processing is subject to warping and cracking. To avoid losses in the quality of the final product, it is necessary to pay great attention to the preliminary preparation of wood using certain technological methods. The manufacturing process of interior doors includes the following steps:

1. Timber (round timber) of pine species is sawn into blanks using band saws with automatic feeding of logs.

   Logs are sawn into blanks of the required thickness.

2. The blanks are treated with high temperature and steam in drying chambers to avoid uneven drying and warping of the wood. At the end of the drying process, a mandatory moisture control is carried out.

   Drying of lumber is carried out under the influence of steam and high temperature.

3. Dried blanks are cut into bars of technological section and defective fragments (chips, knots, cracked and rotten areas) are removed from them, which can affect the quality of the door frame and leaf.

   Defective areas are cut out of a blank cut into a beam

4. Then, the blanks are spliced ​​with the help of spikes, glue and a vertical press into a shield, from which, after drying and trimming, a door leaf is obtained.

   With the help of a vertical press, a panel blank of the door leaf is obtained

5. After sanding, the canvas is covered with three-layer veneer or MDF panels with one layer of veneer and placed in a gluing press.
6. At the next stage, figured decorating elements, panels or openings for glazing are cut out with a milling and engraving machine, and after assembly, the door leafs are covered with three layers of varnish with intermediate and final polishing.

   Panel elements or glazing are mounted during final assembly

7. After the final drying, the products are packed, if necessary, supplied with fittings and sent to the consumer.

The technological sequence of manufacturing doors may be different and it depends on the material, equipment and design of the product. For example, expensive solid wood doors do not typically use veneer and are manufactured using complex CNC machines, while budget doors often use corrugated board inserts and cheap laminating film.

It is important to note that in the factory, fittings are usually not installed on a door with a symmetrical decor, since during installation at the consumer's, the product can open both to the left and to the right, respectively, the hinges and handles are installed by installers on site.

Video: making solid wood doors

Rules and norms for the production of interior doors

Door blocks are manufactured on equipment that is located on large production areas. These premises are subject to certain requirements, as to industrial facilities, which include timber warehouses, dryers, a processing shop, a paint shop and a warehouse for finished products. Each production site is equipped according to the rules and regulations, in accordance with the technical conditions for a specific task. The main requirements for production facilities for the manufacture of doors are the following criteria:

• availability of free access roads;
• buildings must be provided with a stable temperature, humidity, natural and artificial lighting;
• power supply, heating, ventilation, water supply and sewerage should be equipped;
• the premises must be equipped with fire alarms, fire extinguishers and emergency exits;
• it is necessary to ensure safe working conditions at workplaces;
• paintwork areas should be isolated from the rest of the premises and provided with forced ventilation.

Personnel are required to undergo professional training and training in labor protection, fire and electrical safety standards, as well as undergo unscheduled, repeated and initial briefings at the workplace.

The production room must be equipped in accordance with the standards

The main norm for the production process is technological documentation, which is based on the Technical conditions for the production of TU 5361-001-58037723-2015 "INTERIOR DOORS, PARTITIONS AND MOLDINGS TO THEM". This document sets out the requirements for the design of interior doors, the quality of the material and the coating of the front surface, as well as environmental requirements. The regulations specify the procedure for acceptance of finished products, certification and installation of a warranty period of operation.

For the buyer, it is important to have a certificate, a warranty period and the compliance of the door, frame and additional elements with the requirements of technical specifications, since this confirms the quality of the product and allows you to count on a long service life.

Current GOSTs for the production of interior doors

The technical characteristics of the doors are determined by the standards that set the general technical conditions or methods for determining the physical parameters and dimensions of the finished product. Many manufacturers create products according to non-standard sizes, but with strict observance of quality requirements. The consumer may be interested in the list of regulatory standards that manufacturers of interior doors work on, namely:

1. General requirements for wooden doors with a list of regulatory documents are established by GOST 6629–88, and requirements for wood products are set out in GOST 475–78.
2. Design options for interior doors, their types and sizes are specified in GOST 24698–81.
3. Requirements for extensions, fasteners and hinges are assigned by GOST 538–88.
4. Methods for determining sound insulation, heat transfer resistance and air permeability are regulated by GOST 26602.
5. The determination of the flatness of the door leaf is carried out according to the standard ST SEV 4181–83.
6. The reliability test methodology is set out in ST SEV 3285-81.
7. Impact load resistance is produced according to the method specified in ST SEV 4180–83.

Accompanying documents for finished products must contain a symbol for door panels, for example, U05195 VERSAL pat. 1014 dec/or door leaf D3 91x 230 L, which means the following door parameters:

• article - U05195;
• the trade name of a particular collection is VERSAL;
• type of finish/color − pat. 1014 dec/oro;
• product name - canvas;
• product model - D3;
• width and height of the canvas - 91x230;
• type of opening, left − L.

Before ordering doors, it is necessary to carefully measure the doorways in order to select the required size of the frame, leaf and the required number of additional elements. For interior doors, there are standard dimensions of openings with the corresponding designation according to SNiP, and this approach makes it easier to choose a door frame according to the table.

Table: the ratio of the size of the opening to the size of the door leaf

Existing regulatory documents guarantee a high level of product quality, standardization in size and compliance with environmental requirements, in addition, the consumer can determine the compliance of the product properties declared by the manufacturer with the quality and price level.

Material for the manufacture of interior doors

In the production of interior doors and partitions, modern materials are used that are environmentally friendly, durable, lightweight and have a long service life. These include metal-plastic and glass doors, the frame for which is an aluminum profile, and the filler is plastic panels or tempered triplex glass with a matte finish. But traditional doors with a wooden frame and inserts made of glass, MDF panels and paneled elements occupy a major niche in the market. In the manufacture of such products, the following materials are used:

1. Defect-free pine lumber with a moisture content of not more than 8%, spliced ​​into a tenon using glue pressing.
2. High density chipboard.
3. Natural veneer from various types of wood with a thickness of 0.6 mm.
4. Laminating film imitating fine wood.

   Laminating film gives the doors the texture of natural wood

5. MDF panels of various thicknesses are used for cladding door panels and creating paneled elements.
6. Frosted, triplex or tempered glass, used for light-scattering and decorative inserts into the door leaf.
7. Corrugated cardboard is used in budget options, as soundproof inserts in the canvas between the frame bars.

   Corrugated cardboard is used for insulation and sound insulation of inexpensive door panels.

8. Wax and waterproof coatings, tinting compounds and varnishes.
9. Glue type "Kleiberit 303.2", MERITIN ADHESIVE D3 and others, is used for industrial gluing of fragments of leaves, door frames and additional elements.

The production of inexpensive doors is based on the use of chipboard, laminating film, corrugated board and MDF, while more expensive products use solid wood with milled elements, panels and tempered glass inserts.

Six years of experience in the operation of veneered panel doors by the author of the article shows their significant reliability. But in rooms with high humidity, I would like to recommend different types of laminated doors with an additional waterproof coating. After four years of service in the bathroom on the inner veneered canvas, despite the treatment with liquid wax twice a year, whitish stains and streaks appeared from exposure to steam and condensate. There was a need for cosmetic repairs, so I had to sand the plane of the door leaf, degrease it with a solvent, cover it with a tinting compound and waterproof varnish in two layers. To a lesser extent, the same problem appeared in the laundry room, and as for the other doors, minor damage to the veneer and scratches were eliminated by gluing and treating with hard, tinted wax in various shades. After such a minor repair, the canvas, boxes and extensions acquire their original appearance and serve for more than six years. Under the conditions of suburban operation during summer residence, wooden doors covered with waterproof varnish serve more than eight years. At the same time, there is no warping and drying out in conditions of temperature changes and changes in humidity. But it should be noted that the best option for summer cottage construction are metal-plastic doors and frames that do not change their properties and retain their geometry under changeable weather conditions.

Equipment for the production of interior doors

The most costly production of interior doors, in terms of the amount of equipment required, is the manufacture of wood products. Factory production of metal-plastic and glass requires a large number of components and a small number of machines for cutting frames and processing glass sheets. Lumber processing is more saturated with machine tools, presses and other equipment. Consider the equipment that is used for the production of wooden doors:

1. Sawmills and band saws used for cutting round timber.

   The sawmill allows you to get lumber of the required thickness from round timber

2. Thermal chambers with steam supply for drying lumber.

   Industrial drying chambers allow you to bring the lumber to the required moisture level and avoid warping of the workpieces

3. Equipment for the production of veneer.
4. Tenoning machine for frame and door leaf.

   Using a pneumatic press, the door leaf is glued

5. Circular saws and panel saws for sawing blanks to size.
6. Copy-milling machines with program control for decorating door panels.

   Using milling machines, figured and paneled elements are produced

7. Grinding machines for intermediate and finishing processing of products.
8. Paint equipment.

The list of the production park can be expanded due to the use of various technological and design solutions in the production of interior doors and components, which has a positive effect on the consumer properties of the final product.

Video: production of interior doors

We examined some types of interior doors, production technology, as well as regulatory documents and requirements governing the production of this type. For the correct choice of doors, it is necessary to know the properties of the coating and the material from which they are made. High-quality equipment and adherence to production technology ensures resistance to external influences and a long service life of products. A wide range of design solutions allows you to give the living room an individual look and unique style.

The segment of the market for the production of interior doors will always be in demand. Good, solid interior doors will always find their buyer and give a good profit.

So, what do you need to start a business for the production of oak and other wooden interior doors from timber?

Door types

Before purchasing equipment and renting premises for the production of wooden interior doors, it is necessary to determine the range of products manufactured in the future.

Wooden doors are of the following types:

• From a wooden massif of various species. Such interior doors are produced from wooden blocks of high-quality expensive wood species, which are spliced ​​together. The resulting solid wood is sanded, calibrated and varnished in the desired shade. Mosaic splicing and toning is possible even in the bars. In such cases, the resulting array is covered with a colorless varnish. For VIP doors, whole pictures are laid out.
• Veneered (veneered) doors. The production of such interior doors consists in veneering doors made of boards, solid wood or made using the technology of a wooden frame, which is filled with honeycomb cardboard, with precious wood veneer. They are in no way inferior appearance doors made of natural solid wood, but they are less durable, more capricious in operation and, if not properly maintained, will require an early restoration. The owner of the workshop for the production of wooden interior doors, when producing products of this type and providing a guarantee, must keep the veneer that matches the sold interior doors in order to eliminate deficiencies during the warranty period;
• Laminated. It is an economy class door, in which a laminated film of the texture and color chosen by the customer is applied to the wooden frame. The price of such doors depends on the method of applying such a coating and its composition.

In this article, we are considering technological scheme launching a workshop for the production of interior doors from sawn oak.

Product range

• door frames;
• platbands;
• interior doors;
• products on running meter- door array, etc.

Sales channels

The organization does not plan to carry out independent installation of its products, finished products will be sold through such distribution channels as: 1) wholesale of interior doors to construction organizations that renovate offices, apartments, etc.; 2) retail outlets selling building materials, windows and doors; 3) construction hypermarkets and large specialized stores.

Raw materials for production

Planned raw materials for the production of interior doors:

• Timber. Price cubic meter sawlogs, for example, oak will be approximately equal to 5000-7000 rubles per cubic meter.
• Glue for end splicing of beams. Such an adhesive is Kleiberit 303.2. Its consumption is 160 grams per square meter. The price for a container weighing 1 ton will be approximately 110 thousand rubles.

Equipment for the production of

You will need the following equipment for the production of interior doors:

• band sawmill. You can, of course, buy ready-made boards, beams, but then the doors will come out very expensive. Price from 110-130 thousand rubles.
• Drying chamber. Necessary for faster drying of wood. In general, this process will need to be approached with all seriousness, because. if you do not dry the wood, then the doors will warp, and this will lead to negative reviews about your products and general dissatisfaction with your customers. Who will need such products, in which cracks are then formed due to continued drying? Nobody.
• Tenoning machine. About 200 thousand rubles. Designed for precise trimming, cutting mini-studs on workpieces for their subsequent splicing. Those. he makes castles.
• End splicing press. From 220 thousand rubles. As a matter of fact, this press is just engaged in splicing through the ends and cuts that the previous machine made.
• Pneumatic press for wooden board splicing. Thanks to him, the entire shield is formed from the previous parts received. From 200 thousand rubles.
• Panel saws. 220 thousand rubles Designed for cutting lumber. They produce longitudinal, transverse, as well as sawing lumber at an angle.
• Milling and copying machine. About 150 thousand rubles. Produces exact copies of wooden parts, which saves a lot of time in the production of the same type of parts.

The total cost of purchasing equipment (without a dryer) for the production of interior doors will be about 1.5 million rubles. Dryers are not sold ready-made, but are made to order. Therefore, we cannot indicate their price here, because prices vary greatly.

Production technology

The entire manufacturing technology of interior doors consists of the following production stages:

1. Sawing of raw materials;
2. Drying of blanks;
3. Dissolution of unedged boards;
4. Cutting spikes and splicing blanks;
5. Cut and calibration of defective places;
6. Glue is applied and the blanks are spliced ​​into a wooden shield;
7. Calibration of canvas dimensions;
8. Coating grinding;
9. Varnishing and applying a special solution;
10. Final drying of the finished product.

Interior doors made of MDF received in last years very widespread. After all, chipboard is a material containing urea-formaldehyde or phenol-formaldehyde resins, and wood is expensive, easily absorbs moisture, and is sensitive to fungal diseases. In addition, MDF interior doors look great, are relatively inexpensive, and also do not pose any danger to the health of people and pets - they can be installed both in the bedroom and in the children's room. Add here high strength and wear resistance, absolute inertness to environment and you will understand the reasons why MDF doors are popular.

The DEMFA company, as a manufacturer, has been manufacturing interior doors from MDF since 1999. For painting, we use only moisture-resistant polyurethane coatings, as well as high-quality patina and acrylic lacquer on water based. It is the concern for the health and wallet of the consumer that makes our products popular. DEMFA products are represented by several model lines of door panels, each of which can be further modified to suit your interior design. We are also engaged in the production of moldings and capitals, doors for the delivery of residential facilities (construction doors).

We paint MDF interior doors in two basic colors: WHITE and CREAM. However, the client can choose any other shade from the RAL catalog, which presents 213 different color solutions. The capital and other molded products can be painted in the same color. The company "DEMFA" does not recognize any framework in terms of interior design. It is also possible to have weak and strong patination of interior doors in various shades (basic - silver and gold) - it looks very impressive!

Since the production of MDF doors at DEMFA is carried out according to a weekly planning scheme, we fulfill even large wholesale orders very quickly. As a rule, the waiting period varies from one week to a month. Moreover, in our warehouse we have a large stock of the most popular items in two primary colors (WHITE and CREAM) - if you are looking for a standard solution for an office or home that will fit into any interior design, you can pick up the ordered interior doors almost on the day order! In addition to standard models, we manufacture products to order:

• Not standard in height, width,
• coloring and patination of the sides in different colors,
• full or partial patination of the door leaf and moldings,
• drawing patterns on the door leaf by milling technology.