Duct Production Market Overview
In modern construction, both cottage and multi-story, both residential and commercial, systems of active and passive ventilation, air purification systems or air heating are widely used.
But if earlier for such purposes voids in walls and ceilings were left, then in today's conditions the installation of ventilation communications is carried out using air ducts, or ventilation pipes - special hollow pipe-like structures to distribute the supply and removal of polluted air.
Air ducts are different and they can be classified according to various criteria: by shape (rectangular ducts and round), material (various plastics, galvanized steel, stainless steel, aluminum, polyester fabric, thermoplastic or other special rubber, silicone, fiberglass, etc. ) the presence of special properties (flexible, flame retardant, etc.), by the method of connection (using nipples or with special fasteners).
The two main types are considered rigid and flexible (sometimes called wireframe).
Manufacturing technology of ventilation pipes depends on their type.
The simplest option is, of course, round or rectangular ducts made of galvanized steel or aluminum: they are practical (cheaper than plastic, easier and faster to install, flame retardant and do not rust, have low aerodynamic resistance) and are usually used in ventilation systems of enterprises, offices, large cultural and entertainment complexes, educational, sports facilities, public catering organizations, as well as any other buildings with large areas, the operation of which involves active air exchange.
More complex - flexible ducts . They are used only in specific conditions: for example, in small rooms that have a complex configuration or are not suitable for the installation of large galvanized ducts or for active ventilation systems (hoods with fans, for the removal of acid fumes and hot air from industrial premises, etc.) .
Although, of course, flexible ventilation pipes are more expensive than rigid ones, it is necessary to start production from the second, as they are more popular and quickly sold.
The process of manufacturing air ducts, both rectangular and round, is completely unremarkable and represents, in fact, simple roll forming operations performed on special automatic machines.
It is much more important to choose the right equipment for the production of air ducts and organize the uninterrupted process of production and sale (marketing) of products.
Selection of equipment for the production of ducts
When choosing production equipment, it is necessary to be guided by three basic parameters of ventilation pipes: sectional area, rigidity and sectional shape from the point of view of market demand.
Moreover, if everything is clear with rigidity: flexible ducts are less in demand, but somewhat more expensive than rigid ones, which, in turn, are more readily purchased, although cheaper, then the area and cross-sectional shape are more complicated: for example, the air flow rate depends on them and, accordingly, , the noise level emitted by them when speed limits are exceeded.
In addition, there are other factors of choice: round ducts are easier and faster to install, do not have protruding parts, have greater strength and create less aerodynamic drag (due to a more natural shape).
In addition, round ventilation pipes are easier to manufacture, as they are fastened with nipples-latches.
But rectangular ducts have better airflow in a ventilated room if a large cross-sectional area is required, or installation is performed in difficult conditions (for example, over suspended ceilings).
Statistically rigid rectangular and round ventilation pipes are sold in approximately equal proportions, therefore, given that they are made generally of the same material (galvanized steel or aluminum from 0.5 to 1 mm thick), then for a more successful business you need to purchase both machines - both for the production of round and rectangular ducts.
A typical line for the production of air ducts of any section includes: an automatic machine for unwinding a rolled metal sheet, a feeding device, a device for straightening the sheet (the deviation of the diagonal of both the air duct and the workpiece sheet admissible by the technology is 0.8 mm - the ventilation pipe with a broken geometry produces a strong noise from the air flow, so all modern equipment is equipped with this option), a guillotine, cutting off the finished duct and an industrial CNC system.
The differences in the production lines for round and rectangular ducts consist only in the fact that in the first case the forming rollers are rolling rollers, while in the second there is a system for applying stiffeners, corner-cutting devices and an automatic bending machine with a rotary beam.
The cost of the line for the production of round ducts produced by one of the Russian manufacturers is 1 377330 rubles, or a little more than 46 thousand dollars (32.6 thousand euros at the current rate); the cost of a rectangular duct production line from the same manufacturer is 1, 687, 115 rubles, or 56.5 thousand dollars (almost 40 thousand euros at the current exchange rate).
As you can see, the total costs are small - 3 064 445 rubles. or a little less than 103 thousand dollars (75.5 thousand euros at the current exchange rate), and taking into account profitability even at 50%, which for such production is considered a rather modest and selling price from 120 to 3000 rubles. per linear meter (depending on diameter) for one-shift work and a five-day work week, net profit per month will be at least 700-800 thousand rubles, and payback, respectively, about six months.
Prospects for the development of a business for the production of air ducts
At first glance, the organization of services for the design and installation of ventilation systems seems to be the most obvious prospect. However, this is only the third step in business development.
The first step can be considered the manufacture of fixing and connecting accessories for air ducts: bends, nipples (couplings), plugs, insets, "umbrellas", galvanized mounting punched tape, etc. Such accessories are often made from scraps and other industrial wastes, as well as substandard goods.
The second direction is the gradual expansion of the range of products: rigid plastic, and flexible PVC (polyvinyl chloride), polyester, rubber, silicone and other ventilation pipes do not require large investments in equipment and will help you occupy at least the regional segment of the ventilation systems market.
And only after thoroughly preparing the production base and having worked steadily for several months, it is possible to hire engineers for ventilation systems (as you know, the services of the installers themselves - low-skilled workers - are not highly valued, as well as the services of workshop workers, who may not have any qualifications at all; unlike engineers in the specialty "Heat and gas supply and ventilation" - specialists with higher education, whose work is not cheap) and offer services for the implementation of ventilation systems, air purification and or air heating.
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Video on how rectangular ducts are made