Being engaged in the design of the bathroom, trying to take into account everything in the interior that will make it comfortable, aesthetically designed, cozy, they carefully choose tiles, furniture, but the main emphasis is on plumbing. And this is understandable: bathroom sanitary ware is the most important element that combines design solutions, functionality and convenience.

In this article we will analyze information about the production of acrylic bathtubs, equipment for it and manufacturing technology.

Plumbing is a sink, toilet, bidet and, of course, a bath. She is given a central place. Recently, of all the varieties, buyers prefer acrylic bathtubs. The price of acrylic baths is different. There are quite affordable democratic options. The low price of acrylic bathtubs does not at all mean their low quality. There can be no doubt about it. Cheapness has a completely different explanation: well-known manufacturers of this type of product make their products quite affordable, and the quality does not suffer, and the performance properties do not get worse. So the thesis “the more expensive the better” does not work in this case.

Equipment for the production of

The most important equipment for the manufacture of acrylic bathtubs is a vacuum forming machine (thermoforming).

The cost of such a machine for making bathtubs will start from about 2,500,000 rubles.

They are also cheaper, but, unfortunately, due to the smaller molding area, such machines will not work. This production requires a machine with a molding area of ​​approximately 2000×2000 mm.

Manufacturing technology

The very name "acrylic bathtubs" speaks of the material from which they are made - acrylic, or acrylan, and if it's completely scientific - methacryl. Its distinguishing characteristics are extraordinary lightness, combined with reliability and durability. Acrylic comes in two varieties: industrial and technical. In the production of technical acrylic, special additives are used to reduce the ability of various harmful microorganisms and bacteria to multiply on its surface. It is this type of acrylic that is used to make bathtubs, making them more hygienic and safer.

Acrylic bathtubs by injection technology

Acrylic bathtubs, which are of high quality and reliability, are made using injection molding technology. The acrylic sheet in this method is heated until it acquires a plastic state. When molten, it is placed in a bath mold into which the acrylic sheet is literally pressed with a vacuum. Strength, reliability and durability are achieved by applying several layers of fiberglass. The number of layers increases the strength and durability of the sanitary ware. Acrylic bathtubs produced in this way will have improved quality characteristics. They will retain their visual appeal for the entire period of operation and will not create any problems for their owners.

ABS acrylic bathtubs

ABS acrylic bathtubs are another type of bathtubs. In their manufacture, the method of combining polymethyl methacrylate with acrylonetrile butadiene styrene was used. In the manufacture of this type of plumbing, the surface of acrylonitrile butadiene styrene is covered with a layer of molten polymethyl methacrylate. Acrylic bathtubs made in this way can only be called conditionally. This type of plumbing is very short-lived - you should keep this in mind. With a very thin inner layer, they are quite vulnerable to mechanical stress. Their service life is 3-4 years, after which they must be replaced.

Vacuum forming equipment for the production of acrylic baths and showers.

Vacuum-forming (thermoforming) machines for the production of sanitary acrylic (ABS + PMMA (PMMA)) bathtubs and shower cabins.

Acrylic bathtubs and shower enclosure parts are made from duplicated ABS+PMMC sheets or single-layer PMMA sheets by vacuum forming. The working surface of the bath is formed by a layer of polymethyl methacrylate PMMA (acrylic, PMMA, PMMA), which has a high surface hardness and abrasion resistance. A layer of ABS plastic is needed to protect the PMMC from impact loads.
Forming products from inhomogeneous two-layer polymer blanks requires specialized vacuum forming equipment.

All major suppliers of ABS + PMMA sheets or PMMA sheets in the accompanying instructions indicate the need to use double-sided heating for such blanks. This is due to the fact that one-sided heating causes a temperature difference across the thickness of the sheet. As a result, inhomogeneity mechanical properties different polymers only intensifies and after vacuum molding, stresses arise between the layers, which lead to the destruction of the product: plastic begins to delaminate over time, cracks appear. In addition, ABS + PMMA is a very hygroscopic material (absorbs moisture from the air), which, in turn, leads to the appearance of "boiling" defects on it during one-sided heating.

MKM offers specialized vacuum forming equipment with separate heating and forming units (VFM2060.2060.600SH) for working with sheets of PMMK, ABS+PMMK and other thermoplastic polymers. Such vacuum forming machines are equipped with a special oven for simultaneous heating of several blanks, which are in it in a state ready for thermoforming at a certain temperature. As needed, the blanks are removed from the oven and transferred to a vacuum forming machine for thermoforming.
This design allows you to double the productivity of thermoforming equipment (compared to a machine with double-sided heating, as well as achieve more High Quality products in border areas with workpiece clamping. An additional support table is used to place the heated billet on the vacuum forming machine's cradle, which prevents the plastic billet from falling into the opening of the molding chamber. After the workpiece is clamped by the frame, the table is moved to the side and then the vacuum forming machine operates in the normal mode. VFM2060.2060.600SH is designed for the production of acrylic bathtubs with dimensions up to 2000x2000 mm. The design of the vacuum forming machine allows you to quickly reconfigure its molding field, in addition, the machine is equipped with a roller table for quick installation of molds. The form is delivered to the thermoforming machine on a special trolley, which is fixed opposite the front opening for loading the forms, after which the form is easily moved along the roller table to the movable table for its fastening.
The furnace for heating blanks is produced by MK MKM. The equipment provides not only heating of the workpiece, but also its drying. If the material is very damp, drying can be carried out at a low temperature as a separate operation. The furnace is equipped with an air recirculation system and automatic control of the maintained temperature.

Forms for the production of acrylic bathtubs and shower cabins.

In addition to vacuum-forming (thermoforming) equipment, for the production of any plastic products, forming equipment (moulds) is required. Ultimately, the quality of the product depends on its quality. Forming equipment on vacuum forming machines operates under conditions of high temperatures and pressure. For example, on a mold with a base area of ​​one square meter, a force equal to 9000 kg acts during molding! Therefore, in the manufacture of forming equipment, it is necessary to take into account the complex nature of the loads and the conditions in which it will work. For the manufacture of acrylic bathtubs and shower cabins, MK MKM offers molds made of composite materials based on polyester resins.

	Vacuum-forming equipment and molds of our company allow us to produce acrylic bathtubs and decorative screens of any complexity.
	Most of the elements of shower cabins are produced on vacuum forming equipment. In an economical variant, including the VFM, it is possible to produce transparent shower cabin doors from PET polyethylene terephthalate. Under the existing conditions for the sale of products, the range of products offered is important. Composite (fiberglass) molds are ideal for solving this problem. This is due to their low cost and rather large working resource. In addition, they are light in weight, which saves time when changing forming equipment on a vacuum forming machine.

The cost of forms for acrylic bathtubs and shower cabins is determined individually after the provision of drawings or product samples. The form is supplied with delimiting strips for clamping the workpiece. The cost of forming equipment includes vacuum forming of a trial quality sample of the product.

Vacuum forming machines, vacuum forming machines and other thermoforming equipment MKM are produced in various technical designs, depending on customer requirements. MKM offers vacuum forming machines with classical arrangement of clamping frame and cradle, as well as vacuum forming machines manufactured in accordance with modern European requirements, which provide for the possibility of double mutual movement of clamping bars along two coordinates.

Acrylic bathtubs, bidets, toilets, sinks and shower bowls have become very popular. Indeed, cast iron, steel and ceramics are gradually disappearing from specialized stores, giving way to new material. As one of the key postulates of business says, demand creates supply. And, logically, since the products are on store shelves, it means that there is a potential buyer who is ready to purchase them. And since there is a client, it means that you can compete for it. Should You Start an Acrylic Bathtub Business? What will be needed for this? We will understand the intricacies of organizing a viable "production and plumbing" business.

Repair or production?

Before discussing specific business schemes, let's figure out what exactly can be done: repairing cast iron and steel bowls using liquid acrylic mixtures or manufacturing products? This is fundamentally important, because the essence of the processes is completely different.

Repair is the restoration of the coatings of old cast iron and steel bathtubs by pouring acrylic with a hardener. The procedure does not require special equipment, it is performed on the spot. And she's in demand. Production - vacuum molding of the finished product on special equipment.

We repair

The first service belongs to the “economy” segment (both in terms of business costs and target audience). It allows you to make a new coating for the old bath with a service life of more than 10 years. On average, a mixture for one procedure costs about three thousand rubles, the master will take the same amount for work. The work takes an hour and a half (or an hour with a good qualification of a specialist). With a sufficient number of orders, the turnover can reach up to 15-18 thousand per day (5-6 orders).

A quite acceptable amount is obtained per month, and given that you do not invest in either equipment or consumable business is doing pretty well. Many entrepreneurs even work independently, optimizing costs and offering a service at an affordable price.

We produce

With the production of baths, everything is more complicated. To begin with, you will need equipment (a vacuum forming machine with a heater), tooling (molds), etc. In addition, you will need to resolve the issue of raw materials. It can be technical methacrylic sheet or ABS composite sheet coated with technical methacrylic.

Bathtubs are produced using almost identical technology: the material is heated to a plastic state and pressed into a mold by a vacuum method. Methacrylic products are durable, but less moldable. ABS bathtubs can be molded into almost any design, but only last three to five years.

Production costs are quite serious. You will need a room where the equipment will be placed, the price of a vacuum forming machine starts from 2.5 million rubles. We also write down the costs of molds and raw materials. The price of the form varies from several tens to several hundred thousand rubles. It all depends on the shape and material of manufacture. A sheet of technical methacryl will cost 10-20 thousand rubles, depending on the manufacturer. Composite is cheaper. His sheet costs from 3 thousand rubles. Do not forget about the fittings for the bathroom and other "little things". They cost money too. The costs are pretty clear. The budget for the organization of production with a small inventory will come close to 4 million rubles.

And who wants an acrylic bath?

Before planning the organization of production, it is necessary first of all to study possible distribution channels. If you are not the owner of your own stores or you do not have a friendly network, then you have to seriously rack your brains.

The fact is that the production of acrylic bathtubs has existed in Russia for a long time. Many companies that started working with the material ten years ago already have production, are working to reduce costs and have a stable market. It is difficult to beat them with price, but with quality it may turn out to be unprofitable.

To illustrate this idea, let's look at a simple example. Let's compare two enterprises: one of them produces 1000 units of products per shift, and the second - only 100. The first one has modern and powerful equipment that serves 3 people. The second also has modern equipment, but less powerful, which also serves three people. Yes, don't be surprised. Modern technologies quite accept such a situation.

The first buys raw materials in the amount of 100 tons per month, and the second - 10 tons. The first enterprise is a strategic partner for the supplier, and the second is only an ordinary client. The former receive a 30% discount, while the latter do not. The logistics of the first allows the use of cheap rail transport, while the second must use expensive road transport. The first has its own laboratory and quality control, and the second cannot afford it due to economic circumstances.

Sadly for a novice entrepreneur, the products of a large enterprise will always be more competitive in the mass segment than the products of a small workshop. This is the law of economics, and you can't get away from it. That is why it will be difficult to offer products retail stores if the products of a major manufacturer are already on their shelves. Study the companies of your and neighboring regions. If they have a large plant, then think about whether it is better to become its distributor than to invest in your own production?

Features of conquering the market

Not? Have you definitely decided to devote yourself to competition? Well, there are several tricks on this field that can play into your hands.

1. Get out of the mass segment and start making an exclusive product. Bathtubs on order. With painting under Gzhel or with the bottom of the Adriatic Sea. Everything the client wants. And for his money, of course. The market niche will be narrower, but this will give a chance to rebuild from a competitor. Flaw large-scale production in his inertia. It takes months and years to redesign a factory process. And your production is still flexible.
2. Additional services. Create your own retail online store and, at the same price, offer free shipping and installation. Of course, this step should be calculated economically and not bring losses.
3. Focus on the quality of your production. Oddly enough, many customers still believe that small-scale products are more reliable than large factories. It can be assumed that this is a relic of our Soviet past. Or offer a lifetime warranty. For some clients (especially those who do not trust acrylic, and there are many) this can be a decisive factor.
4. At the start, try to cut the margin so as to bring the wholesale price closer to the prices of competitors ( large enterprises). Do not be greedy, especially at the stage of establishing a business.

Eventually

So, the pros and cons of organizing the production of acrylic bathtubs are quite clear. If you are determined to embark on this path, then get ready for serious difficulties. But no one said that the path to business would be easy. Once again, calculate everything and get down to business. After all, even water does not flow under a lying stone. What can we say about money.

The approach to the design of the bathroom is always meticulous. The smallest nuances in the interior are taken into account, sometimes non-standard design decisions are made - all this is aimed at creating convenience, aesthetic superiority of the bathroom, and comfort. The choice of plumbing is decisive in determining the interior, because it is the main component of the bathroom. Plumbing should be comfortable, well-designed, functional.

The production of acrylic bathtubs is becoming a popular trend in the sanitary ware market. For its affordable price, material strength, long service life and variety of design, Russian consumers fell in love with acrylic bathtubs. Prices for acrylic bathtubs vary, but it is in this case that the price cannot be correlated with quality indicators.

Acrylic bathtubs are very beautiful and relatively inexpensive.

A low price does not mean a bad product at all, because in the production of bathtubs the principle of pricing for finished products has other grounds. Popular manufacturers of acrylic bathtubs are trying to make them affordable to the consumer, but strength and durability do not depend on this. There is no doubt that acrylic bathtubs of any price category will last a long time and retain a decent appearance.

Basic equipment for the production of acrylic bathtubs

The main unit for the manufacture of acrylic baths is a machine for molding the finished product from flat sheets of acrylic, which is heated and under the influence of vacuum takes the desired shape, the excess material is cut off. In other words, it is a vacuum molding machine, thermoforming.

On the Russian market there are offers of vacuum forming machines costing from 2.7 million rubles, with a molding area of ​​up to 1000 × 700 mm. They look like this:

Equipment for the production of acrylic bathtubs will cost the entrepreneur over 2.5 million rubles. Some manufacturers offer cheaper options, but such machines are small in size to create a shape. For successful production, you should buy vacuum forming units with a sufficient forming area.

Acrylic types:

• Industrial;
• Technical.

Technical acrylic is created by combining liquid acrylic with special ingredients designed to eliminate bacterial growth and keep the bathtub surface hygienic for use. Acrylic or acrylan (scientific methacryl) is a lightweight and high-strength material. Thanks to their chemical characteristics considered successful for giving any shape to finished products. Acrylan has excellent technical specifications. It is this quality that ensures long-term operation and an unchanged appearance of the material.

Injection molding technology

Injection molding technology provides finished products with reliability, durability and high quality characteristics. Before creating a mold, the acrylic sheet is moderately melted, and then placed in thermoforming car. With the help of a vacuum, an acrylic sheet is given the desired shape. Then the acrylic surface must be covered with several layers of fiberglass. It is worth noting that the number of layers of fiberglass determine the strength and longevity of operation. This method of manufacturing acrylic baths has a high functionality in its technical features finished product. Durable material ensures durability appearance baths under various influences in normal use. That saves the owners from problems for the entire period of their service.

The production process is captured on video:

ABS acrylic bathtubs

ABS acrylic bathtubs - this type of acrylic bathtub is made by combining acrylonitrile butadiene styrene and polymethyl methacrylate, where the surface acrylonitrile butadiene styrene covered with polymethyl methacrylate heated to a plastic state in one layer. The name "acrylic" for these types of baths can be used conditionally. Such plumbing equipment is short-lived, due to the creation of a thin base layer that is sensitive to mechanical stress. ABS bath will last up to 4 years. After this period, the sanitary ware should be replaced with a new one.