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UPVC Profile EXTRUSION Line – Version 1 (ECO1)
Description
UPVC Profile EXTRUSION Line – Version 1 (ECO1)
Engineered by Extrutex Austria – A Complete Solution for Sustainable, Economical, and High-Quality Profile Manufacturing
Introduction: Redefining Modern Construction with UPVC Profiles
The modern construction industry is evolving at an unprecedented pace. Architects, developers, and homeowners alike demand building materials that combine aesthetics, durability, energy efficiency, and long-term value. Among the most critical elements in this transformation are UPVC (Unplasticized Polyvinyl Chloride) profiles, which serve as the foundation for high-performance windows, doors, and architectural fittings.
UPVC profiles are not merely structural components; they are enablers of comfort, sustainability, and cost-efficiency. Their superior thermal and acoustic insulation properties help reduce energy consumption while ensuring a quieter indoor environment. In addition, UPVC profiles resist weathering, corrosion, and wear, making them an indispensable material in contemporary construction projects worldwide.
Meeting the growing demand for such profiles requires a production system that delivers accuracy, reliability, and efficiency. That’s where Extrutex Austria, with its decades of expertise in extrusion technologies, sets itself apart.
The UPVC Profile EXTRUSION Line – Version 1 is a flagship solution developed by Extrutex, designed for manufacturers who value European engineering precision, energy efficiency, and long-term profitability. This line integrates cutting-edge extrusion technology, modular design, and seamless automation, offering a complete pathway from raw material to finished profile.
The Heart of Excellence: Key Components of Version 1
The Version 1 production line is a finely tuned symphony of advanced machinery, each unit working harmoniously to ensure consistent quality and optimized performance. Its core components are:
| Production Line Unit | Model | Function Description |
|---|---|---|
| Main Extruder | ATC 53 | Parallel twin-screw extruder with advanced melting, precise temperature/pressure control, and versatile material handling |
| Output Capacity | 120 kg/h | Balanced throughput for standard UPVC profiles with optimized energy use |
| Calibration Table | ACT 5000 | 5-meter calibration table with vacuum system, water spraying, and auto-dimension control |
| Haul-Off / Cutter | APS 15 / SA1 | Powerful haul-off with automatic cutting saw for precise, damage-free cutting |
| Final Collection Table | ATT6 | 6-meter robust collection table for stacking, bundling, and smooth handling |
Let’s explore each unit in detail.
1. ATC 53 Twin-Screw Extruder – The Beating Heart of the Line
At the core of this production line lies the ATC 53 parallel twin-screw extruder, an advanced machine designed to process UPVC compounds with unparalleled precision. Its role is to transform raw material into a homogeneous, stable melt ready for shaping into profiles.
Key Highlights of ATC 53:
Precise Temperature Management: Equipped with PID-controlled heating and cooling loops, the extruder maintains optimal processing temperatures, ensuring consistent quality.
Advanced Screw Geometry: The specially engineered screw design reduces melting time while improving mixing uniformity, leading to bubble-free, strong profiles.
Energy Efficiency: Integrated low-consumption motors and frequency-controlled inverters significantly cut power usage, reducing operational costs.
Versatile Material Handling: Capable of processing virgin compounds and recycled blends, the extruder supports sustainable manufacturing.
Durable Construction: High-strength steel and wear-resistant coatings extend machine life and minimize maintenance.
This extruder is not only powerful but also user-friendly, enabling operators to monitor and adjust parameters through an intuitive control panel.
2. ACT 5000 Calibration Table – Shaping Precision into Reality
The transition from molten material to a solid profile begins at the ACT 5000 calibration table, a critical stage where dimensional accuracy is established.
Features of the ACT 5000:
5-Meter Length: Offers sufficient cooling and calibration space for most UPVC profile sizes.
Vacuum Calibration: Centralized vacuum system stabilizes profiles immediately after extrusion, preventing deformation.
Cooling System: Integrated water circulation with spray nozzles ensures even, controlled cooling across all surfaces.
Adjustable Dimensions: Both manual and automatic adjustments allow operators to fine-tune profile thickness, width, and geometry.
Interchangeable Calibration Molds: Supports rapid transitions between different profile designs, increasing flexibility.
This stage guarantees that every profile maintains precise geometry, which is crucial for compatibility with window and door systems.
3. APS 15 Haul-Off and SA1 Automatic Cutter – Strength Meets Accuracy
Once profiles are formed and cooled, they must be conveyed smoothly and cut into precise lengths. This is the responsibility of the APS 15 haul-off combined with the SA1 automatic cutter.
System Advantages:
Powerful Haul-Off: Dual rubber tracks provide steady, vibration-free pulling force, ensuring profiles are neither stretched nor compressed.
Variable Speed Control: Easily synchronized with extrusion speed to maintain dimensional consistency.
Durable Contact Surfaces: Rubber jaws are resistant to wear and gentle on profile surfaces.
SA1 Automatic Saw: High-precision cutting system with length detection sensors guarantees clean, square cuts without burrs or cracks.
Multi-Profile Capability: Enables simultaneous cutting of multiple profiles to maximize productivity.
This combination minimizes waste while maximizing precision—essential for cost-effective, large-scale production.
4. ATT6 Collection Table – The Final Step with Reliability
The journey ends with the ATT6 collection table, where finished profiles are carefully handled before packaging.
Key Characteristics:
6-Meter Length: Adequate space for long profile handling and inspection.
Soft Rollers: Prevent scratches or surface damage during collection.
Height Adjustability: Easily adaptable to different equipment setups.
Optional Counting System: Automatic profile counting and grouping for streamlined packaging.
Robust Frame: Built from reinforced steel to endure years of industrial use.
This final stage ensures smooth handling and readiness for logistics.
Technological Advantages of Extrutex Production Line
Extrutex Austria has infused its Version 1 UPVC Profile Production Line with cutting-edge technologies and smart design principles. Here’s why it stands out:
European Quality Standards – Every component is built to EU specifications, ensuring reliability, safety, and long lifespan.
User-Friendly Operation – Intuitive controls and simplified setups allow operators to master the system quickly, reducing errors and downtime.
Multi-Layer and Co-Extrusion Capability – Expand production by incorporating decorative foils, gaskets, or recycled layers.
Energy Efficiency – Designed with variable-speed drives, optimized pumps, and efficient motors, lowering energy costs significantly.
Compatibility with Recycled Materials – Supports circular economy initiatives by incorporating recycled PVC without sacrificing quality.
Reduced Waste – Automated synchronization reduces scrap generation during startups and transitions.
Durability and Low Maintenance – Built with wear-resistant materials and modular designs for easy servicing.
Applications of Produced Profiles
The profiles produced by the Extrutex Version 1 line meet the diverse needs of modern construction. They are suitable for:
UPVC windows and doors of multiple dimensions and designs
Frames for double- and triple-glazed units
Weather seals, gaskets, and water-drainage strips
Decorative wall claddings and railing systems
Laminated or color-coated profiles for aesthetic applications
Custom extrusions tailored for architectural projects
These profiles are compatible with global construction standards and deliver long-term performance under diverse climatic conditions.
Customer-Oriented Services and Support
Extrutex Austria goes beyond delivering machinery—it partners with clients throughout their production journey. Services include:
Pre-Sales Consultation: Assisting in selecting the right production line for your needs.
Installation & Commissioning: On-site setup by specialized engineers.
Operator Training: Comprehensive training sessions to build skilled teams.
After-Sales Support: Fast delivery of spare parts, remote troubleshooting, and scheduled maintenance services.
Upgrades & Retrofits: Modernization of older lines for improved performance and efficiency.
This holistic approach guarantees that customers can rely on consistent support throughout the equipment’s lifetime.
Why Choose Extrutex Version 1 Line?
The UPVC Profile Production Line – Version 1 is more than just a collection of machines; it is a complete manufacturing ecosystem designed for sustainability, profitability, and product excellence.
Top Reasons to Invest:
European engineering with global recognition
Balanced capacity (120 kg/h) for cost-efficient medium- to large-scale production
Flexibility for both standard and custom profiles
Integration of recycled materials without compromising quality
Low energy consumption for reduced operational costs
Long service life with minimal maintenance
Strong technical support and customer partnership
For manufacturers seeking to expand their product range, enhance efficiency, and position themselves as leaders in sustainable building solutions, this line represents an ideal investment.
Conclusion: Building a Sustainable Future with Extrutex Austria
As the world demands greener, smarter, and more resilient construction solutions, UPVC profiles remain a cornerstone of progress. The Extrutex Version 1 UPVC Profile Production Line empowers manufacturers to meet this demand confidently.
With its blend of European craftsmanship, innovative design, and customer-focused service, Extrutex delivers not just a production line but a pathway to long-term success. From energy efficiency and versatility to flawless product quality, this line embodies everything a forward-thinking manufacturer requires.
In short, the Version 1 line is a smart, future-ready solution—built to deliver consistency, profitability, and sustainability for decades to come.
Sub-Profile Tooling for UPVC Profile EXTRUSION Line – Version 1
Optimized for Complementary Profiles, Seals, and Decorative Elements
Introduction: The Essential Tooling for Complementary UPVC Profiles
In the modern construction and window manufacturing industry, precision and versatility are key to producing high-quality UPVC profiles. While main profiles such as window and door frames dominate the final product, secondary or complementary profiles play an equally critical role. These include gaskets, seals, adapter strips, reinforcing profiles, and decorative elements that ensure the structural integrity, functionality, and aesthetic appeal of doors and windows.
To meet this demand, Extrutex Austria has developed the Sub-Profile Tooling, a specialized set of molds engineered for the Version 1 UPVC Profile EXTRUSION Line. This tooling is designed to deliver consistent performance, high output, and flawless quality for a wide variety of secondary profiles. It enables manufacturers to diversify their product portfolio while maintaining the reliability and precision associated with Extrutex machinery.
Key Technical Specifications
The Sub-Profile Tooling has been engineered to integrate seamlessly with the Version 1 production line, offering an ideal balance between speed, output, and precision.
| Specification | Details |
|---|---|
| Model | Sub-Profile Tooling (Non-Main Profile) |
| Compatible Line | Version 1 UPVC Profile EXTRUSION Line |
| Production Speed | 2.5 – 7.5 meters per minute |
| Output Capacity | Approximately 120 kg/h |
| Material Compatibility | Virgin UPVC and recycled blends |
| Co-Extrusion Ready | Yes, separate injection ports for rubber or decorative strips |
This tooling has been optimized for medium-speed lines while maintaining high dimensional accuracy and surface quality. It allows operators to switch between different profiles with minimal downtime, ensuring efficient and cost-effective production.
Design Features and Advantages
1. Modular Structure for Easy Maintenance
The Sub-Profile Tooling is built with a modular design, allowing operators to quickly disassemble and reassemble individual components. This modularity offers several benefits:
Simplified Maintenance: Components can be replaced or serviced without dismantling the entire mold.
Quick Adjustments: Minor modifications can be made on-site to adapt to different secondary profiles.
Reduced Downtime: Production interruptions are minimized, enhancing overall line efficiency.
This design philosophy ensures that manufacturers can maintain high output while keeping maintenance costs low.
2. Uniform Melt Flow for High-Quality Profiles
A critical aspect of secondary profile production is ensuring a smooth, defect-free extrusion. The Sub-Profile Tooling incorporates precision-engineered channels to guide molten UPVC evenly through the mold.
Benefits include:
Bubble-Free Extrusion: Eliminates voids and imperfections that can compromise structural integrity.
Consistent Profile Geometry: Ensures uniform thickness and shape along the entire length.
Reduced Warping or Twisting: Maintains precise dimensions even for thin or delicate profiles.
This consistent flow is particularly important for gaskets, seals, and decorative strips, which must fit perfectly in the final assembly.
3. Compatibility with Recycled Materials
Sustainability is a growing priority in modern manufacturing, and Extrutex tooling supports this trend. The Sub-Profile Tooling can process a combination of virgin and regrind materials without affecting final quality.
Eco-Friendly Production: Reduces waste by incorporating recycled UPVC.
Flexible Formulation: Allows the use of different recycled grades depending on cost and availability.
Maintained Performance: Profiles produced from mixed materials meet the same standards as virgin-only products.
This feature ensures that manufacturers can reduce environmental impact while maintaining profitability.
4. Long-Lasting Durability
Constructed from high-grade European tool steel, the Sub-Profile Tooling offers exceptional wear resistance and long service life. Key characteristics include:
High Hardness: Resists abrasion from continuous exposure to UPVC compounds.
Corrosion Resistance: Suitable for humid production environments.
Stable Geometry: Maintains dimensional accuracy even after thousands of production hours.
Investing in durable tooling reduces long-term costs and ensures consistent product quality over time.
5. Efficient Cooling System
Maintaining precise profile dimensions requires effective cooling immediately after extrusion. The Sub-Profile Tooling integrates specialized channels for circulating water or coolant.
Even Cooling: Prevents warping, shrinkage, or surface defects.
Rapid Solidification: Supports medium-speed production without sacrificing quality.
Customizable Flow: Cooling intensity can be adjusted for different profile thicknesses.
This cooling system guarantees that every profile emerges dimensionally accurate and ready for the haul-off stage.
6. Co-Extrusion Capability
For advanced applications, the Sub-Profile Tooling supports co-extrusion, allowing secondary materials like rubber gaskets or decorative strips to be integrated directly during extrusion.
Separate Injection Ports: Enables precise placement of additional layers without contamination.
Enhanced Product Functionality: Adds features such as flexible seals, color accents, or weather-resistant layers.
Aesthetic Versatility: Supports production of profiles with decorative laminates or colored inserts.
Co-extrusion expands the range of products a manufacturer can offer, increasing market competitiveness.
Applications of Sub-Profile Tooling
The Sub-Profile Tooling is ideal for producing a wide range of complementary UPVC profiles, including:
Gaskets and Seals – Essential for airtight and watertight performance in doors and windows.
Adapter Profiles – Used to bridge main profiles or connect different frame sections.
Reinforcing Profiles – Thin profiles that add structural integrity to doors, windows, or curtain walls.
Decorative or Low-Thickness Profiles – Profiles with aesthetic finishes for visible areas of doors and windows.
Weatherstrips and Trim Strips – Provide protection against wind, rain, and dust while enhancing appearance.
By accommodating a broad range of secondary profiles, this tooling allows manufacturers to produce complete window and door solutions from a single production line.
Operational Benefits
Investing in Sub-Profile Tooling provides tangible advantages for manufacturers:
Stable Operation: Maintains high-quality output even over extended production periods.
Surface Excellence: Produces smooth, defect-free surfaces with uniform color.
Low Maintenance Costs: Modular design reduces downtime and repair expenses.
Precise Adjustability: Fine-tuning screws allow quick adjustments to maintain dimensional accuracy.
Flexible Speed Range: Suitable for low- to medium-speed production lines, providing versatility across different production requirements.
This combination of operational efficiency and product quality ensures that manufacturers can meet tight delivery schedules while maintaining profitability.
Conclusion: A Smart Choice for Secondary UPVC Profiles
The Sub-Profile Tooling for Version 1 UPVC Profile EXTRUSION Line represents a strategic investment for any manufacturer looking to expand their product range and enhance production efficiency. By integrating precise engineering, modular design, and advanced functionality, this tooling enables the creation of high-quality complementary profiles, seals, and decorative elements with minimal downtime and maximum reliability.
Whether producing gaskets, adapters, reinforcing strips, or decorative profiles, the Sub-Profile Tooling ensures uniform quality, dimensional stability, and operational flexibility. It also supports sustainability initiatives by allowing the use of recycled materials and co-extrusion capabilities.
In short, the Sub-Profile Tooling is not merely an accessory; it is an essential extension of the Version 1 UPVC Profile EXTRUSION Line, empowering manufacturers to deliver complete, high-quality window and door solutions while reducing costs, improving efficiency, and meeting modern construction demands.
UPVC PROFILE EXTRUSION LINE
Extrutex Austria Downstream Profile Equipment
Engineered for Precision, Designed for Efficiency
Introduction: Excellence in Profile Manufacturing
In the highly competitive world of UPVC profile manufacturing, precision, reliability, and efficiency are non-negotiable. While extrusion lines often steal the spotlight, the performance of downstream equipment plays an equally critical role in determining the final quality, efficiency, and profitability of the production process.
Extrutex Austria, a pioneer in extrusion technologies, has redefined downstream machinery with a focus not on mass production but on premium quality, operational reliability, and exceptional service. By engineering solutions that emphasize precision, user-friendliness, and energy efficiency, Extrutex provides manufacturers with the tools they need to produce superior UPVC profiles consistently.
Downstream equipment encompasses all post-extrusion machinery, including calibration tables, haul-off units, water circulation and cooling systems, and filtration and vacuum systems. These machines ensure dimensional accuracy, surface quality, and operational stability while minimizing waste and downtime.
Core Philosophy: Precision Over Volume
Extrutex Austria operates with a philosophy that prioritizes excellence over sheer production volume. The company’s downstream profile equipment is intended for markets where manufacturers demand:
The highest level of performance and process stability
Uncompromised surface quality for premium profiles
Long-term reliability with minimal maintenance
By focusing on these aspects, Extrutex has developed downstream solutions that guarantee that every meter of extruded UPVC profile meets rigorous quality standards.
Key Features of Extrutex Downstream Equipment
1. Energy Efficiency
Extrutex downstream systems are engineered to optimize energy consumption without compromising output quality. This is achieved through:
Servo-Controlled Systems: Using precision servo motors for vacuum, haul-off, and other critical units minimizes energy waste and maintains precise operation.
Optimized Water Flow: Calibrated cooling channels ensure maximum heat exchange with minimal energy input.
Streamlined Design: Each component, from pumps to conveyors, is designed for low friction and energy-efficient operation.
The result is a system that is both economical to operate and environmentally responsible, reducing operational costs while supporting sustainable manufacturing practices.
2. Process Stability
Stable processes are the foundation of high-quality UPVC profiles. Extrutex downstream equipment incorporates advanced automatic control systems to ensure continuous, defect-free production:
CVR (Constant Vacuum Regulation): Maintains consistent vacuum levels across different areas of the calibration table, preventing deformation or dimensional inconsistencies.
CWP (Constant Water Pressure): Regulates water pressure in cooling channels to maintain uniform cooling rates.
CWT (Constant Water Temperature): Ensures that cooling water cycles remain stable, avoiding warping or surface defects caused by temperature fluctuations.
These controls enable manufacturers to maintain repeatable results, even with varying raw material properties or ambient conditions.
3. User-Friendly Operation
Extrutex downstream systems are designed to be accessible even to operators with limited technical experience. Features include:
Touch-Screen Interfaces: Intuitive controls display key parameters and allow quick adjustments.
Pre-Set Parameters: Operators can select from optimized settings for different profile types, reducing setup time and human error.
Guided Menus: Step-by-step guidance ensures correct operation during startup, calibration, and production.
This focus on usability reduces training requirements, minimizes errors, and increases overall production efficiency.
4. Advanced Vacuum Systems
The vacuum system is critical in stabilizing profiles immediately after extrusion. Extrutex employs servo-controlled vacuum pumps for precision and reliability:
Accurate Control: Servo controllers allow exact regulation of vacuum intensity for consistent dimensional stability.
Siemens Control Integration: High-precision automation reduces human error and maintains repeatable results.
Long-Term Reliability: Built to operate continuously with minimal maintenance, ensuring long operational life.
By stabilizing profiles effectively, this system improves surface finish, reduces rework, and enhances overall product quality.
5. Bypass Filtration Systems
Clean cooling water is essential for profile quality. Extrutex integrates advanced bypass filters to remove impurities and prevent contamination:
Optimized Calibration: Clean water ensures uniform cooling and prevents marks or surface defects.
Reduced Maintenance: Filters extend the life of downstream machinery by preventing buildup and corrosion.
Advanced Design: Allows high filtration efficiency without slowing down production.
These filtration systems are especially important in high-speed lines where even minor impurities can affect surface quality and dimensional stability.
6. Haul-Off Unit Innovations
Extrutex haul-off units combine automation, precision, and durability to handle profiles smoothly:
Fully Automated Operation: Synchronizes with extrusion speed to maintain consistent pulling force.
Tension-Controlled Chains: Ensure uniform transmission of mechanical power across all rollers.
Central Motor and Gearbox Layout: Provides stable torque and reduces mechanical stress.
Optimized Accessibility: Easy access to pods and wear parts simplifies maintenance and minimizes downtime.
These innovations contribute to reduced stops, faster adjustments, and extended component lifespan, which are critical in maintaining high throughput and profitability.
7. Advanced Cooling Cycles
Cooling is a crucial step to preserve profile geometry and surface integrity. Extrutex cooling systems are engineered for efficiency and uniformity:
SWC – Dry Calibration Water Cycle: Simultaneously controls flow, temperature, and volume to maximize cooling efficiency.
SWC – Wet Calibration Water Cycle: Ensures even surface quality and prevents contraction or warping, particularly in high-speed lines.
FBF – Wet Calibration Filter: Provides additional filtration for sensitive profiles, ensuring flawless surface finish.
DWD – Direct Water Discharge System: Automates water drainage and prevents sediment buildup, ensuring clean, efficient operation.
Together, these cooling technologies ensure that profiles maintain precise dimensions and excellent surface quality from start to finish.
Strategic Advantages for Manufacturers
1. Easy Startup
Touch-screen interfaces, guided menus, and pre-set parameters enable rapid setup without specialized technical knowledge.
2. Low Maintenance
Modular design and easy access to components allow for fast, economical repairs and replacements.
3. Compact Footprint
Optimized layouts deliver high performance while occupying minimal space, making them ideal for facilities with space constraints.
4. Reliability and Warranty
Extrutex Austria provides a two-year official warranty along with full technical support and spare part availability.
Extrutex Vision: Beyond Technology
Extrutex Austria is more than a machinery provider—it is a partner in success. The company’s approach encompasses:
Design Consultation: Tailored solutions for every production requirement.
Installation & Commissioning: On-site setup and optimization for immediate operation.
Operator Training: Ensures staff can maximize equipment potential safely.
After-Sales Support: Comprehensive maintenance, spare parts, and technical assistance.
This long-term partnership model guarantees that customers receive world-class service and support throughout the equipment’s life.
Ideal Users
Extrutex downstream profile equipment is designed for manufacturers who aim to:
Produce high-precision profiles with consistent dimensional accuracy.
Compete in markets where surface quality and reliability define success.
Reduce energy and maintenance costs while maintaining operational efficiency.
Optimize production with state-of-the-art technology and intelligent process control.
Whether producing windows, doors, or specialized profiles, Extrutex downstream equipment provides a reliable, high-performance backbone for any extrusion line.
Conclusion: The Extrutex Advantage
In today’s competitive landscape, superior technology, energy efficiency, and operational reliability are the hallmarks of successful UPVC profile production. Extrutex Austria’s downstream profile equipment offers a perfect blend of engineering innovation, user-friendly operation, and energy-conscious design.
By choosing Extrutex, manufacturers gain:
Advanced process stability for consistently high-quality profiles
User-focused design for rapid startup and minimal training
Long-lasting, modular machinery for reduced downtime and maintenance
Optimized energy consumption for cost-effective operation
In essence, Extrutex downstream equipment is not just machinery—it is a strategic investment. It empowers manufacturers to maintain a competitive edge, achieve superior product quality, and secure a sustainable, profitable future in the UPVC industry.
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UPVC Profile EXTRUSION Line – Version 1 (ECO1)
Engineered by Extrutex Austria – A Complete Solution for Sustainable, Economical, and High-Quality Profile Manufacturing
Introduction: Redefining Modern Construction with UPVC Profiles
The modern construction industry is evolving at an unprecedented pace. Architects, developers, and homeowners alike demand building materials that combine aesthetics, durability, energy efficiency, and long-term value. Among the most critical elements in this transformation are UPVC (Unplasticized Polyvinyl Chloride) profiles, which serve as the foundation for high-performance windows, doors, and architectural fittings.
UPVC profiles are not merely structural components; they are enablers of comfort, sustainability, and cost-efficiency. Their superior thermal and acoustic insulation properties help reduce energy consumption while ensuring a quieter indoor environment. In addition, UPVC profiles resist weathering, corrosion, and wear, making them an indispensable material in contemporary construction projects worldwide.
Meeting the growing demand for such profiles requires a production system that delivers accuracy, reliability, and efficiency. That’s where Extrutex Austria, with its decades of expertise in extrusion technologies, sets itself apart.
The UPVC Profile EXTRUSION Line – Version 1 is a flagship solution developed by Extrutex, designed for manufacturers who value European engineering precision, energy efficiency, and long-term profitability. This line integrates cutting-edge extrusion technology, modular design, and seamless automation, offering a complete pathway from raw material to finished profile.
The Heart of Excellence: Key Components of Version 1
The Version 1 production line is a finely tuned symphony of advanced machinery, each unit working harmoniously to ensure consistent quality and optimized performance. Its core components are:
| Production Line Unit | Model | Function Description |
|---|---|---|
| Main Extruder | ATC 53 | Parallel twin-screw extruder with advanced melting, precise temperature/pressure control, and versatile material handling |
| Output Capacity | 120 kg/h | Balanced throughput for standard UPVC profiles with optimized energy use |
| Calibration Table | ACT 5000 | 5-meter calibration table with vacuum system, water spraying, and auto-dimension control |
| Haul-Off / Cutter | APS 15 / SA1 | Powerful haul-off with automatic cutting saw for precise, damage-free cutting |
| Final Collection Table | ATT6 | 6-meter robust collection table for stacking, bundling, and smooth handling |
Let’s explore each unit in detail.
1. ATC 53 Twin-Screw Extruder – The Beating Heart of the Line
At the core of this production line lies the ATC 53 parallel twin-screw extruder, an advanced machine designed to process UPVC compounds with unparalleled precision. Its role is to transform raw material into a homogeneous, stable melt ready for shaping into profiles.
Key Highlights of ATC 53:
Precise Temperature Management: Equipped with PID-controlled heating and cooling loops, the extruder maintains optimal processing temperatures, ensuring consistent quality.
Advanced Screw Geometry: The specially engineered screw design reduces melting time while improving mixing uniformity, leading to bubble-free, strong profiles.
Energy Efficiency: Integrated low-consumption motors and frequency-controlled inverters significantly cut power usage, reducing operational costs.
Versatile Material Handling: Capable of processing virgin compounds and recycled blends, the extruder supports sustainable manufacturing.
Durable Construction: High-strength steel and wear-resistant coatings extend machine life and minimize maintenance.
This extruder is not only powerful but also user-friendly, enabling operators to monitor and adjust parameters through an intuitive control panel.
2. ACT 5000 Calibration Table – Shaping Precision into Reality
The transition from molten material to a solid profile begins at the ACT 5000 calibration table, a critical stage where dimensional accuracy is established.
Features of the ACT 5000:
5-Meter Length: Offers sufficient cooling and calibration space for most UPVC profile sizes.
Vacuum Calibration: Centralized vacuum system stabilizes profiles immediately after extrusion, preventing deformation.
Cooling System: Integrated water circulation with spray nozzles ensures even, controlled cooling across all surfaces.
Adjustable Dimensions: Both manual and automatic adjustments allow operators to fine-tune profile thickness, width, and geometry.
Interchangeable Calibration Molds: Supports rapid transitions between different profile designs, increasing flexibility.
This stage guarantees that every profile maintains precise geometry, which is crucial for compatibility with window and door systems.
3. APS 15 Haul-Off and SA1 Automatic Cutter – Strength Meets Accuracy
Once profiles are formed and cooled, they must be conveyed smoothly and cut into precise lengths. This is the responsibility of the APS 15 haul-off combined with the SA1 automatic cutter.
System Advantages:
Powerful Haul-Off: Dual rubber tracks provide steady, vibration-free pulling force, ensuring profiles are neither stretched nor compressed.
Variable Speed Control: Easily synchronized with extrusion speed to maintain dimensional consistency.
Durable Contact Surfaces: Rubber jaws are resistant to wear and gentle on profile surfaces.
SA1 Automatic Saw: High-precision cutting system with length detection sensors guarantees clean, square cuts without burrs or cracks.
Multi-Profile Capability: Enables simultaneous cutting of multiple profiles to maximize productivity.
This combination minimizes waste while maximizing precision—essential for cost-effective, large-scale production.
4. ATT6 Collection Table – The Final Step with Reliability
The journey ends with the ATT6 collection table, where finished profiles are carefully handled before packaging.
Key Characteristics:
6-Meter Length: Adequate space for long profile handling and inspection.
Soft Rollers: Prevent scratches or surface damage during collection.
Height Adjustability: Easily adaptable to different equipment setups.
Optional Counting System: Automatic profile counting and grouping for streamlined packaging.
Robust Frame: Built from reinforced steel to endure years of industrial use.
This final stage ensures smooth handling and readiness for logistics.
Technological Advantages of Extrutex Production Line
Extrutex Austria has infused its Version 1 UPVC Profile Production Line with cutting-edge technologies and smart design principles. Here’s why it stands out:
European Quality Standards – Every component is built to EU specifications, ensuring reliability, safety, and long lifespan.
User-Friendly Operation – Intuitive controls and simplified setups allow operators to master the system quickly, reducing errors and downtime.
Multi-Layer and Co-Extrusion Capability – Expand production by incorporating decorative foils, gaskets, or recycled layers.
Energy Efficiency – Designed with variable-speed drives, optimized pumps, and efficient motors, lowering energy costs significantly.
Compatibility with Recycled Materials – Supports circular economy initiatives by incorporating recycled PVC without sacrificing quality.
Reduced Waste – Automated synchronization reduces scrap generation during startups and transitions.
Durability and Low Maintenance – Built with wear-resistant materials and modular designs for easy servicing.
Applications of Produced Profiles
The profiles produced by the Extrutex Version 1 line meet the diverse needs of modern construction. They are suitable for:
UPVC windows and doors of multiple dimensions and designs
Frames for double- and triple-glazed units
Weather seals, gaskets, and water-drainage strips
Decorative wall claddings and railing systems
Laminated or color-coated profiles for aesthetic applications
Custom extrusions tailored for architectural projects
These profiles are compatible with global construction standards and deliver long-term performance under diverse climatic conditions.
Customer-Oriented Services and Support
Extrutex Austria goes beyond delivering machinery—it partners with clients throughout their production journey. Services include:
Pre-Sales Consultation: Assisting in selecting the right production line for your needs.
Installation & Commissioning: On-site setup by specialized engineers.
Operator Training: Comprehensive training sessions to build skilled teams.
After-Sales Support: Fast delivery of spare parts, remote troubleshooting, and scheduled maintenance services.
Upgrades & Retrofits: Modernization of older lines for improved performance and efficiency.
This holistic approach guarantees that customers can rely on consistent support throughout the equipment’s lifetime.
Why Choose Extrutex Version 1 Line?
The UPVC Profile Production Line – Version 1 is more than just a collection of machines; it is a complete manufacturing ecosystem designed for sustainability, profitability, and product excellence.
Top Reasons to Invest:
European engineering with global recognition
Balanced capacity (120 kg/h) for cost-efficient medium- to large-scale production
Flexibility for both standard and custom profiles
Integration of recycled materials without compromising quality
Low energy consumption for reduced operational costs
Long service life with minimal maintenance
Strong technical support and customer partnership
For manufacturers seeking to expand their product range, enhance efficiency, and position themselves as leaders in sustainable building solutions, this line represents an ideal investment.
Conclusion: Building a Sustainable Future with Extrutex Austria
As the world demands greener, smarter, and more resilient construction solutions, UPVC profiles remain a cornerstone of progress. The Extrutex Version 1 UPVC Profile Production Line empowers manufacturers to meet this demand confidently.
With its blend of European craftsmanship, innovative design, and customer-focused service, Extrutex delivers not just a production line but a pathway to long-term success. From energy efficiency and versatility to flawless product quality, this line embodies everything a forward-thinking manufacturer requires.
In short, the Version 1 line is a smart, future-ready solution—built to deliver consistency, profitability, and sustainability for decades to come.
Sub-Profile Tooling for UPVC Profile EXTRUSION Line – Version 1
Optimized for Complementary Profiles, Seals, and Decorative Elements
Introduction: The Essential Tooling for Complementary UPVC Profiles
In the modern construction and window manufacturing industry, precision and versatility are key to producing high-quality UPVC profiles. While main profiles such as window and door frames dominate the final product, secondary or complementary profiles play an equally critical role. These include gaskets, seals, adapter strips, reinforcing profiles, and decorative elements that ensure the structural integrity, functionality, and aesthetic appeal of doors and windows.
To meet this demand, Extrutex Austria has developed the Sub-Profile Tooling, a specialized set of molds engineered for the Version 1 UPVC Profile EXTRUSION Line. This tooling is designed to deliver consistent performance, high output, and flawless quality for a wide variety of secondary profiles. It enables manufacturers to diversify their product portfolio while maintaining the reliability and precision associated with Extrutex machinery.
Key Technical Specifications
The Sub-Profile Tooling has been engineered to integrate seamlessly with the Version 1 production line, offering an ideal balance between speed, output, and precision.
| Specification | Details |
|---|---|
| Model | Sub-Profile Tooling (Non-Main Profile) |
| Compatible Line | Version 1 UPVC Profile EXTRUSION Line |
| Production Speed | 2.5 – 7.5 meters per minute |
| Output Capacity | Approximately 120 kg/h |
| Material Compatibility | Virgin UPVC and recycled blends |
| Co-Extrusion Ready | Yes, separate injection ports for rubber or decorative strips |
This tooling has been optimized for medium-speed lines while maintaining high dimensional accuracy and surface quality. It allows operators to switch between different profiles with minimal downtime, ensuring efficient and cost-effective production.
Design Features and Advantages
1. Modular Structure for Easy Maintenance
The Sub-Profile Tooling is built with a modular design, allowing operators to quickly disassemble and reassemble individual components. This modularity offers several benefits:
Simplified Maintenance: Components can be replaced or serviced without dismantling the entire mold.
Quick Adjustments: Minor modifications can be made on-site to adapt to different secondary profiles.
Reduced Downtime: Production interruptions are minimized, enhancing overall line efficiency.
This design philosophy ensures that manufacturers can maintain high output while keeping maintenance costs low.
2. Uniform Melt Flow for High-Quality Profiles
A critical aspect of secondary profile production is ensuring a smooth, defect-free extrusion. The Sub-Profile Tooling incorporates precision-engineered channels to guide molten UPVC evenly through the mold.
Benefits include:
Bubble-Free Extrusion: Eliminates voids and imperfections that can compromise structural integrity.
Consistent Profile Geometry: Ensures uniform thickness and shape along the entire length.
Reduced Warping or Twisting: Maintains precise dimensions even for thin or delicate profiles.
This consistent flow is particularly important for gaskets, seals, and decorative strips, which must fit perfectly in the final assembly.
3. Compatibility with Recycled Materials
Sustainability is a growing priority in modern manufacturing, and Extrutex tooling supports this trend. The Sub-Profile Tooling can process a combination of virgin and regrind materials without affecting final quality.
Eco-Friendly Production: Reduces waste by incorporating recycled UPVC.
Flexible Formulation: Allows the use of different recycled grades depending on cost and availability.
Maintained Performance: Profiles produced from mixed materials meet the same standards as virgin-only products.
This feature ensures that manufacturers can reduce environmental impact while maintaining profitability.
4. Long-Lasting Durability
Constructed from high-grade European tool steel, the Sub-Profile Tooling offers exceptional wear resistance and long service life. Key characteristics include:
High Hardness: Resists abrasion from continuous exposure to UPVC compounds.
Corrosion Resistance: Suitable for humid production environments.
Stable Geometry: Maintains dimensional accuracy even after thousands of production hours.
Investing in durable tooling reduces long-term costs and ensures consistent product quality over time.
5. Efficient Cooling System
Maintaining precise profile dimensions requires effective cooling immediately after extrusion. The Sub-Profile Tooling integrates specialized channels for circulating water or coolant.
Even Cooling: Prevents warping, shrinkage, or surface defects.
Rapid Solidification: Supports medium-speed production without sacrificing quality.
Customizable Flow: Cooling intensity can be adjusted for different profile thicknesses.
This cooling system guarantees that every profile emerges dimensionally accurate and ready for the haul-off stage.
6. Co-Extrusion Capability
For advanced applications, the Sub-Profile Tooling supports co-extrusion, allowing secondary materials like rubber gaskets or decorative strips to be integrated directly during extrusion.
Separate Injection Ports: Enables precise placement of additional layers without contamination.
Enhanced Product Functionality: Adds features such as flexible seals, color accents, or weather-resistant layers.
Aesthetic Versatility: Supports production of profiles with decorative laminates or colored inserts.
Co-extrusion expands the range of products a manufacturer can offer, increasing market competitiveness.
Applications of Sub-Profile Tooling
The Sub-Profile Tooling is ideal for producing a wide range of complementary UPVC profiles, including:
Gaskets and Seals – Essential for airtight and watertight performance in doors and windows.
Adapter Profiles – Used to bridge main profiles or connect different frame sections.
Reinforcing Profiles – Thin profiles that add structural integrity to doors, windows, or curtain walls.
Decorative or Low-Thickness Profiles – Profiles with aesthetic finishes for visible areas of doors and windows.
Weatherstrips and Trim Strips – Provide protection against wind, rain, and dust while enhancing appearance.
By accommodating a broad range of secondary profiles, this tooling allows manufacturers to produce complete window and door solutions from a single production line.
Operational Benefits
Investing in Sub-Profile Tooling provides tangible advantages for manufacturers:
Stable Operation: Maintains high-quality output even over extended production periods.
Surface Excellence: Produces smooth, defect-free surfaces with uniform color.
Low Maintenance Costs: Modular design reduces downtime and repair expenses.
Precise Adjustability: Fine-tuning screws allow quick adjustments to maintain dimensional accuracy.
Flexible Speed Range: Suitable for low- to medium-speed production lines, providing versatility across different production requirements.
This combination of operational efficiency and product quality ensures that manufacturers can meet tight delivery schedules while maintaining profitability.
Conclusion: A Smart Choice for Secondary UPVC Profiles
The Sub-Profile Tooling for Version 1 UPVC Profile EXTRUSION Line represents a strategic investment for any manufacturer looking to expand their product range and enhance production efficiency. By integrating precise engineering, modular design, and advanced functionality, this tooling enables the creation of high-quality complementary profiles, seals, and decorative elements with minimal downtime and maximum reliability.
Whether producing gaskets, adapters, reinforcing strips, or decorative profiles, the Sub-Profile Tooling ensures uniform quality, dimensional stability, and operational flexibility. It also supports sustainability initiatives by allowing the use of recycled materials and co-extrusion capabilities.
In short, the Sub-Profile Tooling is not merely an accessory; it is an essential extension of the Version 1 UPVC Profile EXTRUSION Line, empowering manufacturers to deliver complete, high-quality window and door solutions while reducing costs, improving efficiency, and meeting modern construction demands.
UPVC PROFILE EXTRUSION LINE
Extrutex Austria Downstream Profile Equipment
Engineered for Precision, Designed for Efficiency
Introduction: Excellence in Profile Manufacturing
In the highly competitive world of UPVC profile manufacturing, precision, reliability, and efficiency are non-negotiable. While extrusion lines often steal the spotlight, the performance of downstream equipment plays an equally critical role in determining the final quality, efficiency, and profitability of the production process.
Extrutex Austria, a pioneer in extrusion technologies, has redefined downstream machinery with a focus not on mass production but on premium quality, operational reliability, and exceptional service. By engineering solutions that emphasize precision, user-friendliness, and energy efficiency, Extrutex provides manufacturers with the tools they need to produce superior UPVC profiles consistently.
Downstream equipment encompasses all post-extrusion machinery, including calibration tables, haul-off units, water circulation and cooling systems, and filtration and vacuum systems. These machines ensure dimensional accuracy, surface quality, and operational stability while minimizing waste and downtime.
Core Philosophy: Precision Over Volume
Extrutex Austria operates with a philosophy that prioritizes excellence over sheer production volume. The company’s downstream profile equipment is intended for markets where manufacturers demand:
The highest level of performance and process stability
Uncompromised surface quality for premium profiles
Long-term reliability with minimal maintenance
By focusing on these aspects, Extrutex has developed downstream solutions that guarantee that every meter of extruded UPVC profile meets rigorous quality standards.
Key Features of Extrutex Downstream Equipment
1. Energy Efficiency
Extrutex downstream systems are engineered to optimize energy consumption without compromising output quality. This is achieved through:
Servo-Controlled Systems: Using precision servo motors for vacuum, haul-off, and other critical units minimizes energy waste and maintains precise operation.
Optimized Water Flow: Calibrated cooling channels ensure maximum heat exchange with minimal energy input.
Streamlined Design: Each component, from pumps to conveyors, is designed for low friction and energy-efficient operation.
The result is a system that is both economical to operate and environmentally responsible, reducing operational costs while supporting sustainable manufacturing practices.
2. Process Stability
Stable processes are the foundation of high-quality UPVC profiles. Extrutex downstream equipment incorporates advanced automatic control systems to ensure continuous, defect-free production:
CVR (Constant Vacuum Regulation): Maintains consistent vacuum levels across different areas of the calibration table, preventing deformation or dimensional inconsistencies.
CWP (Constant Water Pressure): Regulates water pressure in cooling channels to maintain uniform cooling rates.
CWT (Constant Water Temperature): Ensures that cooling water cycles remain stable, avoiding warping or surface defects caused by temperature fluctuations.
These controls enable manufacturers to maintain repeatable results, even with varying raw material properties or ambient conditions.
3. User-Friendly Operation
Extrutex downstream systems are designed to be accessible even to operators with limited technical experience. Features include:
Touch-Screen Interfaces: Intuitive controls display key parameters and allow quick adjustments.
Pre-Set Parameters: Operators can select from optimized settings for different profile types, reducing setup time and human error.
Guided Menus: Step-by-step guidance ensures correct operation during startup, calibration, and production.
This focus on usability reduces training requirements, minimizes errors, and increases overall production efficiency.
4. Advanced Vacuum Systems
The vacuum system is critical in stabilizing profiles immediately after extrusion. Extrutex employs servo-controlled vacuum pumps for precision and reliability:
Accurate Control: Servo controllers allow exact regulation of vacuum intensity for consistent dimensional stability.
Siemens Control Integration: High-precision automation reduces human error and maintains repeatable results.
Long-Term Reliability: Built to operate continuously with minimal maintenance, ensuring long operational life.
By stabilizing profiles effectively, this system improves surface finish, reduces rework, and enhances overall product quality.
5. Bypass Filtration Systems
Clean cooling water is essential for profile quality. Extrutex integrates advanced bypass filters to remove impurities and prevent contamination:
Optimized Calibration: Clean water ensures uniform cooling and prevents marks or surface defects.
Reduced Maintenance: Filters extend the life of downstream machinery by preventing buildup and corrosion.
Advanced Design: Allows high filtration efficiency without slowing down production.
These filtration systems are especially important in high-speed lines where even minor impurities can affect surface quality and dimensional stability.
6. Haul-Off Unit Innovations
Extrutex haul-off units combine automation, precision, and durability to handle profiles smoothly:
Fully Automated Operation: Synchronizes with extrusion speed to maintain consistent pulling force.
Tension-Controlled Chains: Ensure uniform transmission of mechanical power across all rollers.
Central Motor and Gearbox Layout: Provides stable torque and reduces mechanical stress.
Optimized Accessibility: Easy access to pods and wear parts simplifies maintenance and minimizes downtime.
These innovations contribute to reduced stops, faster adjustments, and extended component lifespan, which are critical in maintaining high throughput and profitability.
7. Advanced Cooling Cycles
Cooling is a crucial step to preserve profile geometry and surface integrity. Extrutex cooling systems are engineered for efficiency and uniformity:
SWC – Dry Calibration Water Cycle: Simultaneously controls flow, temperature, and volume to maximize cooling efficiency.
SWC – Wet Calibration Water Cycle: Ensures even surface quality and prevents contraction or warping, particularly in high-speed lines.
FBF – Wet Calibration Filter: Provides additional filtration for sensitive profiles, ensuring flawless surface finish.
DWD – Direct Water Discharge System: Automates water drainage and prevents sediment buildup, ensuring clean, efficient operation.
Together, these cooling technologies ensure that profiles maintain precise dimensions and excellent surface quality from start to finish.
Strategic Advantages for Manufacturers
1. Easy Startup
Touch-screen interfaces, guided menus, and pre-set parameters enable rapid setup without specialized technical knowledge.
2. Low Maintenance
Modular design and easy access to components allow for fast, economical repairs and replacements.
3. Compact Footprint
Optimized layouts deliver high performance while occupying minimal space, making them ideal for facilities with space constraints.
4. Reliability and Warranty
Extrutex Austria provides a two-year official warranty along with full technical support and spare part availability.
Extrutex Vision: Beyond Technology
Extrutex Austria is more than a machinery provider—it is a partner in success. The company’s approach encompasses:
Design Consultation: Tailored solutions for every production requirement.
Installation & Commissioning: On-site setup and optimization for immediate operation.
Operator Training: Ensures staff can maximize equipment potential safely.
After-Sales Support: Comprehensive maintenance, spare parts, and technical assistance.
This long-term partnership model guarantees that customers receive world-class service and support throughout the equipment’s life.
Ideal Users
Extrutex downstream profile equipment is designed for manufacturers who aim to:
Produce high-precision profiles with consistent dimensional accuracy.
Compete in markets where surface quality and reliability define success.
Reduce energy and maintenance costs while maintaining operational efficiency.
Optimize production with state-of-the-art technology and intelligent process control.
Whether producing windows, doors, or specialized profiles, Extrutex downstream equipment provides a reliable, high-performance backbone for any extrusion line.
Conclusion: The Extrutex Advantage
In today’s competitive landscape, superior technology, energy efficiency, and operational reliability are the hallmarks of successful UPVC profile production. Extrutex Austria’s downstream profile equipment offers a perfect blend of engineering innovation, user-friendly operation, and energy-conscious design.
By choosing Extrutex, manufacturers gain:
Advanced process stability for consistently high-quality profiles
User-focused design for rapid startup and minimal training
Long-lasting, modular machinery for reduced downtime and maintenance
Optimized energy consumption for cost-effective operation
In essence, Extrutex downstream equipment is not just machinery—it is a strategic investment. It empowers manufacturers to maintain a competitive edge, achieve superior product quality, and secure a sustainable, profitable future in the UPVC industry.
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