Production process
1. Preliminary production and cutting PVC profiles
The production starts in the preliminary production department with the creation of a work order. A special work order is made for every buyer, and it contains the detailed specifications of all the characteristics of the final product. Digital work orders are then sent to the production hall, to the automatic saw, where the work on the PVC profiles starts.
The profile for the production of the product is determined using a computer, and the appropriate barcode is assigned to it. The length of the profiles before they are processed and cut is 6.5 metres. The elements of the work order appear on the screen located on the saw, and the printer in the saw prints out the labels for each individual profile. The saw automatically determines and cuts the length of the profile according to the barcode for every individual profile, and the label with all the information necessary for further work on the product is attached to the profile.
2. Work on the PVC profile
After the profiles are cut, galvanized steel, specifically profiled for windows, doors, and frames, is introduced into each section of the profile.
The product then enters into the computerised processing centre manned by only one person. Using the barcode, the processing centre recognises the profile and starts working on the profile according to the characteristics from the work order: drilling holes for latches, drilling holes for connectors, drilling drainage openings, and drilling holes for later installation of the product.
3. Forming PVC profiles into the final product: PVC windows and doors
After all the parts of the profile have gone through the processing centre, they enter into the welding and cleaning process used to form the final product. All the activities are done using fully automated CNC machines without human interventions (aside from servicing the machine).
A four point welding machine welds all the corners at the same time, which prevents deviations and makes all the welds equal. The welding machine annuls and compensates for possible deviations from -2 mm to +4 mm, which makes the final PVC product perfectly rectangular.
After welding, the product proceeds to cleaning, a fully automated cleaning process for the welds.
Extruded gaskets also add to the quality of PVC joinery, they prevent the misalignment of gaskets. We offer black, grey, and light brown gaskets.
At Iveta, we use GU fittings of exceptional quality and design. GU fittings are famous for their resistance to corrosion, which makes them essential for PVC joinery on buildings near the sea, on industrial facilities, or farms and similar. Installing the fittings on window sashes and the frame is done separately, on special machines for installing fittings.
After that, the windows and doors proceed to glazing. A special bench is used for that purpose, which simulates the installation conditions. This is used to check the diagonal lines of the sashes and the accuracy and precision of the installed fittings (the condition that must be met is the perfect balance and grip between the sash and the window frame).
Then the glazing bar is set, depending on the gasket and the profile model, which can be Softline, Topline, or Swingline, if we are talking only about the options and the combinations of 3 profiles with the installation width of 70 mm, grey or black gasket.
4. Production variations depending on the type of PVC joinery
4.1. Doors
Front doors, plantation shutters, winter gardens, arched and pitched elements, and roller shutter boxes with and without mosquito nets are made at special workstations.
Due to the specific nature of their construction and the technical procedures which are more complex than for PVC windows, the front doors go through the processing centre, welding, and cleaning separately. Locks, anti-burglary fittings, and GU connectors of great load bearing capacity, with exceptional durability and quality, are installed in the doors. The doors are also checked at the glazing bench, where glass panes or decorative panels are installed, depending on the client’s wishes. After that, the doors are ready for transport and installation at the end buyer.
4.2. Pitched and arched windows and doors
The construction of pitched windows and arched windows goes through a somewhat different production process, characterised by the process of “bending” profiles. The “bender” is a special machine which enables bending of arched products. Iveta is one of the few companies that have this machine available for their production.
This production is fully done by hand, since the arch radius is specific for each individual product, and due to the complexity of the production process, production control is more frequent. Fittings for pitched and arched windows and doors are specific for those types of products.
Finished products are transported to the loading ramp and delivered to the client according to pre-arranged delivery terms, or, according to the client’s order, our installers will install the manufactured joinery.
