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UPVC Extrusion tooling – Version 3 (High Performance, High Capacity)
Description
EXTRUTEX Austria UPVC Extrusion Line – Version 3 (High Performance, High Capacity)
The EXTRUTEX Austria UPVC Extrusion Line – Version 3 represents the ultimate in high-performance, high-capacity UPVC profile manufacturing. Engineered for precision, efficiency, and industrial-scale productivity, this extrusion line integrates decades of expertise in mechanical design, materials engineering, and process optimization. With Version 3, EXTRUTEX Austria delivers an extrusion system capable of producing profiles of exceptional quality at maximum throughput, making it the ideal choice for manufacturers seeking industrial-grade UPVC profile production.
Overview of Version 3 Extrusion Line
Version 3 is the latest generation of EXTRUTEX Austria extrusion lines, designed to meet the increasing demands of modern UPVC manufacturing. With a focus on high capacity, precise dimensional control, and operational reliability, this line is built for manufacturers who require continuous, high-volume production without compromising on quality.
The line integrates the ATP 73 conical extruder, ACT 8000 multi-stage calibration table, APS 30/SA1 haul-off and cutting unit, and ATT6 downstream handling table. This complete system ensures seamless extrusion, cooling, calibration, cutting, and handling of profiles for doors, windows, frames, panels, cable ducts, decorative trims, and other UPVC construction components.
Key Features and Advantages
High Dimensional Accuracy
The Version 3 extrusion line guarantees exact dimensional control for UPVC profiles. The combination of precision extruder design, multi-zone temperature regulation, and calibration ensures consistent wall thickness, width, and geometric precision. This accuracy is crucial for high-quality assembly in doors, windows, and other architectural components.Advanced Multi-Stage Cooling and Calibration
The ACT 8000 calibration table employs multiple vacuum zones and controlled water circulation to stabilize profiles immediately after extrusion. This multi-stage cooling system ensures uniform profile contraction, prevents warping, and maintains a smooth, defect-free surface. It allows manufacturers to produce profiles with varying shapes, thicknesses, and sizes while maintaining strict tolerances.High Throughput and Stable Production Speed
Version 3 achieves a stable production speed of 2.6 meters per minute with an output capacity of 260 kilograms per hour. This high capacity allows manufacturers to meet large-scale project demands efficiently, whether for domestic distribution or export markets. High throughput combined with precision control ensures that profile quality remains uncompromised at all times.Integrated Haul-Off and Cutting System (APS 30/SA1)
The downstream APS 30/SA1 unit ensures synchronized profile haul-off and precision cutting. Its dual-fork design guarantees even tension and prevents profile deformation, while the cutting system delivers millimeter-accurate lengths. Fully programmable and PLC-controlled, the unit ensures consistent output across high-volume production.ATT6 Downstream Handling Table
After cutting, profiles are transferred to the ATT6 downstream handling table. The table provides secure handling, temporary storage, and preparation for packaging, minimizing the risk of damage or distortion. Adjustable supports and shock-absorbing features allow smooth profile transfer to secondary operations or packaging.ATP 73 High-Performance Extruder
At the heart of the extrusion line is the ATP 73 conical extruder, engineered for high-capacity, continuous operation. Its twin-screw design ensures uniform melting, blending, and conveying of raw UPVC materials, including virgin and recycled components. High torque and multi-zone temperature control maintain precise processing conditions for various formulations containing fillers, stabilizers, or additives.Extruder Features:
Gear-motor with high torque for continuous operation
Twin-screw design resistant to wear
Multi-zone ceramic heaters for precise temperature control
PLC integration for real-time monitoring and process stability
Compatibility with hard PVC and blended formulations
Energy Efficiency
While delivering high capacity, the Version 3 line has been engineered for optimized energy consumption. Servo-controlled motors, inverters, and intelligent water circulation reduce operational costs while maintaining peak performance. Efficient use of recycled UPVC material further enhances the system’s sustainability credentials.Flexible Mold Compatibility
Version 3 accepts single, dual, or multi-cavity molds and supports co-extrusion for colored or soft-seal layers within a single production pass. This flexibility allows manufacturers to produce a wide variety of profiles, from standard window frames to decorative trims and specialized architectural elements.Digital Control and Automation
All line components are integrated into a central PLC system with a touchscreen HMI interface. Operators can adjust and monitor extrusion temperature, pressure, haul-off speed, and cutting length in real-time. Optional remote monitoring allows off-site supervision, predictive maintenance alerts, and process optimization recommendations.
Technical Specifications – Version 3
| Component | Model / Type | Functionality |
|---|---|---|
| Extruder | ATP 73 | Conical twin-screw extruder with automatic feeding and multi-zone temperature control |
| Calibration Table | ACT 8000 | Multi-stage vacuum and water cooling for precise profile dimension stabilization |
| Haul-Off / Saw | APS 30/SA1 | Dual-fork haul-off with synchronized high-precision cutting; PLC-controlled |
| Downstream Table | ATT6 | Safe handling, temporary storage, and packaging preparation |
| Output Capacity | 260 kg/hour | Stable, high-capacity extrusion for industrial applications |
| Production Speed | 2.6 meters/minute | Consistent high-speed profile extrusion |
| Profile Thickness | 2.5 mm – 4 mm | Suitable for standard and reinforced profiles |
Advantages Compared to Version 2
| Feature | Version 2 | Version 3 |
|---|---|---|
| Energy Efficiency | Medium | Optimized with inverters and servo controls |
| Cooling System | Single-stage | Multi-stage for precise dimensional control |
| Temperature Control | Manual / semi-automatic | Fully digital with PLC monitoring |
| Remote Monitoring | Limited | Full capability with software integration |
| Mold Compatibility | Standard | Multi-cavity and co-extrusion molds |
| Structural Design | Classic | Space-saving, high-performance industrial layout |
Applications
The Version 3 extrusion line supports the production of a wide range of UPVC profiles, including:
Door and window frames, sashes, and reinforcement profiles
Double-glazed beads and sealing strips
Decorative panels, trims, and skirting boards
Cable ducts, gutters, cornices, and baseboards
Custom architectural profiles for industrial and residential projects
Operational Benefits
Consistent Quality
Precision extrusion, calibration, and downstream handling ensure profiles meet strict dimensional and surface quality standards. Continuous monitoring minimizes defects and waste, producing profiles suitable for premium construction applications.High Capacity Production
With 260 kg/hour output and 2.6 m/min speed, the Version 3 line is ideal for high-volume manufacturing, large-scale projects, and export-oriented operations. Its modular design simplifies maintenance and reduces downtime.Automation and Ease of Use
Centralized PLC control and HMI interface allow operators to manage all process parameters efficiently. Advanced users can optimize production for maximum output and quality, while less-experienced operators can safely operate the line with minimal training.Sustainability
Optimized water and energy management, combined with compatibility with recycled materials, ensures a lower environmental footprint while maintaining high-quality profile production.Economic Benefits
Reduced energy consumption and operational costs
Minimal material waste and defective products
High productivity to meet large orders efficiently
Flexibility to produce multiple profile types on the same extrusion line
Installation, Training, and Support
EXTRUTEX Austria provides comprehensive support, including:
On-site installation and commissioning
Full operator training
Manuals in Persian and English
12-month warranty on core components
Spare parts supply and maintenance support
Compliance and Standards
All Version 3 components adhere to CE, ISO 9001, and RoHS standards. Siemens or Schneider PLC systems, German Becker pumps, and European-grade steel in critical wear parts ensure reliability, safety, and long operational life.
Conclusion
The EXTRUTEX Austria UPVC Extrusion Line – Version 3 (High Performance, High Capacity) sets a new standard for industrial UPVC profile production. Combining advanced extruder design, multi-stage calibration, automated downstream handling, and digital process control, this line enables manufacturers to produce high-quality profiles with maximum throughput and minimal operational costs. Version 3 is the ideal solution for manufacturers seeking industrial-scale efficiency, precision, and consistent high performance, offering a significant competitive advantage in domestic and international markets.
EXTRUTEX Austria UPVC Extrusion tooling – Version 3 (High Performance, High Capacity)
In the manufacturing of UPVC profiles, the extrusion die is the heart of the process, dictating the quality, dimensional accuracy, surface finish, and output efficiency of the extrusion line. The EXTRUTEX Austria Extrusion tooling, specifically designed for the Version 3 high-performance extrusion line, represents the pinnacle of precision engineering in die technology. Engineered for high-capacity operations, the Version 3 die enables manufacturers to produce UPVC profiles with thicknesses greater than 2.5 millimeters, at speeds of up to 2.5 meters per minute and with a downstream output of up to 260 kilograms per hour.
This die system is ideal for industrial production of reinforced door and window frames, double-glazed beads, multi-chamber profiles, and various structural and decorative components. Every aspect of its design has been optimized to ensure stability, precision, and repeatable high-quality results.
Key Technical Specifications
| Parameter | Value / Description |
|---|---|
| Profile Thickness | Over 2.5 mm |
| Maximum Production Speed | 2.5 meters per minute |
| Achievable Output | 260 kg/hour |
| Number of Die Lips | 1–2 (multi-cavity options available) |
| Body Material | Chrome-molybdenum alloy steel |
| Adjustment Method | Manual or micrometer screw |
| Maximum Working Temperature | 220–240°C |
| Calibration Support | Fully compatible with ACT 8000 calibration table |
| Replaceable Die Lips | Modular design for quick replacement |
High-Performance tooling Design
The EXTRUTEX Version 3 die is built for precision and reliability. Its pressure-type two-stage design ensures uniform material flow, high dimensional accuracy, and stable output. The die consists of several key components, each engineered to optimize profile formation, surface quality, and downstream handling efficiency.
1. Flow Channel System
The flow channel is the backbone of the extrusion die, designed to deliver molten UPVC uniformly and symmetrically across the die lips. Advanced engineering principles have been applied to minimize pressure variations within the flow, ensuring consistent wall thickness throughout the profile. This uniform flow pattern is crucial for high-precision profiles, particularly when producing thick or multi-chamber designs.
Key benefits of the flow channel:
Eliminates uneven thickness or warping in high-speed extrusion
Reduces material stress and potential defects
Ensures consistent downstream performance and calibration
2. Die Lips (Output Nozzles)
The die lips are the most critical section of the extrusion die, directly affecting surface quality, dimensional tolerance, and output rate. EXTRUTEX Version 3 dies feature fully adjustable die lips that allow operators to perform fine-tuning while the extrusion line is running. This capability ensures precise control over wall thickness and surface finish without interrupting production.
Features of the die lips:
Modular construction for rapid replacement or upgrades
Micro-adjustment capability to fine-tune profile dimensions
Optimized geometry for smooth surface finish and minimal flow turbulence
Supports single or multi-cavity configurations for higher output
3. Calibrators and Secondary Adjustment Plates
Immediately downstream of the die lips, calibrators stabilize profile dimensions and smooth surface imperfections. These plates work in conjunction with advanced cooling channels and precision water spray systems to prevent early-stage deformation. This early calibration is critical for producing thick, reinforced profiles with strict dimensional requirements.
Advantages of calibrators:
High accuracy in maintaining dimensional tolerances (<0.1 mm)
Enhanced surface smoothness for premium-quality profiles
Compatibility with multi-stage ACT 8000 calibration tables
Adjustable for profiles of varying shapes, thicknesses, and designs
Material and Mechanical Properties
The body of the Version 3 die is constructed from high-grade chrome-molybdenum alloy steel, hardened to resist thermal and mechanical stress. This ensures durability and long service life, even under continuous, high-speed operation. Surface coatings provide additional wear resistance, minimizing maintenance requirements and extending operational uptime.
Hardness and wear resistance suitable for industrial-scale high-capacity production
Resistant to deformation at temperatures up to 240°C
Long-lasting structural integrity for over 2 years of continuous operation
Optimized thermal conductivity for stable molten PVC flow
Operational Advantages
High Downstream Output
By combining optimized flow channels, adjustable die lips, and effective cooling, the Version 3 die achieves a stable downstream output of 260 kilograms per hour. This high throughput is ideal for large-scale industrial operations and export-oriented production, ensuring that manufacturers can meet high-volume demands efficiently.Exceptional Dimensional Accuracy
Precision CNC machining ensures the die maintains a tolerance below 0.1 millimeters. This level of accuracy allows manufacturers to produce consistent profiles batch after batch, reducing waste and ensuring customer satisfaction with every order.Durability and Longevity
The combination of alloy steel construction, hardening, and wear-resistant coatings guarantees that the die maintains its performance characteristics over years of continuous operation. Its resistance to mechanical stress, heat, and abrasion reduces downtime and maintenance costs.Easy Adjustment During Operation
The modular design and adjustable die lips allow operators to make small changes to profile thickness or width without halting the extrusion line. This capability is critical for continuous production and flexible manufacturing, enabling rapid adaptation to changing project requirements.
Applications
The EXTRUTEX Version 3 extrusion die is versatile, supporting a wide range of profile types for residential, commercial, and industrial applications:
Reinforced window and door frames for high wind-load areas
Thick double-glazed door sashes and panels
Multi-chamber sealing profiles for enhanced thermal and acoustic insulation
Architectural and decorative profiles, including skirting, trims, and cornices
Cable ducts, guttering, and specialized construction profiles
Integration with Version 3 Extrusion Line
The Version 3 die is fully compatible with the EXTRUTEX high-performance, high-capacity Version 3 extrusion line. Installed downstream, it works seamlessly with the ATP 73 extruder, ACT 8000 calibration table, APS 30/SA1 haul-off and cutting system, and ATT6 downstream handling table. This integration ensures optimal material flow, precise calibration, efficient cutting, and secure handling of finished profiles.
Support and Services
EXTRUTEX Austria provides comprehensive support for all Version 3 dies, ensuring that manufacturers achieve the highest possible performance and longevity from their equipment:
Custom die design based on client specifications
On-site testing and commissioning of the die
Training for operators on adjustment and maintenance
Rapid supply of spare parts, including die lips, screws, and calibrators
Repair and refurbishment services for existing dies
Economic and Operational Benefits
Investing in the EXTRUTEX Version 3 extrusion die brings tangible economic and operational advantages:
Maximizes downstream throughput with minimal waste
Reduces operational downtime due to durable, low-maintenance construction
Ensures consistent profile quality, reducing rejected materials
Enables flexible adjustment for multiple profile designs without line stoppage
Optimizes energy and material efficiency, supporting sustainable production practices
Conclusion
The EXTRUTEX Austria UPVC Extrusion Die for Version 3 represents the culmination of decades of engineering experience in high-performance extrusion technology. Designed for industrial-scale, high-capacity production, this die ensures superior dimensional accuracy, consistent surface quality, and efficient downstream operation. Its modular, adjustable design, combined with durable construction and advanced flow engineering, makes it a critical component for any manufacturer seeking premium-quality UPVC profiles.
With the Version 3 die, manufacturers can achieve stable, high-throughput production, flexible profile customization, and reduced operational costs, all while maintaining the highest standards of quality. EXTRUTEX Austria’s technical support and spare parts service further enhance the value of this die, providing a complete, professional solution for modern UPVC extrusion lines.
For inquiries about custom dies, technical drawings, or professional consultation, EXTRUTEX Austria’s technical and sales teams are ready to assist.
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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