Lean Production for Door Frames with Dallan D60: Maximum Flexibility and Speed

October 2024 Punching, Rollforming

The production of door frames, including sub-frames, is a complex process characterized by numerous operations to incorporate hinges, locks, and fasteners.

Additionally, various factors influence production, such as dimensions, opening direction, accessories, and materials.

Since 1992, Dallan has been leading the industry’s innovation with its flexible and parametric machines, particularly the D60 model, which enables LEAN production of door frames with no material waste and unprecedented efficiency.

Flexibility of Dallan’s Door Frame Production Lines

Thanks to the PXN parametric punching machines, Dallan’s lines stand out for their ability to produce door frames with very different characteristics while maintaining constant cross-sections.

The real innovation lies in the PXN punching machines’ capability to manage job lists sent in the form of Excel, XML, or CSV files, allowing the machine to execute operations autonomously without human intervention.

This not only optimizes the process but also eliminates the need for manual programming, saving a significant amount of time.

Many manufacturers still work with aluminum profiles and use complex machine tools, with production times that can reach up to 10 minutes per frame.

With the Dallan Lean D60 system, which works from coil, the production time for a complete frame is reduced to just 90 seconds!

Additionally, using coils allows for 100% material utilization, with no waste.

Components of the Dallan D60 System

The D60 door frame production system is generally composed of:

  • Decoiler;
  • Straightener;
  • Coil punching machine (such as PXN);
  • Precision roll forming machine;
  • Final die sets for further processing.

Depending on the customer’s specific needs, additional processing units can be added to complete complex assemblies.

This makes the D60 system extremely flexible and ideal for producing frames for armored doors, fire doors, and multi-purpose doors, in both European and U.S. markets.

Armored Door Frame Line with +/-45° Cutting Unit

This advanced production line includes a double saw cutting unit for +/-45° angle cuts, perfect for producing armored door frames of variable dimensions.

The system is highly modular, with 24 processing stations performing precise bending operations.

One of the most innovative features is the printing of a QR code on the profiles before roll forming, which is read by special cameras providing all necessary processing information.

This allows for the production of highly complex profiles, including deep drawing and threading, with perfect cutting angles ready for welding.

➡️ Watch the video of the armored door frame line:

 

Fire Door Line with PXN Punching

The second system we review is a fire door production line featuring a high-speed PXN punching machine.

This machine fully leverages the capabilities of PXN units to produce complex profiles quickly and efficiently.

It is ideal for manufacturers needing to produce doors with high specifications, while maintaining excellent production standards.

➡️ Watch the video of the fire door line:

 

Advantages of the Dallan D60 System

  • Efficiency: The Dallan D60 system drastically reduces production times, with a complete door frame cycle taking only 90 seconds.
  • Flexibility: PXN punching machines allow for the production of door frames with varying dimensions and characteristics, using simple job files sent to the machine.
  • Material Savings: Working directly from coil ensures maximum material usage, with no waste.
  • Modularity: Dallan lines are fully modular, allowing the addition of further processing units depending on the customer’s specific needs.

 

The Dallan D60 production lines are the ultimate solution for door frame manufacturers seeking efficiency, flexibility, and cost reduction.

Thanks to the innovations introduced by PXN punching machines, Dallan offers customers the ability to remain competitive in a constantly evolving market.

For more information about our solutions or to watch the full Masterclass, contact us

 

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