PVC Windows Business: Feasibility Study
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Today, not a single construction of new facilities is complete without PVC windows, in addition, more and more people want to replace old wooden windows with metal-plastic structures. Due to the high demand for products, more and more entrepreneurs want to organize their own production of PVC windows. Such companies can benefit from competitors who offer products from leading manufacturers, but fulfill orders for a long time. Therefore, in this material we will carry out the calculation of economic feasibility for a small enterprise for the production of plastic windows.
Organization of an enterprise for the manufacture of PVC windows
When opening an enterprise for the production of PVC windows, it is necessary to submit an application to the USRIP, in which you need to indicate the main OKVED codes:
- 25.23 - Manufacture of plastic products that are used in construction;
- 45.42 - Production of joinery and carpentry;
- 51.53.24 - Wholesale of building materials;
- 45.44.1 - Production of glass works.
After registering OKVED codes, you need to submit an application to the tax office to register a UTII payer. Therefore, the production of metal-plastic structures will be on the general taxation system, and the entrepreneur will need to accrue and pay personal income tax and VAT. During pre-production, all certification tests must be carried out. They will confirm the high quality of products, the possibility of its use in certain climatic conditions.
These tests can be carried out both on the territory of Russia - for compliance with the requirements of Building Regulations, GOST and SNiP standards, and in Germany - for compliance with DIN standards and the RAL color palette.
Obtaining a certificate of conformity for plastic windows from 2010 to 2011 was a mandatory procedure. It was carried out in order to confirm the quality of windows to the requirements GOST 30674-99.
This procedure has now been replaced declaration. Certification tests are still carried out, but in accordance with the mandatory clauses of regulatory documentation.
Also, in order to sell PVC windows, an entrepreneur must obtain Gosstroy license and sanitary and epidemiological conclusion.
PVC window production technology
The production process for the manufacture of plastic windows includes the following steps:
1. Profile cutting
At this stage, it performs cutting of metal profile and PVC rods. The quality of the finished product largely depends on the level of execution of this operation, therefore, close attention should be paid to observing the cutting plane and the location of the profile whips. Cutting of blanks is carried out in accordance with the order form and taking into account the margin for welding (5-6 mm). - cutting of plastic profile. The frame and sash profiles are cut with a saw at an angle of 45°. Bay windows, stand profiles, imports are cut at an angle of 90 °, taking into account the reserves on each side (2.5-6 mm). - cutting of the reinforcing profile is carried out on a special saw at an angle of 90°.
2. Milling drainage channels
To compensate for wind pressure and remove excess moisture drainage holes are made in the sash, impost and frame. The location of these holes should be in accordance with the profile supplier's recommendations.
Holes should be oblong and made with a special tool or on a drainage machine.
3. Fixing a metal profile in a plastic one
We place a metal profile in a special chamber for the plastic profile blank and fix it with self-tapping screws. This operation can be carried out using a manual screwdriver or an automatic screwdriver.
4. Milling holes for the lock of the main constipation and for the handle
To install the fittings, you must first make the appropriate holes. This operation is carried out on a copy-milling machine.
5. Milling the ends of the mullion
To install the impost in a frame or sash, it is necessary to properly process the edges of the workpiece. This action is performed on a face milling machine. Further, the impost is attached to the sash or frame using mechanical connectors.
6. Welding PVC windows.
During welding, the following conditions must be observed:
- the temperature of the welded knife should be 230-250°;
- carefully treat the surface of the knife;
- seam heating time - from 25 to 40 seconds;
- seam welding time - from 25 to 40 sec.
Before placing the workpieces on the welding machine, it is necessary to make sure that they are clean, as dust, metal shavings or PVC impair the quality of welding. After the completion of this operation, a visual quality control of the weld is carried out.
7. Cleaning corners of metal-plastic products - removal of weld overlay
This operation can be performed manually or on a special machine. The automatic machine cuts the overlap from the front surface of the profile with special knives, then the cutter cleans the end surface of the profile.
A special cutter is selected for each type of profile!
8. Installation of sealing rubber
The immersion of the sealing rubber into the groove must be started from the middle of the upper crossbar. Rubber is manually placed in the groove so that it does not stretch. It is necessary to dock the seal using a special glue.
9. Window structure assembly operations include installation of mullions and fittings
After installing the fittings, it is necessary to place the sash on the frame and insert the rebate inserts, gaskets under the double-glazed window.
10. Cutting glazing beads
A glazing bead is a contour that is needed to fasten a double-glazed window in a sash or frame. Actions for cutting glazing beads are carried out on a special saw, sometimes on a pendulum saw.
At the end of the production process, you need to put a double-glazed window into the sash or frame, and hammer the glazing beads into special grooves. This operation can be carried out on a glazing stand. After that, the window is ready for installation.
The largest factories in Russia have automated PVC window production line where the full production cycle is carried out. For example, in a factory Kaleva there is not only an assembly shop and a complex of production equipment, but also an extrusion line.
PVC window production equipment
Since today PVC windows are in demand and are presented in a wide variety, there is no shortage of equipment supply. The greatest demand in the equipment market is for the lines of Turkish brands - Yilmaz, NISSAN, KABAN and Nikmak, as well as machines and tools of domestic manufacturers.
The list of equipment for the manufacture of plastic windows includes:
- Single and double-head saws for cutting PVC profiles and reinforcement;
- roller tables;
- PVC welding machines;
- Copy-milling machines;
- Saws for cutting a reinforcing profile;
- Corner cleaning machines;
- Machines for milling the end face of the impost;
- Saws for cutting glazing beads;
- Punching saws;
- Bending machines;
- Glazing stands;
- Hoods;
- washing machines;
- Extruders;
- Demineralizers;
- Mounting lifting devices.
PVC window production business plan
Features of the choice of premises
The area of the premises directly depends on the volume of production. The company plans to produce standard double-leaf windows with dimensions of 1400*1200. To open a workshop for the production of PVC windows, which will produce 20 structures per shift, a room of 200 sq. m. It is worth remembering that the ceiling height must be more than 3 meters.
Nearby there should be a warehouse of finished products.
Machine tools for the manufacture of metal-plastic structures will not be able to work without electricity. The supply voltage must be 380V/50Hz. The optimum room temperature is 18 ° C, otherwise the production technology may be violated.
Also in the room should be created good ventilation system. Particular attention should be paid to the creation of a lighting system. General lighting is done throughout the workshop, and for individual sections - local "light".
Recruitment
To organize a small enterprise for the production of PVC windows, you need to hire about 10 people and install a special program.
Such a program, with the least errors, will calculate the cost of metal-plastic structures and provide all the information necessary for production.
Control
The production process must be controlled production manager, and the chief technologist will be able to check whether the finished product meets the generally accepted standards and customer requirements? He must also distribute tasks between workers and control the technological process.
The enterprise must have engineer who will monitor the operation of the equipment and, if necessary, eliminate breakdowns. The staff of workers must be hired at least 7 people, one of them must be a storekeeper who receives or sends goods. The optimal layout of the technological line and the composition of production sites are shown below.
Capital expenditures
To open a plant for the production of PVC windows with a capacity of 20 finished products per shift, it is necessary to purchase the following equipment:
- Double-head saw with frontal drive of the disk - 372,000 rubles;
- Corner cleaning machine (Yilmaz CA) -225,000 rubles;
- Face milling machine (Yilmaz km-212) - 30,000 rubles;
- Two-head welding machine - 411,600 rubles;
- Equipment for cutting reinforcement - 9000 rubles;
- Copy-milling machine (Yilmaz FR-225) - 106,400 rubles;
- Remezza compressor - 26,000 rubles;
- Machine for creating drainage holes - 86,000 rubles;
- Automatic saw for cutting plastic glazing beads - 99,600 rubles;
The total cost of a complete set of equipment is 1,365,000 rubles.
The cost of delivery and installation of equipment - 50,000 rubles;
Other expenses (for obtaining a license, certificates) - 50,000 rubles.
Total capital costs: 1,465,000 rubles.
Calculation of the cost of materials for the production of PVC windows
The cost of materials that are necessary for the manufacture of double-glazed windows
Consumption rate, cost per unit of materials, financial costs (rubles) per 1 sq. production meter:
- Glass (C-300 rubles/sq.m.): cost rate - 2 sq.m. m; cost of consumption - 600 rubles;
- Shell (S-100 rub./m): cost rate - 4 m; cost of consumption - 400 rubles;
- Butyl (C-35 rubles / kg): cost rate - 0.1 kg / sq. m; cost of consumption - 3.5 rubles;
- Other consumables per 1 sq. meter of production - 200 rubles.
Total production costs for 1 sq. meters of double-glazed windows - 1203.5 rubles.
The cost of materials that are needed to create a metal-plastic structure:
- PVC profile (S-1000 rubles / m): cost rate - 0.5 m / sq. m; cost of consumption - 500 rubles;
- Rolled metal (С-582.5 rubles / m): cost rate - 1 m / sq. m; cost of consumption - 582.5 rubles;
- Accessories and other consumables - 2000 rubles.
Total: 3082.5 rubles/sq. m.
The total cost of materials for the manufacture of 1 square. meters of products - 4,286 rubles.
Material costs per month: 22 shifts * 20 finished products * 1.68 sq. m * 4,286 rubles = 3,168,000 rubles.
Monthly income for the month (including the price of the finished product - 9,500 rubles): 22 shifts * 20 units of finished products * 9,500 rubles = 4,180,000 rubles
Fixed monthly costs
- Rent of production premises and warehouse - 50,000 rubles;
- Utility payments - 25,000 rubles;
- Salary of workers (10 people) - 100,000 rubles;
- The cost of materials and components for production - 3,168,000 rubles.
Total costs per month: 3,343,000 rubles.
Income tax (20%) - 167,400 rubles.
Total expenses: 3,510,400 rubles.
Profitability and profit
Net profit: 4,180,000 - 3,510,400 \u003d 669,600 rubles.
The profitability of the enterprise for the production of PVC windows will be 19.07%.
With a net profit of 669,600 rubles per month, the payback period will be 1 year and 9 months. But, these calculations are indicative and a novice entrepreneur must remember that with high competition, it will be necessary to increase costs and include an additional item - the cost of an advertising campaign. As a result, the payback period may increase.
