Manufacturing technology of interior doors from MDF. All about making interior doors with your own hands

The segment of the market for the production of interior doors will always be in demand. Good, solid interior doors will always find their buyer and give a good profit.

So what does it take to start a business for the production of oak and other wood interior doors from timber?

Types of doors

Before purchasing equipment and renting premises for the production of wooden interior doors, it is necessary to determine the range of products produced in the future.

Wooden doors are of the following types:

From solid wood of various species... Such interior doors are produced from wooden blocks of high-quality expensive woods, which are spliced together. The resulting solid wood is sanded, calibrated and varnished in the required shade. Mosaic splicing and tinting is possible even in bars. In such cases, the resulting array is coated with colorless varnish. Whole pictures are laid out for VIP doors.
Veneered (veneered) doors... The production of such interior doors consists in revealing doors made of boards, solid wood or made using the technology of a wooden frame, which is filled with honeycomb cardboard, with veneer made of valuable wood. They are in no way inferior in appearance to doors made of natural solid wood, but they are less durable, more capricious in operation and, if not properly maintained, will require an early restoration. The owner of a workshop for the production of wooden interior doors, when releasing products of this type and providing a guarantee, must keep a veneer suitable for the sold interior doors in order to eliminate deficiencies during the warranty period;
Laminated... It is an economy class door in which a laminated film of the texture and color chosen by the customer is applied to the wooden frame. The center of such doors depends on the method of coating and its composition.

In this article, we consider the technological scheme for launching a workshop for the production of interior doors from sawn oak.

Range of products

door frames;
platbands;
interior doors;
products per running meter - door array, etc.

Product distribution channels

The organization does not plan to carry out independent installation of its products, the finished products will be sold through such sales channels as: 1) wholesale of interior doors to construction organizations that are engaged in the repair of offices, apartments, etc .; 2) retail outlets selling building materials, windows and doors; 3) construction hypermarkets and large specialized stores.

Raw materials for production

Planned raw materials for the production of interior doors:

Timber... The cost of a cubic meter of sawlogs, for example, oak, will be approximately 5000-7000 rubles per cubic meter.
Glue for butt splicing of beams... Such an adhesive is Kleyberite 303.2. Its consumption is 160 grams per square meter. The price for a container weighing 1 ton will be approximately 110 thousand rubles.

Equipment for the production of

You will need the following equipment for the production of interior doors:

Band sawmill... You can, of course, buy ready-made boards, beams, but then the doors will be very expensive. Price from 110-130 thousand rubles.
Drying chamber... It is necessary for faster drying of wood. In general, this process will need to be approached with all seriousness, since if you do not dry the wood, then the doors will squint, and this will lead to negative reviews of your products and general dissatisfaction of your customers. Who needs such products, in which cracks are formed later due to the continuation of drying? Nobody.
Tenoning machine... About 200 thousand rubles. Designed for precise trimming, cutting mini-spikes on workpieces for their subsequent splicing. Those. he makes "locks".
End Fusion Press... From 220 thousand rubles. As a matter of fact, this press is just engaged in splicing through the ends and cuts that the previous machine made.
Pneumatic wood board splicing press... Thanks to him, the entire shield is formed from the previous received parts. From 200 thousand rubles.
Panel saws... 220 thousand rubles Designed for sawing sawn timber. They are used for longitudinal, transverse and angle sawing of sawn timber.
Milling and copying machine... About 150 thousand rubles. Produces exact copies of wooden parts, which saves a lot of time when producing similar parts.

The total cost of purchasing equipment (without a dryer) for the production of interior doors will amount to about 1.5 million rubles. Dryers are not sold ready-made, but are made to order. Therefore, we cannot indicate their price here, since prices vary greatly.

Production technology

The entire technology of manufacturing interior doors consists of the following production stages:

Sawing of raw materials;
Drying of workpieces;
Dissolution of unedged boards;
Cutting of thorns and splicing of blanks;
Cutting and sizing of defective spots;
Glue is applied and the workpieces are spliced into a wooden board;
Sizing of the canvas;
Grinding the coating;
Varnishing and applying a special solution;
Final drying of the finished product.

Interior doors made of MDF have become very widespread in recent years. After all, chipboard is a material containing urea-formaldehyde or phenol-formaldehyde resins, and wood is expensive, easily absorbs moisture, and is sensitive to fungal diseases. In addition, MDF interior doors look great, are relatively inexpensive, and do not pose any danger to the health of people and pets - they can be installed both in the bedroom and in the children's room. Add to this high strength and durability, absolute inertness to the environment, and you will understand the reasons why MDF doors are popular.

The DEMFA company, as a manufacturer, has been practicing the production of interior doors from MDF since 1999. For painting, we use only moisture-resistant polyurethane coatings, as well as high-quality patina and water-based acrylic varnish. It is the concern for the health and wallet of the consumer that makes our products popular. The products of the DEMFA company are represented by several model directions of door panels, each of which can be additionally modified to suit your interior design. We are also engaged in the production of moldings and capitals, doors for the delivery of residential buildings (construction doors).

We paint interior doors from MDF in two basic colors: WHITE and CREAM. However, the client can choose any other shade from the RAL catalog, where 213 different color schemes are presented. Capital and other molded products can be painted in the same color. DEMFA does not recognize any framework in terms of interior design. A weak and strong patina of interior doors in various shades (basic - silver and gold) is also possible - it looks very impressive!

Since the production of MDF doors in the DEMFA company is carried out according to a weekly planning scheme, we carry out even large wholesale orders very quickly. Typically, the waiting period varies from one week to a month. Moreover, our warehouse has a large stock of the most popular items in two main colors (WHITE and CREAM) - if you are looking for a standard solution for an office or home that will fit into any interior design, you can pick up the ordered interior doors almost a day. order! In addition to standard models, we manufacture products to order:

Not standard in height, width,
coloring and patinating the sides in a different color,
full or partial patination of the door leaf and moldings,
drawing patterns on the door leaf using milling technology.

Interior doors are a necessary part of residential, industrial and office premises. When choosing door leaves and additional elements, you need to know how and according to what rules they are made, as well as understand the advantages and disadvantages of the materials used in the production of doors. Modern manufacturers use high-tech equipment that allows them to produce a large number of high quality products with various types of coatings and modern designs.

Manufacturing technology of interior doors

Doors serve to separate the various functional parts of the room and provide sound insulation, protection from extraneous odors and excess moisture. Methods for making door leaves and additional elements depend on the materials used in the production. The most popular doors are made of solid wood or prefabricated on a wooden frame. Glass inserts make the canvas partially permeable to light and visually expand the space of rooms or corridors.

The most complex and multi-tier technological process takes place in the manufacture of doors using wooden elements. The fact is that timber that has not gone through the full cycle of preliminary drying and processing is prone to warping and cracking. To avoid losses in the quality of the final product, it is necessary to pay great attention to the preliminary preparation of wood using certain technological methods. The process of manufacturing interior doors includes the following steps:

Pine timber (round timber) is cut into blanks using band saws with automatic log feed.
Logs are sawn into workpieces of the required thickness
Billets are processed with high temperature and steam in drying chambers to avoid uneven drying and warping of wood. At the end of the drying process, a mandatory moisture control is performed.
Drying of lumber is carried out under the influence of steam and high temperature
The dried workpieces are cut into bars of technological section and defective fragments (chips, knots, cracked and rotten areas) are removed from them, which can affect the quality of the door frame and door leaf.
Defective areas are cut out of the workpiece cut into a bar
Then the workpieces are spliced using spikes, glue and a vertical press into a shield, from which, after drying and trimming, a door leaf is obtained.
With the help of a vertical press, a panel blank of a door leaf is obtained
After grinding, the sheet is covered with three-layer veneer or MDF panels with one veneer layer and placed in a gluing press.
At the next stage, shaped decorative elements, panels or openings for glazing are cut out with a milling and engraving machine, and after assembly, the door leaves are covered with three layers of varnish with intermediate and final grinding.
Panel elements or glazing are installed during final assembly.
After final drying, the products are packed, supplied with fittings, if necessary, and sent to the consumer.

The technological sequence of manufacturing doors may be different and it depends on the material, equipment and product design. For example, for expensive doors made of solid valuable wood species, the use of veneer is not typical and they are made using complex CNC machines, and in budget doors, corrugated cardboard inserts and cheap lamination films are often used.

It is important to note that in the factory, the hardware is usually not installed on doors with a symmetrical decor, since during installation at the consumer's site, the product can open both to the left and to the right, respectively, the hinges and handles are installed by the installers locally.

Video: making doors from solid wood

Rules and regulations for the production of interior doors

Door blocks are manufactured on equipment that is located in significant production areas. Certain requirements are imposed on these premises, as to industrial facilities, which include timber warehouses, dryers, a processing shop, a paint and varnish section and a finished product warehouse. Each production site is equipped according to the rules and regulations, in accordance with the technical conditions for a specific task. The main requirements for production facilities for the manufacture of doors are the following criteria:

availability of free access roads;
buildings should be provided with stable temperature, humidity, natural and artificial lighting;
electricity, heating, ventilation, water supply and sewerage must be equipped;
the premises must be equipped with fire alarms, fire extinguishing equipment and emergency exits;
at workplaces, it is necessary to ensure safe working conditions;
paint and varnish areas should be isolated from the rest of the premises and equipped with fresh ventilation.

The personnel are obliged to undergo professional training and education on labor protection, fire and electrical safety standards, as well as to undergo unscheduled, repeated and initial instruction at the workplace.

The production area must be equipped in accordance with the standards

The main standard for the production process is the technological documentation, which is based on the Technical conditions for the production of TU 5361-001-58037723-2015 "INTERIOR DOORS, PARTITIONS AND FITTINGS TO THEM." This document sets out the requirements for the design of interior doors, the quality of the material and coating of the front surface, as well as environmental requirements. The regulations specify the procedure for acceptance of finished products, certification and installation of the warranty period.

It is important for the buyer to have a certificate, a warranty period and the compliance of the door, frame and additional elements with the requirements of technical conditions, since this confirms the quality of the product and allows you to count on a long service life.

Current GOSTs for the production of interior doors

The technical characteristics of doors are determined by standards that set general technical conditions or methods for determining the physical parameters and dimensions of the finished product. Many manufacturers create products in non-standard sizes, but with strict adherence to quality requirements. The consumer may be interested in the list of regulatory standards used by manufacturers of interior doors, namely:

General requirements for wooden doors with a list of regulatory documents are established by GOST 6629–88, and requirements for wood products are set out in GOST 475–78.
Design options for interior doors, their types and sizes are specified in GOST 24698–81.
Requirements for extensions, fasteners and hinges are assigned by GOST 538–88.
Methods for determining sound insulation, heat transfer resistance and air permeability are regulated by GOST 26602.
The flatness of the door leaf is determined according to the ST SEV 4181–83 standard.
The reliability test methodology is set out in ST SEV 3285–81.
Resistance to shock loading is carried out according to the method specified in ST SEV 4180-83.

The accompanying documents for finished products must contain the symbol of the door leaves, for example, U05195 VERSAL pat. 1014 dec / oro door leaf D3 91x 230 L, which means the following door parameters:

article - U05195;
the trade name of a particular collection is VERSAL;
type of finish / color - pat. 1014 dec / oro;
product name - canvas;
product model - D3;
width and height of the canvas - 91x230;
opening type, left - L.

Before ordering doors, it is necessary to carefully measure the door openings in order to select the required frame size, door leaf and the required number of additional elements. For interior doors, there are standard dimensions of openings with the corresponding designation according to SNiP and this approach facilitates the choice of the door frame according to the table.

Table: the ratio of the dimensions of the opening to the dimensions of the door leaf

Existing regulatory documents guarantee a high level of product quality, standardization in size and compliance with environmental requirements, in addition, the consumer can determine the conformity of the product properties declared by the manufacturer to the quality and price level.

Material for the manufacture of interior doors

In the production of interior doors and partitions, modern materials are used that are environmentally friendly, durable, lightweight and have a long service life. These include metal-plastic and glass doors, the frame for which is an aluminum profile, and the filler is plastic panels or tempered triplex glass with a matte finish. But traditional doors with a timber frame and inserts of glass, MDF panels and panels occupy the main niche in the market. In the manufacture of such products, the following materials are used:

Pine timber cleaned from defects with a moisture content of not more than 8%, spliced into a thorn using glue pressing.
High density particle board.
Natural veneer made of various types of wood with a thickness of 0.6 mm.
Laminating film imitating precious wood species.
Laminating film gives doors a natural wood grain
MDF panels of various thicknesses are used for cladding door leaves and creating panel elements.
Frosted glass, triplex or tempered, is used for light-scattering and decorative inserts in the door leaf.
Corrugated cardboard is used in budget options, as soundproof inserts in the canvas between the frame beams.
Corrugated board is used for insulation and soundproofing of inexpensive door leaves
Wax and waterproof coatings, tinting compounds and varnishes.
Glue of the type "Kleiberit 303.2", MERITIN Glue D3 and others, is used for industrial gluing of fragments of sheets, door frames and additional elements.

The production of inexpensive doors is based on the use of chipboard, laminated film, corrugated cardboard and MDF, while more expensive products use solid wood with milled elements, panels and tempered glass inserts.

Six years of experience in operating veneered paneled doors by the author of the article shows their significant reliability. But in rooms with high humidity, I would like to recommend various types of laminated doors with an additional waterproof coating. After four years of service in the bathroom, on the internal veneered sheet, despite the treatment with liquid wax twice a year, whitish streaks and drips from exposure to steam and condensate appeared. There was a need for cosmetic repairs, so it was necessary to sand the plane of the door leaf, degrease it with a solvent, cover it with a tinting compound and waterproof varnish in two layers. To a lesser extent, the same problem appeared in the laundry room, and as for the rest of the doors, minor damage to the veneer and scratches were eliminated by gluing and processing with hard, tinted wax of various shades. After such minor repairs, the canvases, boxes and accessories acquire their original appearance and serve for more than six years. In the conditions of summer cottage use, wooden doors covered with waterproof varnish serve for more than eight years. At the same time, warping and drying out does not occur in conditions of temperature drops and changes in humidity. But it should be noted that the best option for suburban construction are metal-plastic doors and frames, which do not change their properties and retain their geometry under changeable weather conditions.

Equipment for the production of interior doors

The most costly production of interior doors, in terms of the amount of equipment required, is the manufacture of wood products. Manufactured products made of metal-plastic and glass require a large number of components and a small number of machines for cutting frames and processing glass sheets. Lumber processing is more saturated with machine tools, presses and other equipment. Consider the equipment that is used for the production of wooden doors:

Sawmills and band saws used for cutting round timber.
The sawmill allows you to get lumber of the required thickness from the round timber
Steam chambers for drying lumber.
Industrial drying chambers allow you to bring the lumber to the required moisture level and avoid warping of the workpieces
Equipment for the production of veneer.
Tenoning machine for frame and door leaf.
Using a pneumatic press, the door leaf is glued
Circular saws and panel saws for cutting workpieces to size.
Copy-milling machines with programmed control for decorating door leaves.
Shaped and paneled elements are produced using milling machines
Grinding machines for intermediate and finishing of products.
Paintwork equipment.

The list of the production park can be expanded due to the use of various technological and design solutions in the production of interior doors and component parts, which has a positive effect on the consumer properties of the final product.

Video: production of interior doors

We examined some types of interior doors, production technology, as well as regulatory documents and requirements governing products of this type. For the correct choice of doors, it is necessary to know the properties of the coating and the material from which they are made. High-quality equipment and adherence to production technology ensures resistance to external influences and a long service life of products. A wide range of design solutions allows you to give the living space an individual look and unique style.

Manufacturing technology of interior doors

Pine timber (round timber) is cut into blanks using band saws with automatic log feed.
Logs are sawn into workpieces of the required thickness
Billets are processed with high temperature and steam in drying chambers to avoid uneven drying and warping of wood. At the end of the drying process, a mandatory moisture control is performed.
Drying of lumber is carried out under the influence of steam and high temperature
The dried workpieces are cut into bars of technological section and defective fragments (chips, knots, cracked and rotten areas) are removed from them, which can affect the quality of the door frame and door leaf.
Defective areas are cut out of the workpiece cut into a bar
Then the workpieces are spliced using spikes, glue and a vertical press into a shield, from which, after drying and trimming, a door leaf is obtained.
With the help of a vertical press, a panel blank of a door leaf is obtained
After grinding, the sheet is covered with three-layer veneer or MDF panels with one veneer layer and placed in a gluing press.
At the next stage, shaped decorative elements, panels or openings for glazing are cut out with a milling and engraving machine, and after assembly, the door leaves are covered with three layers of varnish with intermediate and final grinding.
Panel elements or glazing are installed during final assembly.
After final drying, the products are packed, supplied with fittings, if necessary, and sent to the consumer.

Video: making doors from solid wood

Rules and regulations for the production of interior doors

availability of free access roads;
buildings should be provided with stable temperature, humidity, natural and artificial lighting;
electricity, heating, ventilation, water supply and sewerage must be equipped;
the premises must be equipped with fire alarms, fire extinguishing equipment and emergency exits;
at workplaces, it is necessary to ensure safe working conditions;
paint and varnish areas should be isolated from the rest of the premises and equipped with fresh ventilation.

The production area must be equipped in accordance with the standards

Current GOSTs for the production of interior doors

General requirements for wooden doors with a list of regulatory documents are established by GOST 6629–88, and requirements for wood products are set out in GOST 475–78.
Design options for interior doors, their types and sizes are specified in GOST 24698–81.
Requirements for extensions, fasteners and hinges are assigned by GOST 538–88.
Methods for determining sound insulation, heat transfer resistance and air permeability are regulated by GOST 26602.
The flatness of the door leaf is determined according to the ST SEV 4181–83 standard.
The reliability test methodology is set out in ST SEV 3285–81.
Resistance to shock loading is carried out according to the method specified in ST SEV 4180-83.

article - U05195;
the trade name of a particular collection is VERSAL;
type of finish / color - pat. 1014 dec / oro;
product name - canvas;
product model - D3;
width and height of the canvas - 91x230;
opening type, left - L.

Table: the ratio of the dimensions of the opening to the dimensions of the door leaf

Material for the manufacture of interior doors

Pine timber cleaned from defects with a moisture content of not more than 8%, spliced into a thorn using glue pressing.
High density particle board.
Natural veneer made of various types of wood with a thickness of 0.6 mm.
Laminating film imitating precious wood species.
Laminating film gives doors a natural wood grain
MDF panels of various thicknesses are used for cladding door leaves and creating panel elements.
Frosted glass, triplex or tempered, is used for light-scattering and decorative inserts in the door leaf.
Corrugated cardboard is used in budget options, as soundproof inserts in the canvas between the frame beams.
Corrugated board is used for insulation and soundproofing of inexpensive door leaves
Wax and waterproof coatings, tinting compounds and varnishes.
Glue of the type "Kleiberit 303.2", MERITIN Glue D3 and others, is used for industrial gluing of fragments of sheets, door frames and additional elements.

Equipment for the production of interior doors

Sawmills and band saws used for cutting round timber.
The sawmill allows you to get lumber of the required thickness from the round timber
Steam chambers for drying lumber.
Industrial drying chambers allow you to bring the lumber to the required moisture level and avoid warping of the workpieces
Equipment for the production of veneer.
Tenoning machine for frame and door leaf.
Using a pneumatic press, the door leaf is glued
Circular saws and panel saws for cutting workpieces to size.
Copy-milling machines with programmed control for decorating door leaves.
Shaped and paneled elements are produced using milling machines
Grinding machines for intermediate and finishing of products.
Paintwork equipment.

Video: production of interior doors

Many have watched and remember Anton Vasiliev's film "You Can't Prevent Living Beautifully", which was released in 1982 - everyone wants to live beautifully. And one of the components of such a life is the interior of our house or apartment, where the interior doors play an important role, which will not creak. We will talk about doors and their types below, and also watch the video in this article.

MDF door

A good wooden canvas costs good money, and not always and not everyone can afford it - the price of solid wood of valuable species "bites" even in such a forest-rich country as Russia. Of course, there is a way out - this is the so-called "Canadian" - a rack frame sheathed with fiberboard, which has a rather attractive structure and is designed for painting.

But such a canvas will not create the effect of natural wood. Therefore, the best budget option can be called MDF, especially with natural veneer from valuable species.

Suddenly, like in a fairy tale ... 7 qualities

I can list at least 7 excellent qualities that doors and portals made of MDF have:

MDF canvases do not react to changes in humidity and temperature, which is very important for rooms such as a bathroom. This means that they will not swell and, therefore, warp, and the canvas itself will always have a flat (non-behavioral) plane.
The construction market offers a huge range of doors, both in design and in color. Here, perhaps, the largest selection of all existing analogues.
Such a canvas will never delay suspensions., since the weight of an interior door made of MDF is too small and metal hinges do an excellent job with it.
MDF belongs to the group of low-combustible materials, therefore, such canvases are considered fireproof.
MDF topcoats, whether natural or artificial veneer or paints and varnishes, do not lose their color over time. That is, you are not afraid of the abundance of sunlight in the room coming through the windows.
They are extremely easy to care for., moreover, if necessary, they can also be washed with household chemicals.
And, finally, the cost of such a blade in comparison with solid wood is quite low..

It should be noted that the restoration of interior doors from MDF is possible only if the panels remain intact, since they are not restored.

So what is MDF

Medium Density Fibreboard (abbreviation MDF) is a medium density fiberboard. But in the Russian language there is transliteration - MDF, which is often deciphered as a finely dispersed fraction, and this is quite true.

Boards are made from fine wood chips, which are pressed under high pressure and high temperature, which makes the material similar to chipboard or chipboard.

But:

firstly, chipboard also uses coarse shavings together with chips;
and, secondly, the instruction provides for the use of lignin as a binder for MDF.

But lignin is a purely natural substance (lignum in Latin means wood), which is found in the cells of vascular plants and in some types of algae. Consequently, the result is an environmentally friendly material, without any chemical additives.

Note. In terms of technical qualities, MDF is superior to solid wood, since such boards are lighter in weight, resistant to temperature and humidity extremes, and also have higher strength.

Door constructions

Designs of canvases: on the left - paneled, on the right - panel board

The canvases that you see in the top photo, in fact, reflect all types of door structures and it is not at all necessary that they look like that. Just a paneled canvas consists of several parts, where instead of panels there can be glass. And the panel board is the continuous thickness of the entire door.

Paneled construction: 1 - rack tsar; 2 - baguette; 3 - panel; 4 - upper and lower drawers

In the top photo you can see the structure by the principle of which paneled doors are made from any materials. In the case of MDF, glasses are often inserted instead of panels, and the base is either made of a solid MDF profile.

Panel board: 1 - MDF; 2 - veneer; 3- honeycomb filler; 4 - wooden frame; 5 - reinforcing elements

Panel doors are a wooden frame, sheathed with MDF panels, which can be of different types. This design can be used for a bathroom or it can even be used as an entrance door. Such a canvas can also be solid, but it can also be glazed, which is not uncommon for MDF.

All canvases or portals made of MDF can have a slightly different surface - MDF can be veneered, laminated and painted. Of course, the most expensive will be doors covered with natural veneer, and the most moisture resistant - from laminated panels.

But the easiest repairs can be carried out for paintings for painting, since paint for interior doors from MDF in a huge assortment is sold in any hardware stores.

MDF care

As I mentioned above, MDF is not afraid of wet cleaning, but this does not mean that they can be washed with running water - for this there is a wet sponge, with which the canvas is wiped with your own hands.

In addition, you can use household chemicals, but provided that there are no abrasive substances, as this can damage the surface, leaving barely noticeable scratches, from which the background becomes, as it were, dirty or worn out. But in 99% of cases, when buying MDF doors, a care instruction is attached to them, which specifically lists all possible means and methods of cleaning.

Doors with glass fragments or glazed doors along the entire upper part also need maintenance, but this does not mean at all that you can clean the entire canvas with the same means. For glass, you should use other compounds - usually, these are all the same drugs that you use when cleaning windows and mirrors.

Conclusion

If you are thinking about how to paint MDF, then I want to remind you that this material is very similar to natural wood. Therefore, any paints and varnishes used for wood are appropriate here. Perhaps you have any ideas or comments, then please write about it in the comments.