Equipment for the manufacture of kitchen facades. Equipment for the production of MDF facades and other accessories. Painting MDF facades

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

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

Types of MDF boards differ for various reasons: by use (furniture, flooring, interior doors, suspended ceilings, wall panels, etc.), by type of coating (painting, PVC film, paper-resin film, veneer, etc.), by the presence of inserts (lattices, glass, etc.), in shape (flat, bent, etc.).

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

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

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

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

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

To organize the production of MDF facades, special equipment is required. It includes: a panel saw (depending on the model, its price can be 200-250 thousand rubles), a copy-milling table (30 thousand rubles), a milling machine (350 thousand rubles), a vibration grinder (1 , 5-2 thousand rubles), an industrial vacuum cleaner (10 thousand rubles), a piston compressor (5-7 thousand rubles), an airbrush (5 thousand rubles), a vacuum press (150-170 thousand rubles). The performance of this equipment, which can be operated by one specialist, will be about 20-25 square meters. meters per shift and about 100 sq. meters of facades per week. Monthly output can be 400-450 sq. meters. With an increase in the number of production workers to three people, productivity also increases significantly. Since the process of production of MDF facades involves human participation, the quality of the finished product directly depends on the quality of the materials used for its production, and on the qualifications of the worker.

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

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

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

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

Filling

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

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

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

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

Frame

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

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

Assembly

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

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

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

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

Range

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

In addition to facades, MDF is made of:

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

Sales market

construction organizations;
repair companies;
individuals.

Organization of production

The production of MDF facades requires the work of 1-3 specialists. The area of the required premises is 100 sq.m. The pressing room should be free of dust and the temperature should be maintained at a level of at least 15 degrees. The raw materials for production are MDF boards, PVC film and glue.

Necessary equipment

		Cost: 230 850 rubles.
		Cost: 30 000 r.
		Productivity: 2 passes up to 10 m/min. Cost: 390,000 rubles.
		Productivity: 4000-11000 fluctuations/min. Cost: 1990 rub.
		Productivity: 55 l/s Cost: 9 800 rubles.
		Cost: 7 770 rubles.
		Cost: 5 848 rubles.
		Productivity: 8 cubic meters/hour Cost: 165,000 rubles.

Feasibility Study

Capital expenditures

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

Total start-up costs: 1 700 000 rubles.

Calculation of revenue when working 2 people

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

Made of MDF material, it is a significant task for furniture manufacturers in the face of fierce competition. Furniture structures made of MDF are several times superior to templates and finished parts made of laminated chipboard, wood or plastic.

The main material in this process:

MDF board.
PVC material of any color and with an additional ornament for further vacuum pressing.
Laminating paper, which is used for facing the back surface, can be used.

Stages of work

At any production process, the process of work and the manufacture of MDF facades (Krasnodar, Moscow, Novosibirsk and other cities) is carried out on special machines using high-quality equipment. To speed up the process, it is recommended to buy a laser for cutting plywood from the manufacturer. This will significantly save equipment costs and will provide the workshop with high-precision machines.
The stages of work are identical at all enterprises, with the exception of the material itself and the selected product design. On CNC machines, the time to produce a batch of facades is 10 times less than when manufacturing the same quantity on standard units.

Cutting MDF boards is carried out according to the given dimensions without allowances. This saves a lot on material consumption.
A drawing is selected from ready-made blanks or formed in any graphic editor.
Milling and working time depends on the complexity of the ornament. For cutting on kitchen fronts, several models can be placed on the table at the same time, which will speed up the process. The cutting mode is set and after installing the cutter, you can start milling the MDF board.

After that, the process of preparing the slab for facing with PVC film begins. For this:

The finished part is polished for 5-30 minutes, which is affected by the complexity of the design.
Glue is applied to the workpiece and the composition is expected to dry completely. It is not a glue solution that is used, but a melt, which should be remembered.
After the product has completely dried, it is placed on the countertop of a vacuum press, on an MDF substrate. Pressing time approximately 5 minutes.
Next, the machine unit is put into working condition and the film is heated and vacuumed, which will also last about 5 minutes.
The last stage is the removal of the product from the working surface of the table and cutting the film.

The stove requires compliance with a certain technology!
Thus, the entire manufacturing process will not take much time, and with the acquired skill, you can create unique designs and develop your business.

From what equipment is installed at the enterprise for the production of MDFfacades, depends on the quality and volume of products. However, a start-up enterprise should take into account that mass production should be mechanized, and individual orders require more manual labor. On the other hand, not all work can be performed without the use of technical means. And the cost of manual labor is sometimes much more expensive than a one-time investment.

The sawing of MDF boards is carried out, as a rule, on panel saws. With small volumes, you can cut to order from other organizations. Such services are often provided in places where you can buy MDF and chipboard.

If the enterprise uses CNC milling and engraving machines with wide working surfaces, then the pattern of parts of the required dimensions can be performed directly on them. In this case, the pattern will be successfully combined with the processing of the edges of MDF facades, if you choose the appropriate cutter, or a set of cutters.

It is better to purchase your own milling machines for MDF facades, since creativity must always be present here. And it is not always possible to get by with a set of standard templates available to contractors.

The best option would be if you purchase a CNC milling and engraving center, which will ensure the implementation of 90% of all milling work with blanks for MDF facades and countertops.

If financial possibilities are limited, then you should buy a milling and copying machine for MDF facades. However, here virtually all the work is done manually according to templates, so productivity drops sharply compared to CNC machines.

It will not be difficult for beginner small businesses to make a primitive, but very useful milling machine for MDF facades on their own. To do this, a manual milling machine is vertically mounted in the middle of the table from below, and a movable stop bar or stop roller is mounted on top, opposite the hole for the working cutter.

Excessively bulky and heavy parts of MDF countertops are easier to process with manual milling machines. To round corners, you may need a small machine with a moulder and edge cutter with a radius of 2-3 mm.

In addition, for the manufacture of complex curved products, you will need a manual jigsaw and a belt grinder.

Workplaces for sawing, milling and grinding MDF blanks should be equipped with exhaust hoods or powerful vacuum cleaners to filter the air from sawdust and dust.

To clean parts from dust and dirt with a jet of compressed air and apply adhesive for PVC film on the surface of the MDF facade using a spray gun, you will need a compressor with a 50-80 l receiver.

The room for applying glue must be equipped with an exhaust hood. Here, the details for MDF facades are stacked on a special table. It should rotate 360 degrees and have a spiked surface to allow excess adhesive to drip off. Work is done in a dust mask. In addition, this room must be well insulated, as particles of glue can settle on the PVC film, which is usually stored nearby, and after cladding they turn into unpleasant hard-to-remove spots on the surface of the MDF facades.

Equipment for the production of MDF facades in PVC film cannot be complete without a vacuum membrane press. There are a variety of thermo-vacuum machines for MDF facades from various manufacturers. However, they do not have a significant difference in the device and technology of pressing.

You should be aware that a membrane-vacuum press should always be supplied with a silicone membrane, with which it becomes possible to partially use the surface of the machine's desktop to save PVC film, as well as to perform some other production processes, such as laminating (veneering, laminating), production of bent facades from MDF and other operations.

After gluing with PVC MDF film, the facades are cut off on a special table, which must be covered with foam rubber to protect against scratches from accidentally falling grains of sand.

If peeling of the film occurs, or somewhere you need to tighten the corner, you will need a hair dryer with adjustable air supply and temperature, as well as a small electric iron, preferably with a flat surface without holes for steam supply.

When turning on various power units in the power grid, unpleasant power surges are possible, which can lead to the failure of expensive electrical equipment. Therefore, to connect to the network, for example, Russian voltage regulators Shtil should be used.

In addition to all of the above, the production of MDF facades will require the use of sweeping brushes to clean parts from chips; various emery sponges and emery skins, including those stuffed on bars, for grinding curves and flat surfaces, respectively; film cutter; packaging film; accessories for cleaning workplaces, including wet ones.

The main equipment used for the production of MDF facades is often a strong source of dust that enters the air and can be harmful to health. Therefore, work on it should be carried out in special dust masks and goggles.