Sandwich panels are a universal building material, which is widely used in the construction of residential buildings, shopping centers, industrial buildings, as well as other facilities. Most of these products are three-layer.
They consist of a pair of facing sheets, between which a heater is placed. Sandwich panels are in great demand due to their unique characteristics - heat and noise insulation, resistance to mechanical stress, vapor tightness, ease of installation, the ability to operate in a wide temperature range, duration of operation, price availability. The production of sandwich panels is a pretty attractive idea for small businesses. That is why it is worth considering this option.
Features
This material is the most common three layer sandwich. However, instead of bread, additives and sausages, it contains insulation and hard material. For strength, these layers are glued together.
From the purpose for which the panels are intended, they are divided into wall and roofing. Wall sandwich panels can have a smooth cladding, profiled or complex profiled. Profiling is one-sided and two-sided. The upper layers can also be varied.
The production of sandwich panels is becoming increasingly popular, because the ease of installation significantly reduces the time spent on construction and finishing works. In addition, they are distinguished by their practicality and efficiency. All of the above allowed making this material very popular in the construction of multi-storey buildings, warehouses and small retail stalls.
However, there are also disadvantages. First of all, we are talking about the high cost of components in comparison with fiberboard, particleboard, corrugated board and others, but the cost of the finished product is quite low. Installation of finished panels is also very simple.
Attractiveness for business
All the above nuances make the production of sandwich panels profitable for small businesses. However, first you need to determine the type of product manufactured. At first, you should not take more than two. And when the company develops a little, you can develop a larger assortment.
The most popular is the manufacture of sandwich panels from sheets of galvanized steel, between which mineral wool is placed. They are used in the construction of buildings of various types (from small stalls to large residential complexes). In addition, they are acquired by the owners of cottages and private houses.
The production of sandwich panels is a very profitable idea for organizing a small business, especially if we take into account the reconstruction of old and the construction of new facilities. It is worth mentioning the main advantages of sandwich panels in comparison with traditional materials:
- this is a very light material - the weight of one square meter of the panel is only 3-4 kilograms;
- sandwich panels have a high degree of strength and impact resistance;
- they are made from a substance that is difficult to ignite;
- this material is highly resistant to moisture and chemicals, resistant to ultraviolet, frost and heat resistant;
- a sandwich panel is a kind of thermos that allows you to perfectly keep the heat inside the room, not letting in cold or heat outside;
- Each individual element is very simple to assemble in a single monolithic design;
- after the installation of the building, it gets a very attractive look, which allows not to carry out any additional finishing work;
- the presence of a wide range of colors and the ability to choose a specific surface design.
An important advantage of sandwich panels is their ease of use. Here we can talk about the incredible savings in associated costs associated with fitting and decorating walls, as well as other designs. In addition, their use allows to reduce the costs associated with transportation and installation to a minimum, since loading, unloading and assembly are completely dispensed with without the use of hoisting mechanisms and heavy equipment.
As an example, we can say that one KamAZ with a semitrailer will completely cope with the transportation of 8-9 change houses at a time of 2500 * 9000 * 3000 in disassembled condition. In just one working day from this material you can assemble a turnkey house with a total area of 100 square meters.
Project Features
It is necessary to purchase special equipment for the production of sandwich panels. The process itself is not difficult: the insulation is cut and formed to a specific size, a protective film is applied to the metal sheets, and then a profiled pattern. At the same time, a lock is made for the future panel. The process ends on the assembly table, where all the elements are connected together. Then it all goes under the hot press.
Equipment for the production of sandwich panels must be placed in a spacious room with high ceilings, for this you can even use a hangar, the area of which should be 600 square meters or more, with good lighting and ventilation.
Production Line
Everything is clear with the equipment, but a number of questions arise. For example, how to assemble a sandwich panel? Typically, the production line for their production includes an unwinding drum, an input and a cutting device, a loop control mechanism, a lifting and receiving tables, a device that is designed to apply glue and a protective film, a hydraulic press, a rolling mill, a set of tools for each type of profile. At the initial stage, when the equipment has not yet reached its rated capacity, it will be quite enough to hire four workers, and in the future it will take up to 12 people.
Manufacturing process
The line for the production of sandwich panels begins with the unwinding of steel coils. At the same time, the tracking and input device monitors the position of the steel sheet vertically and horizontally, directing it to the profiling machine, where the main and castle profiles are formed.
Profiling machines that currently exist are able to adapt to the production of various types of facings - roofing and wall. When the operation of the profiling machine is completed, the lining is fed to the receiving table, and then to the lifting table. Glue is applied automatically at the exit of the sheet from the profiling machine.
The production of sandwich panels is completed by the pressing process. The necessary thermal conditions and high pressure ensure low glue consumption and the most durable fastening of parts. At the moment, wall sandwich panels are in greatest demand, especially those that consist of a layer of thermal insulation and sheets of galvanized steel. An additional polymer coating provides them with a long service life. Another variety - roofing sandwich panels, which have excellently proven themselves as a reliable material.
Equipment
As with any idea of organizing production, a business plan is needed. Sandwich panels are made on special equipment. There is a special production line for this.The input material is insulating material, i.e. mineral wool, as well as sheet metal with a surface treated accordingly, and glue.
The sandwich panel production line works as follows: at the start of the process, the iron sheets are glued to an insulating lining, which allows to obtain a non-finite panel tape that can be cut into pieces by a saw to the required length.
Production Capabilities
Lines for the production of sandwich panels allow the manufacture of roofing and wall elements, where mineral wool is used as the insulating base. It must first be cut into lamellas, which must be turned ninety degrees before loading.
The production of sandwich panels is carried out using an automatic cutting machine designed for mineral wool, which itself will cut lamellas, turn, and then lay in a row on the input conveyor. The wall panel can be made with profiling in the form of a microtrapeze or a low trapezoid. The roofing panel must be profiled in the form of a deep trapezoid. The production capacity is 1000 linear meters per eight-hour working day.
Part of the equipment
The following equipment is included in the production line:
- roll forming machine;
- the working platform on which insulation is loaded;
- input insulating conveyors;
- equipment for unwinding sheet metal;
- laminating machine;
- a saw for cutting panels of the desired length;
- at the exit, special outlet tables;
- trolleys for manipulating panels;
- special bending machine;
- power tools and hand tools for the production of panels themselves, tin parts and the work of the assembly team.
Mineral Cutting Automation
The mineral wool cutting line must be fully automated. On the input slave conveyor, maintenance personnel lay a pallet with plates of material. The conveyor transports it to a cheaper, where the plates will be discharged one at a time to the cutting machine.
The cutting unit can be reinstalled taking into account the different widths of the required slats. Next, the cut lamellas are redirected using strip and roller conveyors to the cross over equipment, where they are turned 90 degrees. After that, the lamellas are sent to the separation equipment, where they will be stacked in a row, and then redirected to the input conveyor of the laminating machine.
Bending machine
This unit is made in the form of a welded steel construction of racks on which the strips are welded - lower and upper. Between them is a bent sheet of iron. A bending stamp is fixed on the lower bar (by means of a kinematic lever mechanism), which allows bending sheets.
Business development opportunities
Sandwich panel production at the moment can be deployed anywhere in the country in just thirty business days. Raw materials for these tasks are supplied by several manufacturers and suppliers.
The issue of licensing products can be solved very simply and quickly. The cost of sandwich panels, or rather, one square meter of finished products, is approximately 500 Russian rubles, and the selling price starts at 1000 rubles.
Practice shows that a correctly prepared business plan for the production of sandwich panels allows you to create a company, the opening of which will pay off in fourteen months, and this is a good indicator for the construction industry.
