Drywall without exaggeration can be called one of the most popular and sought-after building materials that are used in the renovation of apartments, offices, workshops and warehouses. It breathes and allows you to hide all existing surface imperfections, providing an ideal basis for applying the final layers of putty, paint, wallpapering, etc. Also, with the help of drywall, any curly elements (columns, niches, arches) are created that complete the look of the interior. When installing drywall, you can not do without the use of a metal profile, which will become a reliable basis for the future design.
Making a metal profile at home is a costly business at first, but at the same time quite profitable. Moreover, equipment for the production of roller rolling profiles can be made by hand. More on this later...
Profile Making Machine
The production of galvanized steel profiles does not require great skills and knowledge. You will need a special profile bending machine, which is selected (or converted) for the type of profile that you plan to produce.
To acquire a rolling machine for a profile, you can go in two ways:
- Make a rolling machine with your own hands, which can be upgraded and converted to any type of manufactured product from galvanized sheet.
- Buy ready-made equipment for the production of a profile for drywall.
The most popular machines among gypsum board manufacturers are those with a single strand production line. They give out a certain type of profile (for example, ceiling or guide) at an average speed of 10 running meters per minute. Therefore, in one working hour, the equipment for the production of profiles for drywall allows you to produce up to 500 running meters. This means that after a continuous 8-hour working day, about 4,000 meters of products, completely ready for sale, can be sent to the warehouse. In a month, the volume of finished products can reach up to 88,000 linear meters!
On average, the market price of a rolling machine fluctuates around $4,000. At the same time, the supplier company often not only ensures the delivery of the order, but also conducts comprehensive training on the correct use of the machine, as well as complete adjustment of the equipment and its further repair (if necessary).
But if you do not yet have the opportunity to purchase equipment for $ 4,000, you can make your own machine with your own hands. It may be slightly inferior in performance. For example, it will not have a guillotine and the workpieces will need to be cut in a separate operation. But in general, it will be possible to organize profitable production at home.
How to make a rolling machine for a profile with your own hands
Let's consider a 3D model of a rolling machine for the production of a 29x27 c-shaped or u-profile.
For the manufacture of the machine you will need: metal, bearings, a lathe or a familiar turner with a lathe. Pay attention to the design and device of the rolling machine.
Looking at the picture, the first impression is alarming. And if you look into the details, then there is nothing complicated.
Scheme of the device of the model of the profiling rolling machine
The machine consists of a table on which a worm gear motor NMRVP-063 is fixed. There are also 7 stands fixed on the table. The first receiving stand is already shown in this figure:
- Channel table.
- Worm gear motor NMRVP-063.
- The first receiving stand.
- Chain transmission to the first cage.
Each cage consists of a few simple parts:
- Cage body.
- Self-aligning bearing unit UCST 204.
- Self-aligning bearing unit UCFT 204.
- lower and upper shafts.
- Lower and upper rolling rollers.
- Chain drive sprocket Z=16.
- Guides.
- Struts.
- Adjusting bolts M12X70.
As can be seen above in the figure, all stands are interconnected by a chain drive.
It should be noted that the rollers are removable and mounted on the shafts. This allows you to re-equip the machine for a different type of produced profile. If desired, with the help of new rollers, it is possible to modernize the equipment for the production of LSTC profiles. The construction of houses using LSTK technology is actively gaining popularity in the field of prefabricated buildings.
Technological process of production of drywall profiles
The principle of operation can be easily understood by looking at the end of the article. A sheet of galvanized metal is rolled through a series of rollers, each with a different mould:
Thus, with the help of rolling rollers, the workpiece is gradually transformed into the shape of the finished product.
In order to familiarize yourself with the equipment device in detail, we recommend with all sizes and descriptions of the nodes. This archive contains a 3D model of a metalworking device, which can be disassembled to the smallest bolt or washer and viewed. In the same place, you can take all the dimensions of the parts, and then actually make the machine according to the model no worse than according to the drawings. Perhaps this format is even better than the drawings. 3D model file formats:
- *.sldasm is the main format of the paid program "SolidWorks" (this format is also supported by the free program for viewing 3D models - eDrawings, which is already included in the archive).
- *.step is a standard format for exchanging 3D models between different 3D editor programs. This file format is supported by almost every 3D editor (for example: free FreeCAD, AutoCAD, 3D-Max, Blender, etc.).
Varieties of metal profile
Drywall profile is divided into the following types:
- Used to create racks (CW type. The most common varieties on the building materials market are CW-50, CW-75 and CW-100 profiles).
- Guide (type UW. Brands UW-50, UW-75, and also UW-100).
- Wall-mounted (UD type. But often only UD-27, made of 81 mm steel, is used).
- Ceiling (type CD. Brand CD-60, which is made of galvanized steel 123 mm wide) is most widely and often used in repairs.
The profile varies in its thickness, width, weight and other parameters. Each of these profiles is made from coils of galvanized steel strip, also known as strip.
As you can see, the business of making drywall profiles at home has a fairly high profitability. If you have start-up capital that will cover all start-up costs, while also having an established network for selling finished products, you will be able to reach self-sufficiency in 7-8 months.
This type of product is always in demand. If you master all the nuances of its production technology, you can provide yourself with a stable income for many years.
Start your own production and sales business right now, and the final profit will be the best reward for all your hard work!
Profile for drywall
A business based on the production of metal profiles for drywall is very popular today. This state of affairs exists because drywall sheets (GKL) are widely used for interior decoration. And for the installation of GKL, metal profiles are used.
Drywall profile manufacturing is a profitable business. Their manufacture requires compliance with the technology, as well as the purchase of the necessary equipment.
Before starting the production of profiles for drywall, like any other production, you need to make sure that the products are in demand on the market. Metal profiles are very widely used in construction today, as they have the following advantages:
- can be used in construction even on “bad” soils;
- when using profiles, you can do without the use of heavy construction equipment;
- high energy-saving effect of the material;
- environmental friendliness;
- a certain degree of elasticity, which allows it to withstand a seismic load, up to 9 points on the Richter scale accepted throughout the world;
- anti-corrosion and fire-resistant properties;
- strength and durability;
- installation of the structure can be carried out at any time of the year.
Possessing such characteristics, metal profiles are in great demand in any construction. Therefore, the business of making them will definitely be quite profitable.
Required Equipment
The production of profiles for drywall involves the purchase of appropriate equipment, consisting of machines. Such equipment is produced by the German company Knauf. Thanks to their high quality, Knauf and its machine tools have become very popular all over the world.
Profile machines
A manufacturer such as Knauf produces machines that have the following advantages:
- Ease of Management;
- excellent quality and high reliability;
- used for production lines of various capacities;
- allows you to produce a profile in a short time, as well as with minimal financial investment.
With such advantages, Knauf machines as equipment for the production of metal profiles are used by representatives of medium and small businesses. The manufacturer, using Knauf equipment, will produce only high-quality products that meet all the technical requirements for profiles for plasterboard sheets.
The advantages of the machines of this company are as follows:
- simultaneous release of two paired products;
- it is possible to adjust the equipment using calibration stands;
- product length is unlimited;
- reliability and simplicity of design;
- small dimensions and low weight of the machine;
- the possibility of installing additional equipment.
The resulting products can be used in any area of construction.
line shaping
When creating a profile production line, there are no strict requirements for the parameters of the leased premises. Machines can be installed in large industrial premises or small workshops.
Note! The most important aspect in such a business is the observance of the technology for the production of metal elements to create a frame for drywall sheets. It is under it that all equipment is selected.
Creating a line according to European standards will help you organize a business with a high level of productivity, which, moreover, will pay off very quickly.
production line
The use of high-quality equipment and raw materials, as well as compliance with production technology, will allow you to produce high-quality products and create real competition for less conscientious manufacturers.
So, to organize the line you will need the following equipment:
- roll forming module;
- pneumatic guillotine cut. It can be volatile or stationary. Cuts products after the completion of the profiling process;
- automatic control system (ACS);
- optional touch panel for the operator. With its help, you can greatly facilitate the process of entering parameters for the production of products and controlling this process.
Depending on the need, the line can produce closed or open type products.
Machines for profiles can carry out both running-in products and punching holes in them. In this case, the length of the final product can be adjusted.
In addition, there are different modifications of machines designed for the manufacture of different types of profiles. With their help, you can produce rack-mount (50x50, 75x50 and 100x50), as well as profile guides (50x40, 75x40 and 100x40).
Raw material requirements
The production of drywall profile uses high quality steel as raw material. This raw material has the following requirements:
Strip
- steel must have a thickness of at least 0.55 mm;
- the presence of a galvanized coating on the source material. This will further allow the products to successfully resist the action of various aggressive substances;
- steel compliance with the basic requirements of GOST 14918-8
Note! Very often, unscrupulous manufacturers under the guise of high-quality material sell inexpensive metal with electrolytic galvanization. Therefore, be very careful and always ask suppliers for a certificate confirming the quality of the purchased material.
The source material is taken from coiled steel by cutting it into strips. Approximately 600 metal strips 3 m long can be made from one strip.
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Galvanized profile for drywall today is in demand in any production of various designs. The demand for it is constantly high, therefore, a business on this product can be built quite profitable.
Business organization
To organize a business, it is necessary to register the activity with the tax office. Production can be organized as an individual entrepreneur, or as a limited liability company. If you plan to work with large suppliers, it is better not to take risks and immediately register an LLC. Sometimes large companies prefer to deal only with legal entities.
You also need to choose an appropriate taxation system. A lawyer or accountant may recommend this. Most often, entrepreneurs stop at a simplified system, especially when it comes to starting a business. If you wish, in the new reporting year you will have the opportunity to switch to a more convenient taxation system.
When registering, you must specify OKVED 27.33 production of bent steel profiles.
Premises and staff
To open a workshop, you will need a room of about 300 square meters. m in the industrial area. It is advisable to rent a room at the factory, then it will suit all production parameters. The area must be divided into a workshop and a warehouse for raw materials and finished products. Despite the fact that drywall profiles are lightweight, the finished products are quite large.
To establish uninterrupted work, you will need a technologist, craftsmen, an operator and a production manager. It is advisable to take such specialists who, if necessary, can replace each other.
Profile types
At its core, a drywall profile is a mounting base for sheets that are used in various types of finishing work. In accordance with the purpose of the profile, the following types of it are distinguished:
- angular;
- beacon;
- ceiling;
- guide;
- rack.
The most popular is the guide PPN 27 * 28 and the ceiling PP 60 * 27, because they form the basis of the plasterboard frame. They are used for wall cladding, installation of suspended ceilings, interior partitions and more.
Raw material
For the production of drywall profiles, the business plan must include the purchase of special steel. It must be at least the second class with a thickness of 0.3-0.6 mm, galvanized, thin sheet. It is sold in the form of ribbons, rolled into rolls. Moreover, for the ceiling profile, a tape (strip) with a width of 123 mm is needed, and for a guide - 81 mm. A ton of such tape will cost about 34 thousand rubles. From it you can make 600 three-meter profiles.
Production process
The production of a drywall profile is carried out on a roll forming machine and consists of several stages.
- Setting up the equipment in accordance with the parameters of the raw materials used and the type of profile being produced.
- Filling the strip or workpiece into the machine.
- Profile making and cutting.
Not all these stages are carried out on one machine, so it is easier when there is a ready-made automatic production line in the workshop.
Production lines
The production line can be of various configurations depending on the profile manufacturing plan. For example, if you plan to specialize in a ceiling profile, a single-strand line is purchased. You can purchase domestic equipment, the price of which is 480 thousand rubles. Such a line operates in a semi-automatic mode, has a capacity of up to 20 linear meters per minute and produces a profile of the CD type.
If you plan to specialize in several types of drywall profile, you can buy a roll forming machine that can produce both ceiling profile and CD type guide profile. The price of such a semi-automatic machine is 770 thousand rubles. It produces up to 10 running meters per minute.
In addition to the fact that the workshop should have a production line, the business plan should include the purchase of a beam crane, with which it will be possible to install raw materials on the uncoiler of the machine, and carry out other unloading and loading operations.
quality requirements
For a business to be successful, it is important to produce products of the right quality. For production, it is allowed to use raw materials with a thickness of at least 0.55 mm. Steel must be galvanized without fail, since profiles are often exposed to aggressive materials during operation. In the manufacture, steel must be used that complies with GOST 14918-8.
Sales of finished products
A business plan must necessarily take into account possible options for selling the finished profile. Despite the fact that the demand for these products is high, the marketing plan must be thought out in detail. There are three main channels through which finished products are sold:
- contractors and construction companies;
- contractors and renovation companies;
- private persons.
And if you can work directly with the first two channels, then retail sales can be organized through construction markets, shops, hypermarkets. Hypermarkets are the best help to implement the sales plan, because they have a consistently high turnover.
Economic calculation of the project
The expenditure part of the project consists of the following capital investments:
- renovation of the premises - 300 thousand rubles.
- purchase of raw materials - 500 thousand rubles.
- purchase of inventory and hand tools - 50 thousand rubles.
- purchase of a beam crane - 160 thousand rubles.
- delivery, installation, commissioning - 150 thousand rubles.
- purchase of a production line - 770 thousand rubles.
- other expenses - 50 thousand rubles.
In total, the launch of the project will require at least 2 million rubles. As for the revenue, it comes exclusively from profile sales. If the production line is loaded by 55%, then up to a ton of raw materials can be processed per day. Production can pay off in two or three years. Keep in mind that you will have to work with ever-increasing competition, as the availability and ease of production attracts many entrepreneurs. Due to increased competition, the profitability of production today has decreased to 18%.
Drywall is currently one of the most popular finishing materials. It is used in the construction of multi-level ceilings and for the arrangement of interior partitions. Its flexibility and ease of use allow for do-it-yourself installation even for those who are quite far from the building craft, and therefore this material has become widely popular among home craftsmen.
However, most drywall constructions cannot be realized without the installation of a crate, and therefore the production of drywall profiles these days can be a good business.
The machine for production of profiles for gypsum cardboard.
Production of galvanized profile
In the implementation of finishing works, several types of profile are used.
As a rule, this is:
- guide,
- ceiling,
- rack,
- angular,
- to which, in certain cases, a beacon is added.
In the installation of drywall structures, the most popular are the ceiling and guide profiles, since they form the basis of the frame. (See also the article Drywall Profile Designs: Features.)
The raw material for their manufacture is thin galvanized steel of at least the second class, which is supplied to the market in strips (strips) rolled into rolls.
Sales of finished products
To date, the demand for galvanized profile is high and stable.
Naturally, any business plan for the production of drywall profiles must take into account the places of sale of finished products.
In this case, buyers are divided into three groups:
- Construction companies whose main activity is the construction and repair of housing, as well as commercial real estate.
- Firms engaged in the repair of their premises.
- Individuals who are engaged in the purchase of a profile for repairs in their homes.
As a rule, finished products should be sold through various construction stores, however, sales through construction hypermarkets have the most prospects, since at the moment they have the highest turnover.
Related article: Primer for drywall or create beauty yourself
Photo of various profiles for drywall.
Profile production equipment
The gypsum board profile production line consists of a roll forming machine, which is designed to process thin steel coils. (See also Drywall Installation Features.)
The device of such a machine includes the following elements:
- Profile bending module.
- Stationary or flying pneumatic guillotine for transverse cutting of the product after the profiling process is completed.
- Automatic control system.
- Optional (touch) operator panel. It is not a mandatory attribute, however, it makes it much easier to enter parameters and control them, since ten different operating modes can be entered into the machine's memory through it.
Different types of touch panels of the operator.
Advice!
If profiles are rolled not from strips, but from blanks corresponding to the required width and length, then there is no need for an automatic control system and a guillotine.
This will significantly reduce the total cost of the equipment.
If coiled steel is used in the work, then two people are needed to ensure the correct functioning of the system. One of them, the operator, fills the strip, while setting the desired operating mode to the control system. This refers to the length of the products, their number and speed of work. The second worker monitors the correct functioning of the machine.
With flying cut, automatic drywall profile production line will increase productivity by 25-30% compared to stationary cut. At the same time, the cost of the products obtained, respectively, is reduced.
Machine for the production of a profile, equipped with a flying cut.
Manufacturing process
For the manufacture of a profile for drywall, thin-sheet galvanized rolled steel should be used, the thickness of which can vary between 0.3-0.6 mm.
The instruction provides for the following steps:
- Performing equipment settings. At this stage, you should set the thickness of the sheet used in the machine settings in the range of 0.3-0.6 mm.
- Filling the device with a workpiece or strip corresponding to the set thickness and width.
- Forming a profile from a workpiece, which is carried out in the working area of the machine, as well as cutting finished products of a certain length using a pneumatic knife.
