The Kaleva window profile is snow-white, with a glossy surface. It uses an innovative camera layout - with two rows of cameras placed outside, which increases the energy-saving characteristics of the windows. The company's official website talks about the production of PVC windows, materials and product quality. The Kalev plant is an example of effective labor organization.

The production of Kalev windows is carried out from high-quality imported raw materials. The Kaleva plant is equipped with equipment from such world-famous companies as GREINER (Austria), Krauss Maffei (Germany), CINCINNATY EXTRUSION (Austria), Reimelt Henschel MischSysteme GmbH (Germany).

Our own extrusion production allows us to control the quality of the profile produced. Each batch of PVC profiles manufactured at the Kalev plant for the production of plastic windows is tested according to key indicators.

The first assessment is visual: the Kaleva window profile is snow-white, with a glossy surface and perfectly smooth, which is important for the quality of the windows (even a slight curvature of the profile makes it impossible high quality manufacturing PVC windows according to customer sizes).

The strength characteristics are checked at sub-zero temperatures: the profile is maintained in freezer, and then tested for resistance to sudden mechanical impact (impact) - a load weighing 1 kg freely falls from a height of 1.5 meters. In the cold, the fragility of plastic is known to increase significantly. A high-quality profile should not have chips or cracks.

The Kaleva profile is also tested for tensile strength and change in linear dimensions - for this purpose it is kept at a temperature of 100°C for 2 hours.

Separate heat resistance test: profile softening temperature for manufacturing metal-plastic windows should be at least 75°C, and after holding for 30 minutes at a temperature of 150°C there should be no swelling, cracks or delaminations.

In all respects, the Kaleva profile meets the requirements high quality. With Kalev's technologies, the production of plastic windows has stepped forward.

At the Kalev plant, production is built according to the most advanced industry requirements. The service life of the Kaleva profile, confirmed by tests in accredited laboratories, is 70 conventional years.

You can buy windows made from high-quality Kaleva profiles at the company's representative offices in Moscow and more than 80 cities in Russia.

The production of windows from PVC profiles consists of several stages and is carried out using new generation technological equipment. For the most critical processes today, CNC machines are used, thanks to which it is possible to achieve high precision cutting and assembly. In the production of windows, both format-cutting centers and machines for milling, cutting glazing beads, welding parts and stripping are used corner connections. Manufacturing window designs is always performed in a strictly defined sequence, and this article will tell you about all the main stages of production.

Measurement of plastic windows

The manufacturing process always begins with measurement, and this procedure cannot be isolated from all other stages. It is recommended, since only a specialist knows all the nuances of this process. When customers decide to independently determine the dimensions of windows, they allow standard errors, as a result of which the sizes of windows and openings do not match up or down. Both options are bad because they provoke:

• need to fulfill additional work on adapting openings before installing windows with incorrect sizes;
• depressurization of structures around the perimeter assembly seam;
• deformation of sashes and frames;
• depressurization of the glass unit.

In some cases, if the dimensions are incorrectly determined, it is necessary to order new windows. If the dimensions are provided by the client, all work is performed at his expense.

Specification preparation

Today, determining the size of parts and their quantity is carried out on computers using special software– no one does calculations manually with a calculator. After handing over the documentation to the surveyor, the designer enters all the necessary data into the computer, and the program calculates the dimensions of frames, sashes, double-glazed windows and each component element separately. Then this information is electronic form transferred to workshops for the production of double-glazed windows and window or door blocks.
Some window manufacturers can order double-glazed windows from companies that specialize only in the production of these products. However, the point technological process it does not change where exactly these window elements will be manufactured.

Double-glazed window production

This stage of window manufacturing is also partially automated. All large and medium-sized double glazing enterprises today use CNC centers for glass cutting. Moreover, in some cases, automation affected not only the cutting procedure, but also the assembly of finished products. The entire production process of double-glazed windows is as follows:

When will the sealant go through? full cycle polymerization, which requires from 3 to 12 hours, the double-glazed window is ready for transportation to the workshop where the main production of plastic windows is carried out.

Production of window and door blocks from PVC profiles

This process consists of several stages - cutting, milling, reinforcement, welding (fusion), grinding connecting seams, integrating mullions and tying with fittings. After this, the design of window or door units can be considered virtually ready. All that remains is to insert double-glazed windows into the light openings of the sashes.

Preparation of PVC profiles

This stage includes several procedures. To prepare profiles for the assembly of window structures, three operations are performed with them in sequence:

1. Cutting - according to the specification that came from the computer in the design department to the CNC machine in the workshop, PVC profiles are cut at an angle of 45 degrees.


2. Milling - During this stage, small holes are cut in certain areas of some parts. This procedure is necessary to create drainage channels in the structures of door and window blocks.


3. Reinforcement - steel liners are cut to the dimensions of already cut profiles, which are inserted into the internal chambers and fixed with metal screws. This significantly increases the rigidity of plastic parts.

After completing the listed activities, the profiles are considered ready for assembly into frames and sashes. These steps are performed on welding and stripping machines.

Assembly of window and door blocks

The optimal result, which ensures high strength and precision of connections, is achieved by simultaneously connecting all joints of the frame or sash. That is, all 4 corner connections must be made at once. This can only be achieved with automated equipment. The fusion of profiles is carried out at high temperature and pressure. If you violate optimal mode welding, the quality of the seams will be unsatisfactory.

To achieve the required parameters in strictly fixed gaps between parts made of PVC profiles Special Teflon elements are lowered to melt the plastic. After reaching the desired temperature, the non-stick coated plates are quickly raised, and all parts are simultaneously pressed against each other and held until the plastic hardens completely. Before moving on to the next stage, the machine independently checks the strength of the connecting seams.

Cleaning corner joints

Since the molten plastic is partially squeezed out when joining PVC parts, the joints after fusion of the profiles look very rough. It seems that the frames and sashes are covered with wide scars at the corners. To give the structures a normal appearance, all exposed plastic is removed using a special milling machine. This equipment not only removes excess polyvinyl chloride from joints, but also sands reduced-sized seams. Thanks to this procedure, frames and sashes made of PVC profiles acquire a presentable appearance.
If a laminated profile is used to make windows, after welding and cleaning the seams, narrow white stripes appear at the corner joints. This technological flaw is eliminated by painting over the joints with special markers, the color of which matches the color of the decorative film.

Not long ago, a production technology appeared on the market that makes welding seams invisible to the naked eye.

Milling and integration of mullions

Imposts are inserted into ready-made structures. To integrate the mullions, they must be adapted to the shape of the profiles. This procedure is performed using a special milling cutter that removes excess plastic. After adjustment, the imposts are either attached using corners and self-tapping screws, or welded into the main structure.

Installation of door opening systems

Installation of fittings is carried out on special stands. If such equipment is not available, the harness is attached manually using templates. Along with the installation of the main fittings, the mounting of the strikers from inside the light openings and the fixation of the control handles for the opening systems, which are connected to locking mechanism accessories.

Attaching seal circuits

To fix the seals in the profiles, special grooves are provided. The greater the number of circuits, the higher the level of window tightness. As a result, it is recommended to use systems in which their number is at least three. Sealing contours different shapes are inserted into the grooves on both frames and sashes, after which the window or door units are ready for the final stages of assembly.

Hanging sashes

Elements of the opening mechanism (hinges) are available both on the frame and on the doors. Thanks to this, when performing the hanging procedure, you just need to insert the sashes into the light openings and fix the fittings.

Installation of double-glazed windows

Before performing this procedure, it is necessary to wipe the seals and glass, and also remove any remaining smeared sealant, if any. On inside frames and sashes should be free of dust and other debris. Double-glazed windows are inserted into the light openings after fixing the straightening plates, after which they are fixed using clamping beads. These operations are performed manually and in a strictly defined sequence. Sometimes double-glazed windows are inserted into openings already on site during

Most window companies work with intermediaries who fulfill the products in isolated and remote bases. Such production in “incognito” mode complicates control over the quality of goods, and the final product may differ greatly from the desired one. The advantageous difference of the Windows Master company is own production metal-plastic windows at a plant in Moscow. The company has been pleasing users with warm and cozy windows, which are produced in workshops at our own plastic production plant Rehau windows. In 2007, the plant completed the installation of high-quality equipment, which reduces manual labor costs to zero and allows processing up to 300 prefabricated units per day.

Standard structures workshop

At the Rehau PVC window production plant there is a department for creating basic window systems, which are adapted to the climatic conditions in Moscow and the Moscow region. The department is equipped with equipment from the German manufacturer SCHIRMER and ROTOX - these are the machines that allow us to achieve high accuracy and speed of work. More than 250 people involved in production use the unique developments of Rotox. The plant's operating process is automated as much as possible, and its operation is aimed at the final goal - the creation of durable translucent structures.

Aluminum structures workshop

The plant for the production of plastic windows is also equipped with a separate workshop for aluminum systems. This department is equipped with German SCHIRMER and ROTOX machines, which are designed for processing aluminum and stainless steel profiles. The aluminum systems section offers customers a variety of products - light balcony compositions, serious facade glazing, portal windows and doors. The window production process is completed at the profile receiving lines: here finished goods undergo quality control.

Non-standard designs workshop

To realize the most daring design ideas equipment from the department is used Not standard designs. This is where window systems of interesting configurations are born. During the manufacture of plastic windows, the achievements of the global brand Rehau, which develops energy-efficient systems, are used. The department is equipped with automatic German lines that allow you to create products with any bending radius. Department employees also create compositions of round, oval, triangular and trapezoidal shapes.

Lamination workshop

The production of Euro windows is developing in accordance with popular sentiment - buyers are increasingly choosing interesting textures for the design of window systems. The plant has a special lamination department, in which any customer's imagination is realized - from ordinary window lamination to creating an imitation of expensive wood - walnut or oak. The department operates lamination machines that apply decorative films to profiles. Thanks to the launch of the lamination workshop, the time required to work with colored structures has been reduced.