Stretch ceilings production and installation. We organize the production of stretch ceilings. Which ceilings are better: Chinese or German

Stretch ceiling has recently become an integral part of the interior of the house and office. Its indisputable advantages are moisture resistance and durability. There are a large number of options for colors, shapes and textures, which are due to the use of a special PVC film and special production technologies. In today's article, we propose to study the business plan of stretch ceilings and pay attention to the features of building this type of activity.

general information

A few years ago, there was practically no domestic manufacturer on the stretch ceiling market. All items were imported from Europe. Today, a large share in this segment is occupied by products manufactured in our country. Despite the fact that there are a large number of Russian companies producing stretch ceilings, experts assure that this business area is not highly competitive. It still has enough free space for beginners to this day.

Studies show that Russian consumers do not particularly trust the quality of products made in their own country. This prejudice is wrong when it comes to stretch ceilings. The materials from which they are made are of good quality, and the absence of transportation costs makes the domestic product competitive in price.

A Russian manufacturer can reduce the cost of a product by minimizing losses associated with the storage and transportation of materials. The PVC film of stretch ceilings, which is the basis for their production, can be damaged during long-term transportation, which will lead to significant losses when importing an order.

It should be taken into account that Russian companies often cooperate with European manufacturers and adopt their experience and technologies. This feature is the key to high quality products and enhances the reputation of the company.

Business features

Are you going to open the production of stretch ceilings? Then it should be understood that this type of activity will require significant capital investments, especially at the initial stage. In order to establish film production, it is necessary to purchase special equipment.

In addition, it is necessary to take into account the features of the premises where the production process is planned to be carried out. They must maintain the necessary climatic conditions and comply with production standards. Despite decent financial costs, the production of stretch ceilings pays off very quickly. In the future, you can count on significant profits.

Business "Stretch ceilings": where to start

Like any other type of activity, a newborn enterprise for the production of stretch ceilings should be formalized. To get started, you can register as an individual entrepreneur. This type of organizational and legal form will allow you to significantly simplify the financial and accounting business of the enterprise and save on taxes. When planning a large-scale production with large cash flows, it makes sense to think about registering a limited liability company or a joint-stock company.

In the registration documents, certain OKVED codes should be indicated. These are 25.23, 52.46.7 and 52.61. A license is not required for the production of stretch ceilings, however, certificates for the film from which they will be made must be required. It may be a good idea to conclude contracts for the supply of PVC film directly from its manufacturers.

Production of stretch ceilings. Cutting canvases

At the place of installation of the stretch ceiling, it is necessary to take measurements in advance. On their basis, a pattern of the canvas is made. A special computer program is engaged in the formation of a pattern drawing. The cutter prepares the components for the future ceiling, cutting the canvas exactly according to the scheme. A standard roll of German PVC film has a width of 1.3 to 1.8 meters. If the design provides for a large area, then the cut parts are soldered.

Spike seams

Equipment for stretch ceilings, namely the HDTV machine, makes it possible to ensure that the seams on the product are inconspicuous and very strong.

On a matte basis, it is almost invisible. The pattern is placed on the lower press of the welding surface of the electrodes. When the upper press with the electrode strip is lowered, the HDTV generator is started, and a working capacitor is formed between the electrodes.

High-frequency energy acts on the thermoplastic material, instantly heating it from the inside. The composition of tissues at the molecular level becomes mobile, thereby connecting the two segments into a single monolithic canvas.

After welding is completed, the generator is switched off and the pressurized film cools very quickly. Then the upper press is raised. The strongest seams are obtained with a short cycle, but this requires a powerful generator.

Harpoon

It is a flexible plate made of hard plastic, a special design-lock around the entire perimeter of the film, which is laid in a baguette and allows you to securely and firmly mount the ceiling structure. Using a harpoon installation, it is possible to dismantle the ceiling (for example, in case of a strong bay). The HDTV machine welds the harpoon in the edge of the PVC film web.

Quality checking

After soldering, all seams are checked manually. The prepared film is lined with a special air-bubble pad to avoid deformation during transportation. Then it is packaged.

Equipment

When creating a business plan for stretch ceilings, you should pay special attention to the purchase of equipment. Depending on the scale of production, its quantity can vary significantly. Here is the minimum calculation.

For production

• First of all, you need to purchase a two-station HDTV machine (high frequency welding). Its cost is 365 thousand rubles.
• For the operation of pneumatics, an air compressor is required, the receiver of which is designed for 50-100 liters. Its price is about 20 thousand rubles.
• Additional electrical equipment (machines, cables, etc.) will cost about 15 thousand rubles.
• The program for cutting ceilings and staff training will require another 30 thousand rubles.

For shop

• 2 cutting tables.
• Film racks.
• Tables for supplying PVC film to the machine (2 pcs).

The approximate cost of such a set of equipment is 80 thousand rubles.

For office

At the initial stage, in this position, you can save a little and arrange a mini-office in a small room of your own apartment or in one of the industrial premises. But in the future you will need:

• furniture (table, chairs);
• exhibition stand for displaying product samples and catalogs;
• office equipment (computer, printer);
• other stationery.

About 60 thousand rubles can be allocated to this item of expenditure. Summing up the above figures, we get the final result - 570 thousand rubles.

Perfect renovation is an integral part of the interior. The use of a tension structure allows you to give the ceiling an impeccable appearance. The canvas hides the defects of the rough surface, hides communications. With a harpoon installation system, you can easily dismantle the panel and gain access to the wiring. To guarantee our customers the highest quality, we opened our own production of stretch ceilings. Constant monitoring and compliance with all the rules for the storage of raw materials allows us to maintain the status of the best among all. Stretch ceilings own production helps to maintain punctuality in the execution of orders. By placing an order with us, you do not overpay to intermediaries, stretch ceilings are your own production near the company's head office.

Production of stretch ceilings Moscow

The workshop is located at the address: 32nd km of the Moscow Ring Road China Town shopping center on the -2nd floor. The building has an excellent air conditioning system. So that no material loses its original qualities and properties, the temperature regime is observed in the room. The production of stretch ceilings Moscow has huge racks that can fit hundreds of square meters of future ceilings. The goods are ready to go to the customer at any time. The production of stretch ceilings in Moscow is guarded around the clock and controlled by video surveillance.

Production of stretch ceilings prices

It is much more profitable to order the installation directly. The cost will not include spending on extra logistics, resale and other related costs, it turns out high quality and inexpensive. Production of stretch ceilings prices do not bite.

Production of PVC stretch ceilings

We have our own expensive two-station HDTV machine for welding harpoon and film with high-frequency current. All manipulations are carried out on it, including the soldering of two panels. Also, the production of PVC stretch ceilings has a compressor for pneumatic tools matched to industrial equipment.

Stretch ceiling manufacturer

The cleanliness of the cutting is ensured by a special platform, which is located at a height above half of human height. Particles of dust and dirt do not fall on the matter. The finished product is packed. Stretch ceiling manufacturer takes care of the entire production cycle.

Production of stretch ceilings in Moscow

There is always a warm friendly atmosphere in our team, so it is easy and pleasant for each employee to work. This factor has a positive effect on the overall production, we do the work efficiently and inexpensively. The production of stretch ceilings in Moscow is open daily, seven days a week.

The manufacture of a stretch ceiling was invented in the days of Ancient Greece. There, silk fabrics stretched over special wooden frames were used to decorate the ceiling of the houses of wealthy people. Modern stretch ceilings were invented in the last century, but gained special popularity only after 30 years.

In the photo, samples of stretch fabrics

Variety of stretch fabrics

From the beginning of the appearance of modern stretch fabrics, they were inaccessible to average citizens, since the price was very high. But thanks to the improvement of the production process and the increase in its scale, it was possible to make the cost of stretch panels more acceptable. And here this type of ceiling covering could be appreciated by the middle strata of the population. And not only appreciate it, but also love it very much, because no other type of ceiling covering can compete with durability, practicality and a variety of colors and textures of stretch panels.

The manufacture of a stretch ceiling can be made from two types of materials. In this regard, there are such types of stretch panels:

• fabric stretch ceilings;
• film pvc ceilings.

Tension sheets are supplied in rolls.

Production of a stretch ceiling from PVC film: technology

It is important to understand that the manufacture of a stretch ceiling and the production process of PVC film are two completely different technological processes. Polyvinyl chloride film is produced at chemical-technological enterprises. A few years ago, the main film manufacturers were only in Western Europe, but not so long ago they appeared in China and Russia. However, the cloths of European manufacturers are still considered the best because of their high quality.

If we talk about the process of manufacturing stretch ceilings, then in order to understand it, you need to know the main stages of installing the panel, namely:

1. In the installation room, at the required height, a profile for attaching the panel (baguette) is mounted to the wall. The profile is attached around the entire perimeter of the room.
2. Next, you need to deploy the prepared canvas with a harpoon welded around its perimeter. A harpoon is a special thickening that is welded to the cut film in the factory. It is needed to securely fix the canvas in a baguette.
3. For the ideal tension of the panel, it is necessary that the surface area of ​​the film is 10% smaller than the area of ​​the room.
4. In order for the cloth to become elastic and stretch easily, it must be heated to 60 degrees using a heat gas gun.
5. Now the canvas is fixed in the groove of the baguette with a spatula. After cooling, it stretches and melts perfectly even.

Production of a stretch ceiling

As you can see, in order for the ceiling to be well stretched and smooth, you need to accurately cut the panel. To do this, you need to take a pvc film made at the factory, which is available in rolls of various widths.

Important to know: European-made PVC film is supplied in rolls 1.5-2.2 m wide, therefore, for its installation in large rooms, it is necessary to weld individual parts of the sheet. Such ceilings are called sutural.

In this regard, the manufacture of a stretch ceiling made of PVC film is reduced to the precise cutting of parts of the panels and their welding. This requires the following equipment:

• spacious room with an area of ​​about 100 sq.m. and more;
• special cutting table;
• machine for making a weld.

Stand for rolls with pvc film

Cutting of a cloth is made according to the measurements of the room which are carried out on a place by experts. When the width of the room exceeds the width of the panel, high-frequency current welding is performed on the machine.

The most important thing in the work is the high quality and strength of the weld. Moreover, such requirements are imposed not only on the seam, but also on the welded harpoon. The reliability and durability of the entire stretch ceiling depends on this. By the way, the quality of work depends not only on the skills of the master, but also on the equipment. On an outdated cheap machine, the weld will not only be noticeable, but not durable.

Equipment for the manufacture of stretch ceilings

Fabric ceiling production

As for fabric cloths (), the manufacture of a stretch ceiling from this material is carried out directly at the installation site. This is possible because the width of a roll of fabric sheets is 3.5-5.5 meters, therefore, for most rooms, seamless installation is possible and a welded seam on machines is not required. In addition, fabric sheets are fixed in the baguette not with a harpoon, but with a wedge connection. In this way, the need for welding the harpoon at the factory is also eliminated.

The process of preparing a fabric web for installation is reduced to cutting it according to the size of the room. Moreover, when installing fabric stretch ceilings, a heat gun is not used, and therefore, the canvas does not stretch as much as PVC film. In this regard, when cutting the panel, it is not necessary to reduce its area by 10% of the size of the room, on the contrary, it is necessary to make a small allowance around the perimeter of the panel for the convenience of wedge fastening. Excess fabric is cut in place after installation.

Stretch ceiling printer

Equipment for the manufacture of stretch fabrics

If you want to open your own business for the manufacture of stretch ceilings, then you will need to purchase the equipment necessary for this, namely:

• HDTV machine;
• compressor;
• cutting table;
• serving table;
• packing table;
• racks for storage of film rolls.

The HDTV machine for making welds on the canvas and welding the harpoon costs about 300-350 thousand rubles. The compressor will cost you 15 thousand rubles. In addition, it is worth buying various electrical appliances: cables, machines and much more. It will take you about 11-12 thousand rubles for such details. Thus, for all equipment with tables and racks, you will have to pay about 55-85 thousand rubles.

Panel cutting

Tip: do not forget to include in your business plan the cost of renting space for a workshop for the manufacture of stretch ceilings. In addition, small consumables may be needed, namely chipboard sheets, substrates, corners, etc.

Profitability of production of stretch ceilings

When all the necessary equipment has been purchased and the production room is ready for opening, you can start manufacturing the stretch ceiling. However, do not forget to stock up on consumables. You need to buy:

• plastic baguette;
• film cloth;
• harpoon;
• tool;
• decorative masking tapes;
• packaging materials (bubble wrap, boxes, adhesive tape).

It will take you about 100 thousand rubles to purchase the first batch of consumables.

Production and packaging of stretch ceiling

To understand how much you need to purchase consumables, you can use the ready-made formula. So, for the manufacture of 1000 sq.m. stretch ceiling you need to buy:

• 1000 p.m. baguette for 22 rubles. per meter (made in Russia);
• 1000 p.m. inserts for 10 rubles. per meter (domestic producers);
• 700 p.m. harpoon for 10 rubles. per meter (Russia).

It is better to take a PVC film made in Europe, for example, a PVC sheet (Germany) costs 60 rubles per 1 square meter. So much will have to be paid for a colored ceiling, the white color of the canvas will be a little cheaper. There is also a slight difference, take a glossy or matte ceiling. Premium decorative ceilings are the most expensive. .

Although there are forecasts that over time, domestic-made canvases will be forced out of the European counterparts from the market. Judge for yourself, for the manufacture of 1 square. m. of a stretch ceiling made of domestic materials will have to pay 400 rubles, and the same ceiling made of European materials costs 500-900 rubles.

HDTV machine

Tip: if you plan not only to sell ceilings, but also to install them, then you need to hire about 6 workers to create 3 teams of two people. Approximately 15-20 thousand rubles will go to the salary of employees. per month for each.

All your investments will pay off within the first 6 months of work, provided that you establish sales and keep the brand on top. As you can see, the manufacture of a stretch ceiling is a highly profitable promising business in our country.

On the video we have proposed, you can see how a stretch ceiling is made.

Millions of Russians who have installed modern structures in their apartments, shops, and offices have no doubts about the impeccable appearance and reliability of stretch ceilings. Nevertheless, installers still have a lot of work to do, because the quality of our housing is known to everyone, and major and cosmetic repairs are a procedure that no one could avoid, even the owners of apartments in new buildings. Modern decoration forever frees you from the need to deal with putting the ceiling surface in order.

Who can install a stretch ceiling for you? It can be anyone - a familiar master, an installation team. You will be able to install a simple design even with your own hands - this is not as difficult as it might seem at first glance. But in any case, nothing will happen without the participation of a local or all-Russian factory of stretch ceilings.

The design of a modern stretch ceiling consists of a frame and a canvas stretched in it. The frame is made of an aluminum or plastic profile, fixed along the perimeter of the walls. The installation procedure is simple and in many ways resembles the manufacture of a frame for a suspended drywall or panel system.

With the canvas, everything is much more complicated. Most stretch ceilings are made on the basis of PVC film. As a rule, its width is one and a half meters. In recent years, Chinese-made PVC film with a width of up to five meters has appeared on the Russian market. However, its range is small due to the fact that manufacturers have not yet learned how to pigment a wide canvas with high quality. The bulk of the canvases is made by assembling using a HDTV machine from several cuts of material.

The most practical way of attaching the canvas to the frame is called harpoon. The tension of the material is achieved due to the fact that at room temperature the canvas is 7% less than the base ceiling, and before installation it is heated to a temperature of + 70C. A harpoon is welded along the edges of the canvas during manufacture, which fixes it in the grooves of the mounting baguette. The cooled film is stretched, and the surface becomes absolutely flat.

Thus, the main event is taking place at the factory of stretch ceilings - the production of a canvas ready for installation in the frame of the structure. Everything else is a matter of technique. It follows that the business of stretch ceilings can be divided into two interrelated areas - production and installation.

Who is a Stretch Ceiling Dealer?

In every Russian city you can find a company that installs stretch ceilings. As a rule, this is a dealer of a large company. There are, however, ordinary entrepreneurs who carry out orders for the installation of ceiling structures. However, it is more reliable and promising to be a dealer due to the constant technical, informational and consulting support from the enterprise. Of no small importance is the fact that cooperation is organized on a mutually beneficial basis. The dealer is always offered special prices for materials and components. His requests for the production of canvases are carried out in strict accordance with the contract. It is not at all necessary that the dealer and the company are located in the same city or region. An example is the Moscow factory of stretch ceilings, which has been developing its dealer network for more than ten years. Its dealers operate not only in Moscow and the region, but throughout Russia. Moreover, in many regional centers of neighboring countries, local entrepreneurs have signed contracts with the factory.

The essence of the work of the dealer is as follows:

• After receiving the application, a measuring technologist is sent to the object. His duty is not only to draw up a drawing of the future stretch ceiling, but also to agree on its design, to offer the client a catalog for choosing the material of the canvas.
• Drawing by e-mail or personally sent to production. The sheet is made there and sent to the address indicated by the dealer by a convenient means of delivery.
• Having received the canvas, the installers arrive at the site on the day and hour agreed with the customer and install the structure. It all ends with the signing of the Act of execution of works. After that, the dealer automatically assumes obligations for warranty service of the stretch ceiling.

As you can see, there is nothing particularly difficult. The dealer needs an office where the constant presence of at least one manager is sufficient. The assembly team consists of two people. The number of teams depends on the number of orders. The measurer can be either a separate staff unit, or a part-time installer. The team turns out to be small, but the business, with the right organization, develops successfully.

Stretch ceiling factory

Own production of stretch ceilings is a serious business. If a dealer needs only 30,000 rubles for a complete assembly of one assembly team, then serious investments are needed to start production at the factory.

• First of all, we need production facilities for the workshop, warehouses, office.
• In the workshop, the main tool is a two-station HDTV machine. It is on it that the fabric is made and the harpoon edging is welded. You can buy an imported or domestic machine, new or used. On average, it costs about 350,000 rubles. The machine must be equipped with an air compressor, and this is about 15,000 more. Approximately the same amount will be spent on the purchase and connection of a power cable, automation.
• In the workshop, in warehouses and in the office, furniture, shelves, racks, packing tables, office equipment and a thousand other little things are needed.
• To start your own production of stretch ceilings, you need at least the necessary minimum of a vinyl sheet of various textures and colors, fabric material, plastic and aluminum profiles, a harpoon, and inserts. Naturally, you can not do without packaging material. The minimum set for the first time will cost at least 100,000 rubles.
• The factory produces canvases not only for dealers, but also for their own needs. Therefore, the state must have installers staffed to fulfill orders. A set of tools for one team costs 30,000 rubles.

At first glance, it might seem that creating your own

The Deluxe company has its own production of stretch ceilings in Moscow, which is equipped with the most modern high-tech equipment. This allowed us to establish strict quality control of stretch ceilings at all stages of the production cycle. Our company produces products that meet the highest international standards for all criteria and requirements. Such an integrated approach distinguishes our stretch ceilings from competitors' stretch ceilings.

Own production allowed us to provide you with a number of significant advantages:

• for the production of stretch ceilings, we use only certified PVC films and other consumables;
• our specialists carry out constant quality control at all stages of production: from the receipt of raw materials to the output of finished products;
• Stretch ceilings produced by us are made according to exact individual sizes;
• all offered textures and colors of PVC films are kept in stock in our warehouses, so we start producing stretch ceilings immediately after receiving your order;
• own production makes it possible to offer you the widest range of products. Here you can order a classic (matte or glossy), multi-level, artistic stretch ceiling or stretch ceiling "Starry sky";
• the capacities of our production allow us to implement orders of various volumes and complexity while maintaining optimal production times even during periods of peak loads;
• the absence of intermediaries allows us to significantly reduce the cost of stretch ceilings.