Production scale

Mass production of windows

From a capacity of 100 window units per day, one speaks of mass production. To make this high production capacity possible, a high degree of automation and efficient machine technology is necessary. Mass production is favoured by the reduction of the number of variants. If only standard windows are produced, factories with a daily capacity of 1,000 window units and more are possible. Manual work steps are then avoided as far as possible, and a low-manpower production approach is usually chosen. The minimisation of production costs is of great importance; it justifies the comparatively high investments in machine technology.

Complexity

Standard windows

Window combinations

Complexity

Standard windows

Standard windows have a simple geometry with one or maximum two sashes in standard dimensions. This is where mass production can prove its strength, as many identical or very similar parts have to be produced. The production is usually organized as a flow process on an angular plant. Comparing the different approaches to window production, this way the maximum plant output (window units per day) is possible at minimum production costs.

Standard windows are almost always produced to stock: The windows are carefully packed individually, stored temporarily and only then sold through retailers.

Production Process

Cutting to size
Cross-cutting
From the scantlings in standard delivery lengths, all required parts for window frames and sashes and, if necessary, the glazing beads are cut out. There are numerous variants of cross-cut saws, both cutting from above and from below.
Learn more about Cross-cut saw and Circular saw blade in production step Cross-cutting
Planing
All parts are planed on four sides to obtain perfectly flat surfaces and right angles. This step is important for the dimensional accuracy and precision of all further processing. Usually the material for the glazing beads is cut out of the frame parts in the same operation.
Learn more about Four-sided planer and Cutter head, Saw blade in production step Planing
Production of frames and sashes
Crosswise processing
The frame and sash parts receive their end-face profile, depending on the selected corner joint. For dowel connections, the dowel holes must be inserted in a further step.
Learn more about Tenoning machine, Double-end tenoner, Single sided profiling machine and Cutter head in production step Crosswise processing
Longitudinal processing
The longitudinal sides of the frame and sash parts receive their profile. Any tear-offs that may have occurred during end processing are milled away. For dowelled corner connections, dowel holes must be drilled in a further step.
Learn more about Moulder and Cutter head in production step Longitudinal processing
Sanding
Evenness is important for the appearance and also the durability of the surfaces. Any planing marks from the previous steps must be removed. The longitudinal sides of all parts are therefore usually machine sanded on four sides before gluing. This step can be omitted if the longitudinal processing is of very good quality, or it can also be done after the gluing. However, the internal profiles can then only be sanded manually.
Learn more about Profile sanding machine, Wide belt sander, Brush sanding machine, Orbital sander and Profile sanding tool in production step Sanding
Gluing
The individual frame and sash parts are each joined together to form a finished raw product. This includes glueing (application of the glue), if necessary inserting dowels and screws in the corner joints, assembling the parts and subsequent pressing, including the waiting time until the glue has cured.
Learn more about Frame press, Dowel inserting machine in production step Gluing
Surface finishing
Sanding
Evenness is important for the appearance and also the durability of the surfaces. Any planing marks from the previous steps must be removed. The longitudinal sides of all parts are therefore usually machine sanded on four sides before gluing. This step can be omitted if the longitudinal processing is of very good quality, or it can also be done after the gluing. However, the internal profiles can then only be sanded manually.
Learn more about Profile sanding machine, Wide belt sander, Brush sanding machine, Orbital sander and Profile sanding tool in production step Sanding
Coating
Spraying robots, dip coating or flowcoating plants are used to apply the lacquer. Manual spraying in a spray booth is also possible. Vacuum coating of the profiled parts before gluing is a speciality. In any case, air pollution control is important to ensure a high surface quality and to protect the environment.
Learn more about Dip coating plant, Flowcoating system , Spraying robot, Vacuum coating system , Spraying booth and Spray gun in production step Coating
Fitting
Installing fittings
Sashes and frames receive their mechanical parts or fittings. This includes everything except the window handle, which is only mounted after the window is installed.
Learn more about Cordless screwdriver in production step Installing fittings
Completion
Planing of the glazing beads
The glazing beads are made from the raw material that was sawn out during the four-sided planing of the window scantlings. First, they are profiled lengthwise in a moulder.
Learn more about Four-sided planer and Cutter head, Saw blade in production step Planing
Surface finishing of glazing beads
The glazing beads receive the same surface treatment as the sash parts.
Learn more about Dip coating plant, Flowcoating system , Spraying robot, Vacuum coating system , Spraying booth and Spray gun in production step Coating
Mitre cutting of glazing beads
The glazing beads are precisely mitred to fit each window sash. This can be done by sawing or punching.
Learn more about Mitre saw and Circular saw blade in production step Mitre cutting of glazing beads
Glazing
The last processing step on the window sash is glazing. There are auxiliary devices for handling the panes; apart from this, the glazing is done by hand: the pane is inserted, blocked according to the mounting and opening variant and fixed with glazing beads. Silicone is usually used for sealing. A drying time must then be kept.
Assembling and packing the element
Finally, window sashes and frames are combined, i.e. the sashes are manually inserted into their frames. When the windows are now placed on the market, they must be packaged to protect them from damage. If the windows go from the factory straight to the construction site, they are usually transported unpacked in a vehicle equipped for this purpose.

All manufacturers in production process: Windows – Mass production – Standard windows 27

Tools for production process Windows1

Besides machinery, also additional devices and gadgets are used in woodworking. Machine tools for Windows production are listed here.

Portable spraying equipment (e.g. guns for lacquers / adhesives)
E.g. used in:Carcass furniture, Windows
manufacturers1

Show all

Window combinations are individual productions according to customer specifications or according to measurements taken on site. Several window sashes or fixed glazings are mounted in a combined frame. The mass production of window combinations is the highest degree of difficulty, since a large number of variants must be mastered despite the high throughput. This requires CNC technology in the form of specialised processing centres.

After gluing, the elements are usually large and irregularly shaped. Flow production is therefore often not an option. Machining is also made difficult or even impossible by the dimensions.

Window combinations are transported directly to the customer after production and installed there. Therefore, the same demands are not made on the packaging as for standard windows.

Production Process

Cutting to size
Cross-cutting
From the scantlings in standard delivery lengths, all required parts for window frames and sashes and, if necessary, the glazing beads are cut out. There are numerous variants of cross-cut saws, both cutting from above and from below.
Learn more about Cross-cut saw and Circular saw blade in production step Cross-cutting
Planing
All parts are planed on four sides to obtain perfectly flat surfaces and right angles. This step is important for the dimensional accuracy and precision of all further processing. Usually the material for the glazing beads is cut out of the frame parts in the same operation.
Learn more about Four-sided planer and Cutter head, Saw blade in production step Planing
Production of frames and sashes
Transverse and longitudinal profiling
Sash and frame parts are finished on a machining centre from all sides, i.e. the transverse and longitudinal profiling is carried out and the necessary holes are drilled for frame joints, for the fittings and, if necessary, for the corner joint with dowels. For this machining step, either ordinary table machining centres or centres that specialise in the machining of window parts can be used.
Learn more about Table Machining Center, Machining centre for window parts and Cutter head, Shank cutter, Drill in production step Transverse and longitudinal profiling
Sanding
Evenness is important for the appearance and also the durability of the surfaces. Any planing marks from the previous steps must be removed. The longitudinal sides of all parts are therefore usually machine sanded on four sides before gluing. This step can be omitted if the longitudinal processing is of very good quality, or it can also be done after the gluing. However, the internal profiles can then only be sanded manually.
Learn more about Profile sanding machine, Wide belt sander, Brush sanding machine, Orbital sander and Profile sanding tool in production step Sanding
Gluing
The individual frame and sash parts are each joined together to form a finished raw product. This includes glueing (application of the glue), if necessary inserting dowels and screws in the corner joints, assembling the parts and subsequent pressing, including the waiting time until the glue has cured.
Learn more about Frame press, Dowel inserting machine in production step Gluing
Surface finishing
Sanding
Evenness is important for the appearance and also the durability of the surfaces. Any planing marks from the previous steps must be removed. The longitudinal sides of all parts are therefore usually machine sanded on four sides before gluing. This step can be omitted if the longitudinal processing is of very good quality, or it can also be done after the gluing. However, the internal profiles can then only be sanded manually.
Learn more about Profile sanding machine, Wide belt sander, Brush sanding machine, Orbital sander and Profile sanding tool in production step Sanding
Coating
Spraying robots, dip coating or flowcoating plants are used to apply the lacquer. Manual spraying in a spray booth is also possible. Vacuum coating of the profiled parts before gluing is a speciality. In any case, air pollution control is important to ensure a high surface quality and to protect the environment.
Learn more about Dip coating plant, Flowcoating system , Spraying robot, Vacuum coating system , Spraying booth and Spray gun in production step Coating
Fitting
Installing fittings
Sashes and frames receive their mechanical parts or fittings. This includes everything except the window handle, which is only mounted after the window is installed.
Learn more about Cordless screwdriver in production step Installing fittings
Completion
Planing of the glazing beads
The glazing beads are made from the raw material that was sawn out during the four-sided planing of the window scantlings. First, they are profiled lengthwise in a moulder.
Learn more about Four-sided planer and Cutter head, Saw blade in production step Planing
Surface finishing of glazing beads
The glazing beads receive the same surface treatment as the sash parts.
Learn more about Dip coating plant, Flowcoating system , Spraying robot, Vacuum coating system , Spraying booth and Spray gun in production step Coating
Mitre cutting of glazing beads
The glazing beads are precisely mitred to fit each window sash. This can be done by sawing or punching.
Learn more about Mitre saw and Circular saw blade in production step Mitre cutting of glazing beads
Glazing
The last processing step on the window sash is glazing. There are auxiliary devices for handling the panes; apart from this, the glazing is done by hand: the pane is inserted, blocked according to the mounting and opening variant and fixed with glazing beads. Silicone is usually used for sealing. A drying time must then be kept.
Assembling and packing the element
Finally, window sashes and frames are combined, i.e. the sashes are manually inserted into their frames. When the windows are now placed on the market, they must be packaged to protect them from damage. If the windows go from the factory straight to the construction site, they are usually transported unpacked in a vehicle equipped for this purpose.

All manufacturers in production process: Windows – Mass production – Window combinations 29

Tools for production process Windows1

Besides machinery, also additional devices and gadgets are used in woodworking. Machine tools for Windows production are listed here.

Portable spraying equipment (e.g. guns for lacquers / adhesives)
E.g. used in:Carcass furniture, Windows
manufacturers1

Show all

Necessary peripheral devices for Windows8

Briquetting presses
E.g. used in:Carcass furniture, Windows, Wooden stairs, Mass Timber
manufacturers6
Chips and dust extraction systems (including filters)
E.g. used in:Windows, Wooden stairs, Mass Timber
manufacturers7
Chopping machines (slow-speed)
E.g. used in:Windows
manufacturers9
Extraction machines, stand alone
E.g. used in:Windows, Mass Timber
manufacturers8
Extraction systems
E.g. used in:Carcass furniture, Windows, Flooring, Wooden stairs
manufacturers8
Fire and spark extinguishing systems
E.g. used in:Carcass furniture, Windows, Flooring, Wooden stairs, Mass Timber, Wood-based Panels
manufacturers6
Silos
E.g. used in:Windows
manufacturers8
Stationary hoggers
E.g. used in:Windows, Wooden stairs, Mass Timber
manufacturers8

Show all

Mass production of windows

Cutting to size

Cross-cutting

Planing

Production of frames and sashes

Crosswise processing

Longitudinal processing

Sanding

Gluing

Surface finishing

Sanding

Coating

Fitting

Installing fittings

Completion

Planing of the glazing beads

Surface finishing of glazing beads

Mitre cutting of glazing beads

Glazing

Assembling and packing the element

Tools for production process Windows1

Portable spraying equipment (e.g. guns for lacquers / adhesives)

Cutting to size

Cross-cutting

Planing

Production of frames and sashes

Transverse and longitudinal profiling

Sanding

Gluing

Surface finishing

Sanding

Coating

Fitting

Installing fittings

Completion

Planing of the glazing beads

Surface finishing of glazing beads

Mitre cutting of glazing beads

Glazing

Assembling and packing the element

Tools for production process Windows1

Portable spraying equipment (e.g. guns for lacquers / adhesives)

Necessary peripheral devices for Windows8

Briquetting presses

Chips and dust extraction systems (including filters)

Chopping machines (slow-speed)

Extraction machines, stand alone

Extraction systems

Fire and spark extinguishing systems

Silos

Stationary hoggers