Manufacturing Process
The door manufacturing process begins with the prepping of the door skins, including the cut-outs for hinges, locks, windows and more. Special preparation needs are achieved on a computerized turret press. Next the skin edges and interlocking system are formed and the internal reinforcements are welded in place.
The skins now enter a two stage wash system where they are cleaned and an iron phosphate treatment is applied through an automated line that transports the skins to the assembly area. In the assembly process a urethane based adhesive is applied and the polystyrene core is put in place. Both skins are interlocked together and sent through a pinch roller to ensure proper adhesion. At this point the top and bottom channels are welded in place. Finally doors are then painted in an automated electrostatic system. They are ready to have shipping labels and are wrapped with cardboard to protect them while in transit
The frame manufacturing process also begins with the machining of the steel, including the preparation for hinges and lock reinforcements. The frames are formed and the reinforcements are welded in place. The frames now enter a three stage wash system where they are cleaned and an iron phosphate treatment is applied followed by a coat of rust inhibitive primer and a baking system. They are now ready to be palletized for shipping.
