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UPVC EXTRUSION LINE VER 6 -HIGH CPACITY & HIGH SPEED
Description
UPVC Profile Extrusion Line – Version 6 by EXTRUTEX
High-Capacity, High-Precision, and Long-Term Profitability
Introduction
In the fast-paced world of modern construction, UPVC profiles have become an essential material for windows, doors, and structural elements that demand durability, insulation, and minimal maintenance. Unlike wood, which is prone to swelling, or aluminum, which can conduct heat and corrode, UPVC delivers a balanced combination of thermal stability, weather resistance, and cost-effectiveness.
Behind every reliable UPVC profile lies a carefully engineered extrusion line, where raw PVC compounds are melted, shaped, cooled, cut, and stacked into finished profiles ready for assembly. The heart of such production lies in the extrusion tooling that defines the geometry, and the downstream equipment that ensures stability, accuracy, and efficiency throughout the line.
EXTRUTEX, a company with decades of European engineering experience, has consistently pushed the boundaries of extrusion technology. With the introduction of the Version 6 UPVC Profile Extrusion Line, EXTRUTEX offers its most advanced solution to date — a line designed for output up to 450 kg/h while maintaining world-class dimensional accuracy and surface quality.
This new generation system integrates high-performance extrusion tooling, intelligent downstream equipment, and energy-efficient drives, ensuring manufacturers can achieve high capacity, high profitability, and unmatched consistency in their production.
Core Components of the Version 6 Extrusion Line
1. Extruder ATP 113 – The Powerhouse of the Line
At the heart of the Version 6 system lies the ATP 113 twin-screw extruder, a high-capacity machine engineered to handle even the toughest UPVC formulations with precision and stability.
Technical Highlights:
Twin-screw co-rotating design for homogeneous mixing of PVC, stabilizers, pigments, and fillers.
Advanced screw geometry engineered to balance shear and melt flow for stable plasticizing.
Multiple heating zones with independent controllers for precise temperature management.
Heavy-duty gearbox with high efficiency and reduced vibration for long-term stability.
Energy-efficient motor drive reducing power consumption while delivering reliable torque.
Benefits:
Consistent melt quality ensures defect-free profiles.
Longer screw and barrel life due to optimized metallurgy.
Flexibility in switching between recipes or formulations.
Lower energy costs per kilogram of output.
2. Extrusion Tooling – The Shaping Heart of the Line
The extrusion tooling is where molten PVC transforms into its precise profile geometry. In Version 6, EXTRUTEX has refined its tooling design to meet the highest demands for output, accuracy, and durability.
Key Features:
CFD-simulated flow channels for uniform melt distribution.
Polished die lips for smooth surface finish and minimal friction.
Modular die sets allowing quick changeovers for different profile designs.
High-strength tool steel construction (grades such as 1.2316 or 1.2083) with chrome or nickel coatings for anti-stick performance.
Pre-calibration inserts to stabilize profile geometry before entering the downstream vacuum table.
Advantages:
Reduced back pressure on the extruder.
Longer service life thanks to wear- and corrosion-resistant materials.
Capability to produce profiles up to 350 mm wide and 3 mm thick with flawless surface quality.
Quick cleaning and maintenance due to modular structure.
3. Downstream Calibration – ACT 11000 Vacuum Table
Immediately after exiting the extrusion tooling, the hot profile must be cooled and dimensionally stabilized. The ACT 11000 downstream calibration table provides 11 meters of vacuum and water cooling capacity to ensure profiles maintain their exact dimensions.
Features:
Multiple independent vacuum chambers for high holding force and stability.
High-capacity European-made vacuum pumps for reliable suction.
Spray cooling system for fast and uniform temperature reduction.
Adjustable height and angle for alignment with extrusion tooling.
Benefits:
Perfect dimensional stability, even at high output speeds.
Prevention of warpage, bowing, or collapse.
Smooth, stress-free cooling process extending profile lifespan.
4. Haul-off & Cutting – APS 30 / SA1 Unit
Once cooled, the profile must be pulled and cut with high precision. The APS 30 haul-off combined with the SA1 automatic saw delivers this functionality with uncompromising accuracy.
Haul-off System:
Silicone belt or caterpillar traction for firm grip.
Servo motor control for precise synchronization with extrusion speed.
Independent inverters to fine-tune pulling speed and pressure.
Cutting System:
Alloy steel blade for burr-free cutting.
Automatic length detection via sensors for repeatable cuts.
Servo-driven cutting head synchronized with line speed.
Safety mechanisms for immediate stop in case of fault.
Advantages:
Reduced end waste and minimized scrap.
High accuracy across all cut lengths.
Long-lasting cutting blades reduce operational costs.
5. End Table – ATT6
The final station of the downstream process is the end table, where finished profiles are received, aligned, and stacked.
Features:
Heavy-duty steel frame with anti-corrosion coating.
Wear-resistant rollers for smooth profile handling.
Adjustable height and support arms for different profile sizes.
Function:
Collects profiles neatly without scratches.
Simplifies packing and logistics.
Performance & Productivity
| Parameter | Specification |
|---|---|
| Max Output | 450 kg/h |
| Line Speed | >3.0 m/min (depending on tooling) |
| Calibration Table Length | 11 m |
| Energy Efficiency | Optimized with inverters and PID heat control |
| Profile Width | Up to 350 mm |
| Vacuum Stations | Multi-stage for precision |
| Cutting Accuracy | ±0.5 mm |
| Changeover Time | Approx. 20 minutes with modular tooling |
Key Benefits of Version 6 Line
✅ High Output, No Compromise on Quality – The line maintains consistent profile quality at 450 kg/h output.
✅ Superior Surface Finish – Glossy, defect-free surfaces ready for lamination or direct use.
✅ Dimensional Accuracy – Tight tolerances (<0.1 mm) thanks to tooling and downstream synchronization.
✅ Energy Savings – Inverter-driven motors and optimized heaters reduce energy consumption by up to 15%.
✅ Flexibility in Production – From window frames to industrial channels, multiple profiles can be produced with quick tooling changeovers.
✅ Durability – Wear-resistant materials extend the life of extrusion tooling and downstream machinery.
✅ Centralized Control – One PLC + touchscreen HMI integrates all parameters (temperature, speed, vacuum, cutting).
Applications of Version 6 Extrusion Line
The line is engineered to meet a broad range of industrial and construction needs, including:
Window & Door Frames – Multi-chamber UPVC frames for double- and triple-glazing.
Industrial Structural Profiles – High-strength profiles for load-bearing use.
Cable Ducts & Conduits – Durable, insulating channels for electrical and HVAC systems.
Partition & Panel Profiles – Profiles for modular walls, partitions, and decorative trims.
Specialized Profiles – UV-resistant, waterproof designs for outdoor and export markets.
Maintenance & Support
EXTRUTEX ensures the Version 6 line remains a long-term investment through:
On-site installation & commissioning by skilled engineers.
Operator training programs for efficient daily operation.
Preventive maintenance services to avoid downtime.
Original spare parts available with short lead times.
Remote support & troubleshooting via online connection.
Conclusion
The UPVC Profile Extrusion Line Version 6 by EXTRUTEX represents the pinnacle of extrusion technology. It combines high-output extrusion tooling, sophisticated downstream calibration, and intelligent automation to deliver exceptional performance, reliability, and profitability.
For manufacturers who demand consistent quality, global competitiveness, and long-term cost savings, Version 6 is not just a machine — it’s a production partner for the next decade of UPVC manufacturing.
With 450 kg/h capacity, energy-efficient systems, and world-class support, EXTRUTEX continues to redefine what’s possible in extrusion technology.
Technical Introduction – Double Strands Extrusion Tooling for UPVC Profiles, Version 6 Line
Introduction
In modern UPVC profile production, extrusion tooling is the heart of the process. It is the critical component where melted raw material is transformed into precise, stable, and high-quality profiles. When the tooling is engineered with precision, it directly influences the dimensional accuracy, surface quality, and efficiency of the entire extrusion line.
For manufacturers looking to achieve high output with stable quality, the Double Strands Extrusion Toolingdeveloped for the Version 6 EXTRUTEX line offers an advanced, industrial solution. This system is designed to produce two identical profiles simultaneously, delivering a production capacity of 450 kg/h with speeds above 3.5 meters per minute, while ensuring durability, cost efficiency, and long-term stability.
Key Features of the Double Strands Extrusion Tooling
✅ Dual Outlet Structure (Double Strands Cavity)
The tooling incorporates two fully independent flow channels that form two UPVC profiles at once. Each cavity is engineered with symmetrical flow distribution to guarantee identical dimensions and surface quality.
Benefits:
Doubles productivity without increasing screw speed.
Optimizes plant floor utilization by producing two profiles in parallel.
Reduces per-meter production cost, ideal for high-volume manufacturing.
✅ Optimized Melt Flow Distribution
Inside the tooling, CFD-based flow simulations have been applied to design perfectly balanced channels. The melt is distributed evenly, preventing local pressure build-up or cooling delays.
Result:
Both strands exit the tooling with identical thickness, geometry, and surface smoothness.
✅ Robust, Wear-Resistant Construction
The body of the tooling is manufactured from alloyed tool steel with hardened surfaces and hard chrome platinginside the flow channels. This ensures maximum resistance against abrasion caused by fillers such as calcium carbonate, while also maintaining surface finish for years.
Advantages:
Long tooling life with minimal degradation.
Reduced downtime due to fewer replacements.
Stable operation under high-pressure extrusion.
✅ Integrated Cooling System
Given the high output capacity of 450 kg/h and profile thicknesses above 3 mm, efficient thermal management is crucial. The tooling includes internal water-cooling channels arranged in a closed-loop system to control mold temperature.
Outcome:
Dimensional stability of the extruded profiles.
Prevention of deformation, burning, or warping during the shaping stage.
Smooth transition to downstream calibration.
✅ Adjustable Inserts for Dimensional Flexibility
The tooling incorporates removable and adjustable inserts at the die exit. This design allows fine-tuning of profile width or thickness within a defined range, without replacing the entire tooling set.
Key Benefits:
Faster setup when switching between similar profile sizes.
Cost reduction by minimizing the number of separate tooling sets needed.
Easier maintenance and part replacement.
Performance in Version 6 Extrusion Line
| Specification | Value |
|---|---|
| Tooling Type | Double Strands Extrusion Tooling |
| Profile Thickness | Above 3 mm |
| Line Speed | > 3.5 m/min |
| Total Output | 450 kg/h |
| Tooling Body | Alloyed hardened steel |
| Cooling | Internal closed-loop water channels |
| Flow Distribution | Symmetrical, CFD-optimized |
| Adjustability | Insert-based dimensional tuning |
Advantages of Double Strands Extrusion Tooling
🔹 High Output with Stable Quality
By producing two identical profiles simultaneously, the tooling effectively doubles productivity. This is achieved without overloading the extruder, since the material flow is divided evenly across two cavities.
🔹 Cost Efficiency
Energy and operator effort remain nearly constant, while output doubles. The result is a lower cost per meter of profileand a faster return on investment.
🔹 Superior Surface Quality
The balanced melt distribution and efficient cooling guarantee that each strand has:
Glossy, smooth finish.
No visible flow marks or surface bubbles.
Consistent color and uniform wall thickness.
🔹 Industrial Reliability
Thanks to premium European-grade steel and robust construction, the tooling withstands long production runs under demanding conditions without losing accuracy.
🔹 Easy Maintenance
The modular design allows quick cleaning and part replacement. Flow channels are accessible, and inserts can be swapped individually for size corrections.
Applications
This double strands extrusion tooling is specifically engineered for high-volume production of UPVC profiles used in construction and industry.
Typical Products:
UPVC Window and Door Frames
Double-strand Production of Standard Beads and Sashes
Reinforcement Profiles for Large Frames
Industrial Partition and Connector Profiles
Integration with the Version 6 Downstream Line
The performance of extrusion tooling is maximized when integrated seamlessly with the Version 6 EXTRUTEX extrusion line and downstream equipment.
Calibration Table (ACT 11000): Ensures stable shaping of both strands simultaneously with multiple vacuum zones.
Haul-off & Cutter (APS 30/SA1): Provides synchronized pulling and precision cutting for double output.
End Table (ATT6): Collects and organizes both strands for stacking or packaging.
This synergy between tooling and downstream units results in consistent quality and uninterrupted production flow.
Economic Impact
Manufacturers adopting double strands extrusion tooling report significant advantages:
Up to 100% increase in output without doubling operating costs.
15–20% lower energy consumption per profile meter compared to single-strand setups.
Higher profitability per shift, with reduced material wastage.
Enhanced competitiveness in both local and export markets, thanks to consistent quality and higher throughput.
Maintenance & Best Practices
To ensure long life and sustained performance:
Regular Cleaning – Use non-abrasive cleaning tools for internal channels.
Preventive Lubrication – Protects moving inserts and adjustment parts.
Cooling Water Quality – Ensure closed-loop water is filtered to prevent scaling.
Scheduled Inspections – Check wear levels of chrome-plated areas and replace inserts as needed.
Conclusion
The Double Strands Extrusion Tooling for Version 6 EXTRUTEX lines represents a powerful upgrade for UPVC manufacturers aiming at high capacity, low cost, and consistent quality.
By doubling strand output in a single pass while maintaining perfect dimensional control, this tooling makes large-scale production more profitable, sustainable, and export-ready. With its modular design, wear-resistant construction, and seamless compatibility with downstream equipment, it is not only a tooling system — it is a strategic production advantage for competitive UPVC extrusion plants worldwide.
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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