Vacuum molding machine for acrylic bathtubs. Vacuum forming equipment for the production of acrylic bathtubs and shower cabins. And to whom an acrylic bath

When designing a bathroom, trying to take into account everything in the interior that will make it comfortable, aesthetically decorated, cozy, they carefully choose tiles, furniture, but the main emphasis is placed on plumbing. And this is quite understandable: bathroom fixtures are 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. It has a central place. Recently, of all varieties, buyers have preferred acrylic bathtubs. The price of acrylic bathtubs is different. There are quite affordable democratic options. The low price of acrylic bathtubs does not mean at all their low quality. There is no doubt about it. The 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 baths 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, because of the smaller forming area, such machines will not work. This production requires a machine with a forming area of \u200b\u200bapproximately 2000 × 2000 mm.

Manufacturing technology

The very name "acrylic bathtubs" speaks of the material from which they are made - acrylic, or acrylane, and if quite scientifically - methacrylic. Its distinctive characteristics are extraordinary lightness, combined with reliability and strength. There are two types of acrylic: 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 safe.

Acrylic bathtubs using injection molding technology

Acrylic bathtubs of high quality and reliability are made using injection molding technology. In this method, acrylic sheet is heated until it acquires a plastic state. In molten form, it is placed in a bath mold, into which the acrylic sheet is literally pressed by vacuum. Strength, reliability and durability are achieved by applying multiple 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.

Acrylic bathtubs ABS

ABS acrylic bathtubs are another type of bathtub. In their manufacture, the method of combining polymethyl methacrylate with acrylonetrile butadiene styrene was used. In the manufacture of this type of sanitary ware, the surface of acrylonetrile butadiene styrene is covered with a layer of molten polymethyl methacrylate. Baths made in this way can be called acrylics only conditionally. This type of plumbing is very short-lived - 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 bathtubs and shower cabins.

Vacuum forming (thermoforming) machines for the production of sanitary acrylic (ABS + PMMK (PMMA)) bathtubs and showers.

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

All major suppliers of ABS + PMMK sheets or PMMK 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 drop across the sheet thickness. As a result, the inhomogeneity of the mechanical properties of different polymers only intensifies, and after vacuum molding, stresses arise between the layers, which lead to the destruction of the product: the plastic begins to delaminate over time, cracks appear. In addition, ABS + PMMA is a very hygroscopic material (it absorbs moisture from the air), which, in turn, leads to the appearance of "boiling" defects on it when heated on one side.

To work with sheets PMMK, ABS + PMMK and other thermoplastic polymers MK MKM offers specialized vacuum forming equipment with separate heating and forming units (VFM2060.2060.600SH). Such vacuum forming machines are equipped with a special oven for the simultaneous heating of several blanks, which are in it in a state ready for thermoforming at a certain temperature. As required, the blanks are removed from the oven and transferred to a vacuum forming machine for thermoforming.
This design makes it possible to double the productivity of thermoforming equipment (in comparison with a machine with double-sided heating, as well as to achieve a higher quality of the product in the areas adjacent to the clamping of the workpiece. For laying the heated workpiece on the lodgement of the vacuum-forming machine, an additional support table is used, which does not allow the plastic workpiece to fall into the opening of the molding chamber.After clamping the workpiece by the frame, the table is retracted to the side and then the vacuum forming machine operates in normal mode.VFM2060.2060.600SH is designed for the production of acrylic baths with dimensions up to 2000x2000 mm. allows you to quickly reconfigure its molding field, in addition, the machine is equipped with a roller conveyor for quick installation of molds.The mold is delivered to the thermoforming machine on a special trolley, which is fixed against the front opening for loading molds, after which the mold easily moves along the roller table I'm on a movable table to attach it.
The furnace for heating billets is produced by MK MKM. The equipment provides not only heating of the workpiece, but also its drying. When the moisture content of the material is high, drying can be carried out at low temperatures as a separate operation. The furnace is equipped with an air recirculation system and automatic control of the maintained temperature.

Molds 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 (molds) is required. The quality of the product ultimately depends on its quality. Forming tooling on vacuum forming machines operates under high temperature and pressure conditions. For example, on a mold with a base area of \u200b\u200bone square meter, a force equal to 9000 kg is applied during molding! Therefore, in the manufacture of shaping 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 from composite materials based on polyester resins.

Vacuum-forming equipment and molds of our company allow us to produce acrylic baths and decorative screens of any complexity.

Most of the elements of shower cabins are produced on vacuum forming equipment. In an economical version, including the VFM, it is possible to produce transparent shower cabinets made of PET polyethylene terephthalate.

Under the existing conditions of product sales, the range of products offered is of great importance. Composite (fiberglass) forms are ideal for solving this problem. This is due to their low cost and a fairly large work resource. In addition, they are lightweight, which saves time when changing molds on a vacuum forming machine.

The cost of forms for acrylic baths and shower cabins is determined individually after providing drawings or product samples. Delimiting strips for clamping the workpiece are supplied with the mold. The cost of the shaping equipment includes vacuum forming of a quality test sample of the product.

MKM vacuum forming machines, vacuum forming machines and other thermoforming equipment are manufactured in various technical designs, depending on the customer's requirements. MKM offers vacuum forming machines with a classical arrangement of a clamping frame and a lodgment, as well as vacuum forming machines manufactured in accordance with modern European requirements, which assume the possibility of double mutual movement of the clamping bars in two coordinates.

Bathroom design 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 coziness. 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 durability, durability and a variety of design, acrylic bathtubs are loved by Russian consumers. 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 manufacture of bathtubs, the principle of price formation for finished products has other reasons. Popular manufacturers of acrylic bathtubs are trying to make them available to the consumer, but strength and durability does 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 bathtubs is considered to be a machine for forming a finished product from flat sheets of acrylic, which is heated and under the influence of a vacuum takes the required shape, excess material is cut off. In other words, it is a vacuum forming machine, thermoforming.

On the Russian market there are offers of vacuum forming machines worth from 2.7 million rubles, with a forming area of \u200b\u200bup to 1000 × 700 mm. They look like this:

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

Types of acrylics:

Industrial;
Technical.

Technical acrylic is created by combining liquid acrylic with special components whose task is to eliminate the growth of bacteria and keep the surface of the bathtub hygienic for use. Acrylic or acrylane (scientific methacrylate) is a lightweight and highly durable material. Due to its chemical characteristics, it is considered to be successful for giving any shape to finished products. Acrylan has excellent technical characteristics. It is this quality that ensures long-term operation and unchanged appearance of the material.

Injection molding technology

Injection molding technology provides finished products with reliability, durability and high quality characteristics. Before creating the shape, the acrylic sheet is moderately melted and then laid in thermoforming car. With the help of vacuum, the acrylic sheet is given the required shape. The acrylic surface must then be coated with several layers of fiberglass. It should be noted that the number of layers of fiberglass determines the strength and durability. This technique of making acrylic bathtubs has high functionality in terms of its technical features of the finished product. The durable material ensures that the appearance of the bath remains unchanged 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 acrylonetrile butadiene styrene and polymethyl methacrylate, where the surface acrylonetrile 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. The ABS bath will last up to 4 years. After this period, the plumbing product should be replaced with a new one.

Acrylic bathtubs, bidets, toilets, sinks and shower enclosures have become very popular. Indeed, cast iron, steel and ceramics are gradually disappearing from specialty stores, giving way to a new material. As one of the key tenets of business says, demand creates supply. And, logically, since the products are on the shelves of stores, 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 him. Should you start an acrylic bathtub business? What is needed for this? Let's figure out the intricacies of organizing a viable "industrial and plumbing" business.

Repair or production?

Before we start discussing specific business schemes, let's figure out what exactly you can do: 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 coatings of old cast-iron and steel baths by pouring acrylic with a hardener. The procedure does not require special equipment, it is performed on site. And she is in demand. Manufacturing - vacuum forming of the finished product using 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 bathtub with a service life of more than 10 years. On average, the mixture for one procedure costs about three thousand rubles, the master will take the same amount for the 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 15-18 thousand per day (5-6 orders).

It turns out to be a quite acceptable amount per month, and given that you do not invest in equipment or consumables, the business turns out to be quite good. Many entrepreneurs even work independently, optimizing costs and offering a service at an affordable price.

We produce

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

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

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

Who is the acrylic bathtub for?

Before planning the organization of production, you must first study the 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 puzzle over.

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 facilities, are working to reduce costs and have a stable sales market. It is difficult to kill them at the cost, quality - it may turn out to be unprofitable.

To illustrate this point, 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 uses modern and powerful equipment, which serves 3 people. The second one also has modern equipment, but less powerful, which also serves three people. Yes, don't be surprised. Modern technology fully admits such a situation.

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

Sadly for a budding 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 to retail stores if they already have products from a large manufacturer on their shelves. Explore companies in your and neighboring regions. If there is a large factory in them, then think about whether it is better to become its distributor than to invest in your own production?

Features of market conquest

No? Are you sure you have decided to devote yourself to the competition? Well, there are several tricks on this field that can play into your hands.

Get out of the mass market and start making an exclusive product. Baths on order. Painted under Gzhel or with the bottom of the Adriatic Sea. Anything the client wants. And for his money, of course. The market niche will be narrower, but this will give a chance to separate from the competitor. The disadvantage of large-scale production is its inertia. It takes months and years to rebuild a factory process. And your production is still flexible.
Additional services. Create your own online retail store and offer free shipping and installation for an equal price. Of course, this step must be calculated economically and not bring losses.
Focus on the quality of your production. Oddly enough, many customers still believe that the products of small businesses 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.
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 business formation.

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. Calculate everything again and get down to business. After all, even water does not flow under a lying stone. What can we say about money.

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