INFORMÁCIÓ ÉS AJÁNLATKÉRÉS
INFORMATION AND QUOTATION
Vissza
kisber-uzem-kav-hungaria
2021 / 07 / 21
Home > News > Production of custom doors and windows at the KAV plant

Production of custom doors and windows at the KAV plant

Most domestic companies selling aluminium doors and windows do not have their own production capacity. However, in KAV’s imposing manufacturing plant, they are able to resolve even seemingly impossible profile connections. This is where further thought-out versions of Schüco or Reynaers profile elements and completely unique door and window solutions are manufactured, designed and developed by KAV engineers. We talked to Albert Herbut, the head of KAV’s Kisbér plant, about the production processes and the operation of the plant.

 

What does the production process for aluminium doors and windows look like?

 

At KAV, all processes start in our Budapest office. They consult with the customer, based on which they send us the needs: designed manufacturing material that includes what aluminium structures they want and what the structures should look like. We order the material for these. Pending the arrival of the material, we will prepare the product plans (cutting plans, milling patterns and 3D CAD plans on how to assemble them), then we can find out what other fittings and seals are still needed. Our colleagues in Pest calculate the price using the same software, from where we then prepare the production plans. So they’ll already explore 99 percent of what the customer wants in the calculation phase, based on which we start the production process. We group together to produce the aluminium doors and windows simultaneously, with an identical type of production. There are many different processes performed in the plant, so we try to simplify the tasks to some extent. We tend to sort by profile group: let’s say we first manufacture tilt-and-turn and fixed components and lifting-sliding structures; aluminium doors are manufactured separately; if there are curtain walls and/or glass roofs, they again belong to a separate group. We work with dedicated software and CAD software, which we verify at the end, but we can usually maintain 99 percent preparation accuracy. After tailoring, a barcode label is fixed to the profile, based on which the machining centre can identify the profile. They perform the machining operations: they mill the special connection points and glue injection gaps and holes and prepare the place for the lock, rivet holes, dewatering holes and milling.

 

Where is the biggest challenge, or even the biggest chance of making a mistake in this process? Does it matter how thin or large an aluminium window or door is?

 

The biggest possibility of error, I think, comes during the planning process: how can we implement what was requested? At KAV, we usually always have some extra and unique knowledge, a special solution in any aluminium door and window system. Something the customer has dreamed of, and our sales colleague may not spot that it’s not feasible that way. There may also be errors in the software, which, if left unnoticed, can even go through, all along the machining process, and then we have to start the process all over again. The biggest challenge is that KAV engineers combine a lot of things that are not included in any given system; in other words, that aren’t basic solutions. This is what we are famous for: we do something that others can’t. However, these custom solutions must always be reconciled with the standard components. We manufacture quite a lot of parts for ourselves, such as custom corner elements that are not provided as accessories in the relevant system. If an aluminium sliding door, window or door component has a connection at the corner other than 90-degrees, we always have to manufacture custom corner elements for it. In such a case, the milling and the connection point are redesigned. And if a thermal bridge-free extension or special fastener is needed, we design a 3D printable component – these are still manufactured by third parties – and then add it to our structure.

 

You have worked in many places in the profession. How does KAV differ from a factory producing standard doors and windows?

 

Mainly that we don’t only try but also meet special needs. An aluminium system supplier such as Reynaers or Schüco came up with a solution that has a glass-to-glass connection at right angles to the corner, with no other profile component. This in itself is quite a special structure; it counts as rarity that we produce anything like this. However, we further develop this, by saying that the two glass planes should meet at, say, 112.3 degrees rather than 90 degrees. In such a case, completely new corner elements must be manufactured; completely different milling patterns must be brought together. But it also happens that we try to put together two mismatched profiles that basically wouldn’t be able to meet in reality, so a 3D printed component is used. For example, a four-rail sliding door is now combined with a three-rail sliding door in a corner-opening design. These are just two examples, but I think it is clear that we are able to solve the almost-impossible.

 

Do you like these challenges?

 

I think I would have a hard time if I only had the task of how I could better optimise production, packaging and delivery. I really enjoy what I’m doing now. It’s hard when they try to have these special aluminium doors and windows designed and manufactured by us to a schedule, as if they were system structures. We need to factor into the process that we have to figure these out, and we may not succeed at first, and we need to adjust the a bit more. We may not always be able to estimate the lead time for everything perfectly, especially the time for preparing and manufacturing custom goods. But I love that we create something unique, that no one else does.

 

During the production of custom aluminium doors and windows, will you also need to test to see if a solution really works in the way the engineers and the software designed it?

 

We know about many things by experience, that it will work. The more custom windows we make, the more we are able to assess which solution works, what can be solved, or how a standard Schüco or Reynaers component can be improved. But a pitfall can occur at any time: we don’t notice that two mechanical components don’t fit precisely, or if something has to stand at a different angle. Fortunately, it occurs very rarely that we have to completely re-manufacture a structure.

 

Is aluminium, as a raw material, really capable of such miracles that almost anything can be made out of it?

 

Aluminium is a relatively lightweight but very robust material. It can be used to create thinner door and window structures that cover less of the view. However, we need to adjust to the system suppliers’ profile connections, i.e. those of Schüco or Reynaers. For example, we can’t fit the sash profile of one manufacturer into the casing of the other manufacturer,. We need to adjust to the basic concept of the profile system suppliers and be able to push the limits with them, as this is the basis for factory production control as well as having a declaration of performance issued. But we are already working on the big dream that KAV will have its own system solutions, even within another product range of our suppliers.

How does the supplier process work? Is there any element that can only be purchased from abroad?

 

Our main suppliers, Schüco and Reynaers, have their representatives in Hungary. The former even has a warehouse in Hungary. If, in addition to the system components, we also need a more special component, which may be a handle, a motor, a door closing device or any device that increases the technical content of the door and window, they should contact their factories and suppliers separately. Most of them also have representation in Hungary. If not, we get it from abroad. There are oversized glass planes that we can exclusively get abroad, because there aren’t enough curing ovens in Hungary to prepare them. But we’ve done a lot of research on accessories, like the black cylinder liner, for example.

 

How do you work here at the plant?

 

The most spectacular is our machining centre. Although the cutting machine is already interesting, too, as we send it the cutting list and the machine can cut the profiles automatically. We also usually give a cutting list on paper, so that the cutter can also check that the machine is setting what we want. The door and window profile is then identified by a barcode; ten years ago it was still completely unimaginable. The milling machine and machining centre then identify the profile, based on its barcode. We can’t automate many things, because the aluminium windows and doors we manufacture are so unique. We don’t have series production; it’s rare for us to produce two identical structures for a project. Do colleagues also ask you if you indeed need to make two copies of something? We work with large glass surfaces, two of which would be too much on a family home.

 

How many of you work here?

 

The production office employs three engineers. Engineering preparation, material ordering, physical stock management, checking the software communication of the machines, organising the delivery belong to us. For example, we have a lot of plate orders – cornices, covers – documenting these with accurate colour coding, data, ordering, and order tracking is already a lot of tasks, although I’ve only highlighted a tiny part of our work. But if we need a longer screw then we’ll also find out where to get it. And there are 9 or 10 people working in the factory; we know who is better in which work phase, and they usually work there, but everyone has to know everything. A cutter also needs to know what kind of door, window or glass wall is created ultimately, for which he cuts the first component, and he rotates and cuts the component accordingly. The tasks are very diverse, multifaceted; it isn’t possible for someone to be able to complete just one task consisting of 5 to 10 operations, they have to understand the whole process.

 

How unique is what is happening here at KAV’s Kisbér plant?

 

Significantly fewer sliding doors and large glass structures are produced anywhere else. They focus more on the production of strip windows, curtain walls and façades. Because we go beyond standard solutions, we push the size limits and meet individual needs, it isn’t possible to standardise our production. Series production is much more typical at other manufacturers, while we are better at custom aluminium doors and windows.

Production of custom doors and windows at the KAV plant
01
00
alumínium-nyílászáró-gyártás-Reynaers-Schüco-cnc-automatizálás-ipar40-ablakgyár-ablakgyártó-üzem-tárolás-üveg-üvegragasztás
MoreNews
01
020
2019 / 06 / 21
Nagy-Zoltán-Reynaers
Finding the right solution for the project
Unlike its other competitors, KAV was not thinking about classic “contract manufacturing” - that is, not buying material from us, making and delivering it, so to speak - but actually looking at the whole project, looking for solutions and providing additional services to the Icelandic customer.
Show more
2022 / 01 / 06
Schuco-aluminium-toloajto-ablak-emelo-tolo-KAV-uveg-uveg-sarok-minimal-house-kulter-udvar-terasz-exterior
Aluminium doors and windows in KAV quality, at an affordable price
With the KAV Home product range, our company is making high-quality aluminium doors and windows available to a new customer base. We talked to Zoltán Balázsi, sales engineer, and Károly Lovász, the Executive Director of KAV, about why this opening is important in the life of KAV and why it is worth buying aluminium doors and windows at KAV.
Show more
2021 / 01 / 06
Schüco-alumínium-ASE80-tolóajtó-egy-sínes-minimal-interior-3
The relationship between unique doors and windows and interior design
Unique windows and glass walls are playing an increasingly important role in modern family homes, so working together requires a different approach from both designers and window-door professionals than it did a few years ago. According to Csaba Finta, interior designer and art director of MYD-II, it is important that architects and interior designers take this aspect into account during the planning stage.
Show more
2023 / 06 / 29
Nagy üvegfelületű alumínium nyílászárók beépítése
The Art of Installing Large Glass Panels: A Technical Journey with KAV
In recent times, we have shared several recordings depicting the installation process of large glass surfaces as part of KAV's daily operations. To shed light on the distinctions in window installation and preparation when incorporating larger glass sizes into a property compared to standard glass dimensions, we interviewed Mr. Péter Nagy, Senior Engineer, and Mr. Károly Lovász, CEO of KAV.     
Show more
2021 / 07 / 08
Aluta-Nívódíj-2021-KAV
KAV was given an award in the aluminium door and window small project category
This year, the Aluminium Window and Façade Association (ALUTA) awarded its prizes again. KAV’s work was again given an award in the small project category, with the only prestigious recognition by the Hungarian aluminium door and façade manufacturers.
Show more
2023 / 04 / 26
Schuco-aluminium-nyilaszaro-karbon-elleni-harca-2023
BAU FAIR 2023: The Battle of the Construction Industry Against Carbon
The "BAU 2023" construction industry trade fair took place in Munich from April 17 to 22, 2023. This exhibition is the largest and most significant construction industry event in Europe, providing guidance every two years on planning and construction technologies, building material production, and installation techniques. KAV Hungária sent eight engineers to Germany to process the valuable information and reconsider their domestic and international sales strategy.
Show more
2020 / 07 / 23
Schuco-aluminium-17-PD-FW50-exclusive-window-sliding-door-glass-roof-interior3
Clean shapes, large glass surfaces
In the exclusive family-home market, connection with the environment and the transparency that enables it have clearly become the most important factors in the domestic and international trends in custom doors and windows. On behalf of Etna Kft., KAV is participating in the construction of a building with three fully glazed facades. We talked about that special project and the most important directions of the sector with Nikos Zisidis, the executive manager of the client company.
Show more
2019 / 03 / 29
Keret-nélküli-tolóajtó-rendszer-alumínium-nyílászáró-emelő-toló-ajtó-render-épülő-ház-külső-nézet-3
A house where the doors and windows shaped the design process
What they design, they can do, they guarantee in the long run, and they can operate such a property. We can be sure that the company will not disappear.
Show more
2017 / 06 / 09
Költő-Kert-alumínium-keret-nélküli-tolóajtó-rendszer-Schüco-77-PD-HI-render-Budapest-minimal-house-2
KAV closing systems in Költő Kert (Poets Garden)
“Creating something extreme but which one can relate to”
Show more
2022 / 10 / 20
Reynaers-hifinity-minimal-interior-luxury-glass-keret-nelkuli-sliding-door
Huge glass walls in a villa with breathtaking features
The glass is the soul of the villa designed by architect Péter Koch, the head of Nara Studio. The unique, distinctive building achieves its floating effect through the almost endless glass surfaces, providing the owner with a perfect panoramic view and an unparalleled sense of connection with the environment. We asked the architect about the design process of the building and the collaboration between the various aspects of the project.
Show more
2018 / 10 / 10
Költő-Kert-alumínium-keret-nélküli-tolóajtó-rendszer-Schüco-77-PD-HI-render-Budapest-minimal-house-2
When a dreamt-of work of art becomes a reality
Properties being created in an ongoing KAV project may nearly be interpreted as works of art. No company with relevant references could be found, either in Hungary or abroad, for the implementation of buildings that were considered unique at the European level too. We talked about this special job with Mihály Fodor, the Managing Director of the implementing company, and András Havasy, the project’s Technical Director.
Show more
2019 / 03 / 13
Reynaers-alumínium-nyílászáró-tolóajtó-emelő-toló-ajtó-minimál-homlokzat-lézervágott-lemez-burkolat-terasz-kert-kapcsolat-üveg-építészet-exterior-night
The evolution of closing systems in Hungary
If one spends many years in a specialised technical segment, sometimes answering questions from a professional interviewer will inadvertently recall the period from the beginning to the present. Studying the evolution of window and door products used in residential buildings is also instructive, because fashion always changes along with demand and financial opportunities. Everyone sees the past differently - we, Hungarians are special in this - but sales figures outweigh perceptions.
Show more
2018 / 12 / 12
kav-closing-systems-also-in-iceland
KAV closing systems also in Iceland
It has been a well-kept secret for a long time, and today many in the facade and structure building business are also talking about KAV’s new undertaking. Aluminium closing system products manufactured according to special customer demands are not only interesting due to their specific technical and weather requirements but also because of the installation location.
Show more
2020 / 02 / 27
Tornóczky-Mónika-Alukönigstahl
The goal: carbon neutral buildings by 2050
In the context of climate change, the issue of environmental awareness is increasingly raised, not only in everyday life but also in the context of the built environment. We explored ways to minimize the carbon footprint of a building with architect Mónika Tornóczky, Product Manager at Alukönigstahl, as the Central European Representative for Schüco and Jansen.
Show more
2023 / 06 / 12
Reynaers-aluminium-nyilaszaro-Kenyeres-Laszlo-epitesz-latvanyterv
Windows in the Design Process from an Architect’s Perspective
The question of when to engage window experts in the design process often arises. In this context, architect and head of the Archista architectural firm, László Kenyeres, shares his experiences. He believes that in today's architectural design process, windows and doors are a critical aspect because they represent one of the most complex parts of a building. Therefore, even those not well-versed in the world of windows may require external assistance to confidently complete an execution plan.
Show more
2023 / 01 / 02
Schüco-alumínium-emelő-toló-harmónika-ajtó-étterem-terasz-kapcsolat-homlokzat-sas-baba
A communal gastronomic space where the fusion of outdoor and indoor is facilitated by KAV glass portals
BABA Budapest is not merely a restaurant; it is a space where one can feel at home throughout the day. The main principles of design focused on the seamless transition between indoor and outdoor spaces and the creation of a genuine sense of community experience. We had the opportunity to discuss the BABA with its lead designer, Dóra Fónagy, while sitting at one of its tables, and during our conversation, we ourselves experienced why it provides a truly unique experience.
Show more
2024 / 02 / 05
A nyílászáró minősége négy pilléren műlik
The quality of the windows and doors depends on four characteristics
What makes an windows and doors of good quality? What properties need to be examined in order to purchase a good window, door, or sliding door?
Show more
2019 / 01 / 28
Schüco-ASE-67-PD-keret-nélküli-tolóajtó-rendszer-vízszintes-metszet
What direction will the construction industry take?
Report on the BAU MESSE exhibition in Munich
Show more
2020 / 04 / 21
Schuco-Reynaers-aluminium-window-door-slide-glass-interior-fassaden-night3-k
A refined aesthetic for doors and windows
The popularity of the minimalist style in architecture is one of the reasons that aluminium doors and windows entered the family house sector. Applying the principle of “less is more” to architecture led architects and designers to use unique solutions and austere or transparent surfaces. In a minimalist home, simple shapes and forms help create an atmosphere of harmony, where space itself serves humanity.
Show more
2017 / 09 / 05
Schüco-alumínium-tolóajtó-ablak-emelő-toló-KAV-üveg-üveg-toldás-Schlotterer-80D-raffstore-minimal-house-kültér-udvar-gyep-fű-terasz-exterior
We build for the future rather than for today
Clear shapes, large glass surfaces, spacious interior spaces and creative use of materials – these are the main features of the most predominant architectural style of our era, minimalistic design, in which interest is outstanding in Hungary. However, the number of really well designed and built minimalistic family homes is relatively low. The property our engineers consider as one of the best designed ones our company has met in recent years was built in Budapest. During the project we paid increased attention to the design of large, liberally designed glass surfaces, essential for creating open spaces. We had a conversation with the developer of the house about what was needed to create this property.
Show more