Actual idea for business. Any person who cares about their safety, by all means decides to buy entrance doors made of durable steel. The choice in favor of such structures is made by ordinary citizens and owners of commercial premises - offices, shops.
Market analysis
The level of competition in the production of doors is quite high. But even a novice entrepreneur will be able to find a suitable niche for himself. Fortunately, customers evaluate many criteria at once - quality, reliability level, appearance. The last factor is especially important for those who live in elite houses and cottage settlements. Therefore, if an entrepreneur wants to organize a business in the production of metal doors, then he should first of all pay attention to the external characteristics of the future product. The presence of a large assortment, excellent aesthetic characteristics and an average cost will help you take your place in the market and even compete with well-known brands.
And yet, customers pay great attention to the price. That is why about 80% of the market falls on budget doors with a cost of 7,500 - 8,000 rubles. This means that a metalworker who is excellent at metalworking and who decides to open a business in his garage will be able to start his own business.
Worth it initial stage Decide on who exactly to sell your doors to. The following categories of clients can be considered:
- citizens who have just settled in a new building;
- cottage buyers;
- owners or landlords of offices;
- citizens who inherited an apartment.
For the commercial segment, it is better to develop your own door options, as they must have a special appearance and specific properties.
Features of the selection of premises
The production of entrance metal doors implies the need to organize your own mini-workshop. Its area will depend on the scale of production, and they, in turn, depend on the size of the start-up capital. As a rule, start-up entrepreneurs rent premises on the territory of former factories or in hangars.
A small business can get by with three working shops (metal-rolling, assembly and painting) and a warehouse for storing finished products. And more large enterprise will require renting an office where the company's specialists will sell doors.
Organizational moments
The production of metal doors as a business must be started only after official registration own enterprise. legal form must be chosen based on the scale of sales. A small business can be registered as an individual entrepreneur, and an LLC is suitable for a larger enterprise.
At the registration stage, you must also indicate the OKVED code. In this case, the following shall apply: 75.21 - "Manufacture of armored or reinforced safes, fireproof cabinets and doors." If the company will independently deal with the installation of doors, then you can not do without additional code 25.4 - “Installation of metal building structures”.
You will also need to obtain a special license. Before completing all required documents an entrepreneur needs to carefully study GOSTs 31173-2003, 23118-99 and 5089-97.
Following GOST necessitates the strict fulfillment of special requirements. The production of doors is as follows:
- preparatory stage (steel sheets are checked, if damaged or deformed products are found, they are sorted out, and the slightest signs of corrosion are eliminated);
- markup;
- cutting;
- profile processing;
- construction assembly;
- welding;
- applying paint, varnish;
- sheathing (allows you to get a beautiful and durable door);
- installation of fittings, locks and rubber insulation;
- checking for compliance with standards.
Purchase of the necessary equipment
You will also need specialized equipment for the production of metal doors. Its purchase requires responsibility from the entrepreneur, because the level of productivity of the mini-workshop and the quality of finished products will depend on this. To work, you need to purchase:
- press brake (the most expensive equipment, the cost is not less than 800,000 rubles);
- cutting machine;
- welding machine;
- installation for applying powder paint;
- equipment for sheet surface treatment for subsequent painting;
- oven (with the help of it polymerization occurs);
- spray booth and special gun;
- compressor.
Some equipment can be replaced by manual labor. A fully automated workshop will cost the entrepreneur no less than 4,000,000 rubles.
Purchase of raw materials
An important component of future success is also what kind of raw materials the entrepreneur will purchase for his production. In the manufacture of entrance doors use different kinds black rolled metal.
From what kind of variety the businessman chooses, it will subsequently depend on how safe the construction will turn out, what will be the cost of the door, and hence the selling price.
most accessible and best option involves the use of pipe bending products (corners, channels, pipes). The frame itself is sheathed with sheet steel, the thickness of which is 2 millimeters. Doors of increased strength suggest the need to use a steel sheet with a thickness of 1.5 to 2 millimeters as the basis.
Financial results
The amount of start-up capital directly depends on the scale of production. A medium-sized workshop will require the following investments:
- equipment - 4,000,000 rubles;
- renovation of the premises - 40,000 rubles;
- obtaining permits and licenses - 40,000 rubles;
- purchase of the first batch of raw materials - 30,000 rubles.
Total: 4,110,000 rubles.
The main costs will include rent and wages, the purchase of raw materials, taxes and insurance contributions, transportation costs, communal payments. Net profit will be about 170,000 rubles per month. This means that investments can pay off in about 1.5-2 years.
Modern steel door structures are not an exceptionally reliable protection of the building, but also an element of the interior and exterior. The technology for creating steel blocks is quite remarkable, which is worth considering.
Steel door blocks: necessary equipment for starting a business
Steel metal systems in turn
The main attribute of each building lies in the presence of a reliable overlap of the entrance. Worth mentioning manufacturing process manufacturing stages of iron structures.
So each manufacturer is trying to make the production of steel doors more modernized, and developers in modern times use exclusively metal blocks to block the entrance to new buildings. Today, manufacturers are trying to improve not only the technical performance of systems, but the aesthetic side of the product from a design point of view in relation to the latest trends in interior stylistic fashion.
The business of manufacturing iron structures is not particularly complicated, so any entrepreneur can give life to such a production. So the list of necessary equipment for production purposes can be placed in a single table:
| № | Equipment | Hardware Notes | Cost of equipment |
| Machine for cutting steel sheet (metal) | Laser or plasma can be used, since cutting on such machines occurs quickly and evenly | From $1,800.00 | |
| Metal bending press (sheet bending) | From $11,200.00 | ||
| Welding complex for finishing and spot welding | It is permissible to use conventional devices or specialized welding machines | From $1,600.00 | |
| Installation for powder coloring of products: for preparing the surface of the block for painting | It could be a special spray booth | From $980.00 | |
| Installation for powder coating of products: a compressor for painting, a painting gun and a polymerization chamber (furnace) | Instead of the polymerization step, the surface can be coated after painting with two layers of special vandal-resistant varnishes. | From $2,400.00 |
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The above list of equipment refers to the minimum required equipment. So on
Machine for the manufacture of structures
ready-made complex lines for the production of steel blocks are available on the world market, where all the machines and installations listed above are combined. Typical production lines can be fully automated or partially automated, when a human hand must be applied to a certain stage.
Such automated lines are often produced in the world by foreign manufacturers and are endowed with the following list of equipment:
- Installation of plasma cutting of metal;
- Press for bending metal sheets;
- Automatic coordinate welding of door leaves;
- Two machines for the welding process with tongs with conductors;
- Two points of the final welding process taking place in a special environment (carbon dioxide).
A typical line does not provide for a paint box, which is arranged separately. The productivity of the line is reduced to the production of 10 blocks within one hour of time, but also under the control of at least 10 people. The approximate cost of such a continuous production process in the assembled form comes down to no less than $100,000.
Workshops for the manufacture of metal structures
Workshop for the manufacture of metal structures
On the this moment steel doors are manufactured using various technologies, but in fact all of them are endowed with the same initial aspects. The main part of the production technology processes should take place in separate rooms, so the area must provide for the following workshops:
- Workshop where metal is received and raw materials are prepared;
- A workshop where metal sheets are processed and profiles are rolled;
- Workshop where the welding and assembly process takes place (production line);
- Workshop for painting products;
- Finishing and decorative shop, provided that finishing material produced on the territory of the enterprise, and not purchased in finished form;
- Assembly control shop, where the blocks are completed with locks and other mechanisms;
- Warehouses for storage of finished products.
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Each of the workshops must meet special requirements regarding fire safety. So the premises should be finished (floors, walls), at least with non-combustible materials, and equipped with supply and exhaust ventilation.
Production and technological process of manufacturing steel blocks
The manufacture of iron doors in relation to technology provides for a certain sequence of production steps that are prescribed in specialized documentation (routing or technological map), where:
- Basic requirements for the initial quality of the material used;
- Rules for the transportation of raw materials and finished products, material acceptance and storage of input blocks;
- The documentation of special requirements indicates a complex technical requirements for each stage of the process;
- Methods of quality control and control are prescribed;
- Many specifications(production specifications), which are compiled in accordance with the indications of GOST 31173-2003.
Main technological stages manufacturing of steel structures:
Preparation of raw materials.
At this stage, the metal material is to be sorted. The labeling of sheets is verified, the presence of deformations is checked, which appear mainly after the process of transportation or rolling. At this stage, scale and corrosion are also removed from the material. Storage of rolled metal in warehouses should be carried out on racks or sheets are stacked in piles.
Marking and cutting blanks.
The production of doors starts with the correct cutting of metal sheets relative to the templates applied to the surface using scribers and center punches.
Processing of blanks and parts.
The profile of the door frame is created on the sheet bending equipment.
Blanks for future input blocks are sawn off to eliminate burrs and irregularities. So in the process the surface layer of steel is removed in the places of cutting. Sawing can be done manually using simple files, as well as on specialized filing machines.
The processed blanks are sent to a stamping machine, on which holes of various diameters are made in the details for the needs of installation on fittings and locking systems.
Assembly process and welding work
advantage this business for the production of entrance metal doors is that the process itself is quite simple and does not require any additional knowledge from you. Therefore, any interested entrepreneur can do it.
Equipment for the production of
For the manufacture of metal entrance doors with powder coating, the following equipment is required:
- Metal cutting machine. Plasma or laser is used, because. cutting them is done evenly and as quickly as possible. Price from 100,000 rubles.
- Press brake. Price from 700 thousand rubles.
- Welding equipment for spot and finish welding. These can be conventional devices, or welding machines. Price from 100 thousand per unit.
- Powder coating equipment: complex for surface preparation before painting, spray booth (from 60 thousand rubles), polymerization oven (from 150 thousand rubles), spray gun, compressor.
This applies to machine tools, but there are also ready-made complexes (lines) for the production of metal doors that combine all these machines. They look something like this:
They come in different configurations.
The price for the line presented above is 6 million rubles. It has everything for the production of metal doors, except for the painting function, namely: plasma cutting, a press brake, a machine for coordinate welding of door panels, 2 posts for welding with tongs with conductors, 2 posts for final welding in a carbon dioxide environment. This line is designed for 8 people with a capacity of 10 doors per hour.
Manufacturing technology
The whole manufacturing technology of entrance metal doors is very simple:
- The metal is cut, and all the necessary holes for locks and eyes are made, because. if done after painting, it will cause cracking of the paint around these elements;
- Then it is bent;
- Assembly is carried out and initial - spot welding;
- If everything is in order, then the final finish welding is performed;
- After all this, the door is prepared for painting and placed in the spray booth. There it is painted through the spray gun and then placed in the polymerization oven.
You can watch the whole process in the video:
PS: don't forget about additional service, which you can provide with your own retail— installation of metal doors. She will bring you even more "penny".
Market entry key
official data on how many metal doors annually installed in Russia or at least Moscow, does not exist. However, it is not difficult to estimate the approximate capacity of this market. It is known, for example, that XXX free municipal apartments were built in the capital. At least 75% of the new settlers immediately changed the flimsy "typical" door to a solid metal one. Add here buyers of commercial housing, companies that care about, as well as residents of old houses who have decided to securely hide “everything that is acquired by overwork,” and it turns out that the Moscow market alone needs at least 50,000 doors annually.
Hundreds of enterprises of various levels are trying to make money on meeting this demand - from "garage" shops to large factories. The presence of players in such different “weight categories” is explained by the variety of market niches and a wide range of products in demand: consumers need both cheap doors and the most “fancy” ones. Such a structure of demand, in principle, makes it possible for any firm to expand and develop. Theoretically, every "soldier" is capable of becoming a "general". Even a lone artisan can grow into a head big company, gradually adding necessary equipment and increasing production capacity. But practice shows that in a market with high competition, it is better to start the path to "generals" with "lieutenants" - in our case, with the organization of a mini-factory.
Your own door factory
Experts say that more than 80% of the metal door market falls on simple products worth up to $150. To organize a mini-factory for their production, you will need at least $10,000–$15,000. This amount includes the cost of purchasing a license and renting premises, equipment, components, advertising and wages workers (in the first month of work).
The success of the business initially depends on whether it will be possible to find a suitable production facility and agree with its owner on a lease for a long time.
The mini-factory must have an area of at least 250–300 sq.m. As a rule, entrepreneurs either hangars or rent empty workshops at old "Soviet" enterprises. The range of prices for renting industrial premises is very large. In Moscow, a hangar with an area of 200 sq. m. can be rented for $1700-$3000 per month. A capital building of the same area costs from $4,000.
Beginning entrepreneurs simply cannot pay so much. In this scenario, their business will be unprofitable, - says Evgeny Stepanov, Deputy General Director of Sezam.
Therefore, most firms operating in the capital's market of cheap metal doors place their production facilities in the Moscow region. Historically, most of them are concentrated in Klin.
We rent a 300-meter capital building for $1,500 a month, says Anna Savchenko, co-owner of a door company. - And some firms managed to find something similar in Klin for $500. In any case, rent here is cheaper than in Moscow. Therefore, Klin doors are cheaper than Moscow ones. And buy them better.
As for the equipment, the mandatory set includes welding machines, grinder saws, a guillotine for cutting metal, turning, milling and other machines. You can save money by buying used units.
The number of equipment, as well as the number of workers, is calculated based on the volume of output. The average welder can “weld” two or three doors per day. Thus, a company producing 300 doors per month would need at least five welders. Measurer and installer functions in small firms usually performed by one person. In addition, small producers usually do not have their own fleet. Therefore, installers have to be also drivers operating their own vehicles. Installation of one door takes 1.5-2 hours. That is, in a day, taking into account moving from client to client, one installer can complete 2-3 orders.
Finally, before starting work, a company that produces metal doors must acquire a building license. It costs $800-$1000.
iron stream
In the segment of cheap metal doors, money is mainly earned due to high turnover: in order to "become profitable", you need to produce at least 200-300 products per month.
Before the 1998 crisis, this threshold was lower, says Anna Savchenko. - Then a cheap metal door cost about 1000 rubles, that is, $150. But then imported materials and components rose sharply in price following the dollar. And the proceeds from the sale of the finished door decreased to $60-70.
As a result, the income of manufacturers of cheap products began to fall. The fact is that imported components take about 30 - 40% of all costs for one such door. Another 30% is the cost of staff salaries (welders and installers, as a rule, work piecework, receiving 10-15% of the cost of the product for their work, and remuneration for dispatchers ranges from 15 rubles to 100 rubles per client). The lion's share of the rest of the revenue is "eaten up" by rent and advertising, which is indispensable in this business. And there is no way to raise the price: competition is high, customers are not rich people.
There is only one way out: to increase production and reduce the cost of production. Therefore, most entrepreneurs involved in this business invest most of their income in the purchase of new equipment. Otherwise, do not survive.
How to earn more?
More profit with lower sales volumes are received by firms engaged in the manufacture of expensive products: doors finished with laminated panels, MDF, artificial or natural veneer of valuable wood. The cost of such products is higher, but they also cost 100 - 2000% more. So, a door with an MDF finish costs $280, and an oak veneer door costs $800.
Naturally, the demand for expensive doors is much lower than for cheap ones. But, according to entrepreneurs, this business turns out to be profitable with monthly sales of 60-100 doors.
The high cost of elite products is due not only to the cost of exterior decoration. Imported locks, mostly made in Italy, cost an average of $200-$300 and crash into such doors. High quality fittings are used.
However, saving on locks and fittings is not recommended.
If you equip an elite door with penny handles, then after a while the varnish will peel off on them, - says Andrey Kukinov, president of the Sesame company. “And a cheap lock can fail quickly. And then the client has the right to make a claim, since all expensive doors are provided with a long-term guarantee. If the deficiencies are eliminated, the company will incur losses.
The cost of raw materials, components and wages of workers is about a third of the cost of an expensive door. Another significant expense item for entrepreneurs involved in expensive doors is advertising.
$10,000 for advertising
Firms involved in cheap doors, it is enough to attract customers $ 2-3 thousand per year. Companies working for more affluent citizens spend at least $10,000 on advertising. First, they have to place larger modules in the mass media. Secondly, they are advertised in all kinds of specialized publications on building design and safety. In addition, in order to attract the attention of customers, it is necessary to exhibit samples of their products in large shopping malls specializing in the sale of building materials.
A client who is ready to pay a lot of money for the door wants to see with his own eyes what he is buying, - says Alexey Kiselev, senior manager of the Valiant company. “So we have to give him that opportunity.”
Meanwhile, renting exhibition space in Moscow is not a cheap pleasure. For example, in Stroydvor, near the Voykovskaya metro station, a square meter of exhibition space costs about $70 per month. In Svoi Dom and Crocus City shopping centers - about $170 per month. As a rule, each firm has several exhibition points, each of which exhibits from 4 to 10 doors. Money for the production of exhibition samples is “frozen”, which is also noticeable. It's easy to calculate: if a firm has five showrooms, each with six doors costing $600-$1200, then the one-time cost of making them is over $20,000. Another $5,000–$15,000 needs to be spent on decorating the exposition itself.
Finally, the owner of a luxury door company needs to fork out for highly qualified ones.
Many people do not understand what is the difference between expensive and cheap doors, notes Alexey Kiselev. – A professional should be able to explain to the client that an expensive door is not only a beautiful external panel, but also effective remedy home security.
Qualified sales managers have to be specially trained so that they can talk about design features one or another door and answer any non-standard question of the client.
Big job
To expand the business of selling heavy metal doors, you can go in different ways.
For organization own production at least $110,000-$150,000 is required. Approximately half will have to be spent on the purchase of equipment. In addition to welding machines, large-scale production needs all kinds of presses, guillotines, turning, milling and grinding machines, automatic hacksaws, as well as bending machines that allow you to bend metallic profile. Another $50,000-$70,000 will be spent on renting premises, purchasing vehicles, organizing exhibitions, advertising, and paying staff in the first months of operation.
However, even if the entrepreneur has the necessary amount, it will not be easy to enter the market of elite metal doors and gain a foothold in it, because one of the important components of success is the good reputation of the company. And this image is earned over the years.
Turning to a company that has great experience, the client is more confident that it will not disappear and that they will definitely be helped in the event of a crisis - for example, if the lock jams. Customers are reluctant to use the services of novice companies, fearing to face a one-day business, to which, in which case, you can’t make any claims, - Alexey Kiselev testifies.
If the entrepreneur is not ready to invest a lot of money in organizing his own production of expensive doors, he can become a dealer of some large plant. Then he will have to spend money only on renting an office and exhibition space, on staff salaries and advertising.
For example, in Moscow and 52 other regions of Russia, firms representing the Yoshkar-Ola plant "Guardian" successfully operate. This brand is already "promoted" on the market, and doors from Yoshkar-Ola are popular with consumers. However, there are difficulties with obtaining an "entrance ticket" to the market. The fact is that a businessman can create a new representative office of the Guardian only if he manages to negotiate with dealers already working in a particular city.
This policy is explained by the fact that the appearance of each new dealer entails an outflow of customers from other long-established firms, - says CEO official representation of the plant "Guardian" in Moscow Dmitry Radchenko. - It is possible to conclude a cooperation agreement with the plant only in those cities where there are no official representatives yet. Or where existing dealer firms are unable to meet demand.
So, entrepreneurs who want to trade "foreign" products will have to attend to the search for untapped markets.
A lone handicraft will not get rich
You can make simple cheap doors even in a car garage. You can deliver them to customers in a regular "passenger car". $500 is enough to buy a minimum set of tools. BUT expendable materials cost $30-40 per piece.
For a month, the master can manufacture and install 5-10 doors, - says Sergey Beltsev, who used to be engaged in this business. - It takes a couple of days to go to the customer to measure the doorway and directly to the manufacture of the door. Another day - for its installation and for the purchase of materials for the implementation of the following orders. In parallel with this, you need to search for customers, and this is the main headache.
The largest influx of customers is provided by advertising in the Extra-M newspaper. It does not hurt to scatter leaflets in the mailboxes. Some individuals manage to negotiate the "outbidding" of customers with dispatchers working for firms. Including advertising costs, a private trader making 10 doors a month can earn $200-$300. This salary is comparable to the salary of skilled craftsmen working in firms producing metal doors. Therefore, it is not surprising that many individuals prefer to move to such enterprises as welders or installers.
