Although materials from particleboard 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 ideally suited for the manufacture of furniture (primarily kitchen furniture). It is widely believed that MDF boards in terms of moisture resistance and their mechanical characteristics even surpass natural wood. In addition, unlike the latter material, they are resistant to various fungi and microorganisms, which means that they are safe and hygienic. Of great importance is the cost of this material. MDF products are 60-70% cheaper than similar products from solid wood and almost half the price of solid lumber. MDF boards can be processed in almost any way and veneered with MDF laminate, natural or synthetic veneer, paper resin film, PVC film. For all these reasons, they have become the most common and popular facade material.
Types of MDF boards differ for different reasons: by use (furniture, flooring, interior doors, suspended ceilings, wall panels, etc.), by type of coating (painting, PVC film, paper tar, veneer, etc.), by the presence of inserts (gratings, glass, etc.), in shape (flat, bent, etc.).
So, to organize our own production of MDF facades, you will need a room with an area of about 100 square meters. meters. It should be clean (with a ventilation system) and heated (the temperature in it should not fall below 15 degrees Celsius). The raw materials for the manufacture of facades are MDF boards, facing material (the most widely used PVC film) and adhesive composition.
The production process of facades from MDF consists of several key stages. First, a facade slab is cut using a format-cutting machine. The blanks must be highly accurate, free from defects (chips, cracks, etc.). At the next stage, the specified pattern and volume profile are applied to the plane and the ends of the blanks for the furniture facade, which is created on the milling table using a milling machine. Modern equipment allows you to produce profiles of almost any complexity. Then the parts are grinded using a vibration grinder. Production waste is removed by a vacuum cleaner, and a compressor is used to blow the facades after grinding and before application. Before facing, the surface of the facade must be carefully prepared and cleaned.
There are some of the most common cladding technologies in the manufacture of furniture facades. Lamination is the process of lining 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 with strength, water resistance and high temperature resistance. Lamination is the process of lining MDF with fully cured paper-resin films with preliminary application of the adhesive composition to the base plate. In this case, the film is glued to MDF, which simplifies the lining process (compared, for example, with lamination). In the manufacture of facades, which should have the highest protective and wear-resistant properties, postforming technology is used, which is the process of lining chipboard with laminated laminates or high-pressure plastics.
MDF facades are also covered with plastic, film or enamel, veneered with natural veneer.
Most often, a PVC film is used for facade cladding, since 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 facing, the facade goes under the press, and then excess is removed from it.
To organize the production of MDF facades, special equipment is required. It includes: a format-cutting machine (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 grinding machine (1, 5-2 thousand rubles), industrial vacuum cleaner (10 thousand rubles), piston compressor (5-7 thousand rubles), spray gun (5 thousand rubles), vacuum press (150-170 thousand rubles). The productivity of this equipment, which can be controlled by one specialist, will be about 20-25 square meters. meters per shift and about 100 square meters. meters of facades per week. Monthly production may be 400-450 square meters. meters. With an increase in the number of production workers to three people, productivity also increases significantly. Since the production process of MDF facades involves human participation, the quality of the finished product directly depends on the quality of the materials used for its production and on the qualifications of the employee.
The number of facade production in our country is increasing every year. But most of them cannot boast of high-quality products, since 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 customers give preference to quality products and are willing to pay more for it. Therefore, experts advise to bet on the optimal ratio of price and quality and not seek 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 (in the amount of about 1 million rubles), rental and preparation of premises for production, purchase of a batch of raw materials for a month of work (200 thousand rubles), business registration, other current expenses .
The market for such products is very wide. This includes various construction and repair companies, furniture stores and even private individuals who often order MDF facades directly from the manufacturer. The wholesale price of one square facade of MDF is about 1000 rubles. Profitability of such production reaches 28%. The payback period of the project is estimated at 6-8 months.
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