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UPVC Profile Extrusion Line – Version 3 High-Capacity Industrial System
Description
EXTRUTEX UPVC Profile Extrusion Line – Version 3 High-Capacity Industrial System
Advanced Engineering, Maximum Throughput, and Precision Manufacturing
EXTRUTEX Austria has long been a pioneer in high-performance extrusion technology for the construction industry. With a commitment to innovation, energy efficiency, and precision engineering, EXTRUTEX presents its Version 3 High-Capacity UPVC Profile Extrusion Line, designed to meet the demanding requirements of medium to large-scale manufacturing units. This extrusion line represents a fusion of cutting-edge technology, robust engineering, and optimized downstream processes, capable of delivering unmatched quality, consistent output, and operational efficiency.
This system is particularly ideal for manufacturers seeking high-capacity production, precise dimensional control, and the ability to produce a wide range of UPVC profiles, including window frames, door panels, decorative trims, cable ducts, and multi-chamber profiles. The Version 3 extrusion line ensures high-quality outputs while maintaining low energy consumption and minimal production waste.
Key Components of the Version 3 High-Capacity Extrusion Line
1. ATP 93 Twin-Screw Extruder – The Heart of the Line
At the core of this high-capacity extrusion line is the ATP 93 twin-screw extruder, engineered for precision, stability, and high throughput. The extruder features a 93mm screw diameter with an optimized screw profile, allowing uniform melting, mixing, and conveying of UPVC compounds with maximum efficiency.
Key Features:
High-Power Gearbox System: Ensures consistent torque transmission for heavy-duty extrusion operations.
Energy-Efficient Motor with Frequency Control: Optimizes power usage while maintaining consistent extrusion performance.
Ceramic Heating Elements: Provide precise temperature control with minimal energy loss.
Air/Water Cooling System: Maintains ideal thermal stability for high-quality extrusion.
Output Capacity: Up to 350 kg/h, suitable for large-scale, multi-chamber profiles.
Stable Melt Rate: Delivers uniform extrusion, essential for maintaining dimensional accuracy across thick or complex profiles.
The ATP 93 extruder allows manufacturers to produce multi-cavity, thick-wall UPVC profiles without compromising on quality or output, making it a high-capacity solution for industrial applications.
2. ACT 11000 Calibration Table – Precision Downstream Control
Following extrusion, the profiles are guided into the ACT 11000 calibration table, a 11-meter long downstream system designed for precise shaping, cooling, and stabilization of large-profile UPVC products.
Key Features:
Multi-Zone Vacuum System: Independently controlled zones allow for gradual stabilization of complex profiles.
Stainless Steel Spray Nozzles: Anti-scaling and corrosion-resistant nozzles provide uniform water distribution.
Controlled Water Flow Paths: Adjustable valves regulate pressure and flow to ensure consistent cooling.
Height, Width, and Horizontal/Vertical Adjustability: Supports flexible profile dimensions.
Optimized for Large Cross-Section Profiles: Ensures dimensional stability even for thick, multi-chamber sections.
This table ensures that downstream processes maintain perfectly straight, dimensionally accurate profiles. Combined with a high-capacity extruder, the ACT 11000 table guarantees a stable and repeatable extrusion-to-downstream workflow, minimizing defects and rework.
3. APS 30 / SA1 Haul-Off and Cutting System – Precision Downstream Handling
Downstream from the calibration table, the APS 30 haul-off and SA1 cutting system provides smooth pulling of profiles and accurate cutting to desired lengths. This system is fully synchronized with the extrusion speed, ensuring minimal surface stress or deformation.
Key Features:
Twin-Chain Rubberized Pressure System: Applies uniform pull without deforming the profile.
Servo Motor-Controlled Speed and Pressure: Offers precise adjustments to match extrusion rate.
PLC-Controlled Cutting Mechanism: Supports linear, angled, or sequential cuts for optimized material use.
Integration with Extrusion Line: Ensures seamless coordination between extruder output and downstream handling.
By maintaining uniform tension and accurate cutting, the APS 30/SA1 system ensures that the high-volume throughput of this extrusion line translates into consistently high-quality profiles ready for final finishing or packaging.
4. ATT6 End Table – Organized Downstream Collection
The final downstream stage is the ATT6 end table, where cut profiles are collected, prepared for stacking, or packaged. The table features a sensor-based conveyor system that adjusts to the flow of profiles, preventing jams and minimizing handling errors.
Key Features:
Rust-Resistant Construction: Designed to withstand humid or dusty environments.
Adjustable Height: Automated or manual adjustment for profile alignment.
Integrated Position Sensors: Stop conveyor flow automatically to prevent collisions or damage.
The ATT6 ensures safe handling of high-volume outputs, making it easier to maintain product integrity from extrusion to packaging.
Technical Specifications – Version 3 High-Capacity UPVC Extrusion Line
| Component | Model / Features |
|---|---|
| Extruder | ATP 93 – twin-screw, high torque, up to 350 kg/h output |
| Calibration Table | ACT 11000 – multi-zone vacuum, precise cooling, supports large profiles |
| Haul-Off / Cutter | APS 30 / SA1 – synchronized pulling and cutting, servo-controlled |
| End Table | ATT6 – conveyor-based, sensor-controlled collection |
| Line Speed | Approx. 2.5 meters per minute |
| Material Input | UPVC powder with stabilizers, carbonates, pigments, and additives |
| Applications | Window & door frames, sashes, panels, trims, cable ducts, multi-chamber profiles |
Advantages of the Version 3 High-Capacity Extrusion Line
1. Maximized Productivity with Low Energy Consumption
The Version 3 extrusion line has been engineered for energy-efficient operation. Optimized screw geometry, precise heating elements, and water/air cooling in downstream systems reduce energy loss while maintaining a high throughput of 350 kg/h. This makes it economically viable for industrial-scale operations.
2. Flexible Profile Production
The line supports a wide variety of dies, enabling the production of diverse profile types:
Reinforced thick-wall window frames for high-wind areas
Double-glazed door panels
Multi-chamber profiles for thermal and acoustic insulation
Decorative trims, skirting, and cornices
Cable ducts, gutters, and industrial profiles
This flexibility allows manufacturers to respond quickly to market demands without changing the extrusion line setup extensively.
3. Fully Integrated Downstream Synchronization
All downstream components are digitally controlled via a central PLC system, ensuring perfect coordination between extrusion, calibration, haul-off, and cutting. This minimizes profile deformation, reduces scrap, and ensures repeatable quality across high-volume production runs.
4. Durable and Low-Maintenance Design
EXTRUTEX has incorporated wear-resistant materials, modular components, and automated lubrication systems, which significantly extend the service life of the extrusion line. This translates into lower maintenance costs, reduced downtime, and reliable long-term operation.
5. High-Capacity and Precision
With a throughput of 350 kg/h and a line speed of 2.5 meters per minute, this extrusion line is capable of supplying large-scale industrial projects, exporting markets, or high-demand manufacturing units, without compromising dimensional accuracy or surface quality.
6. Advanced Process Control
The line’s PLC-controlled system provides real-time monitoring and adjustments for:
Extruder temperature zones
Screw speed and torque
Vacuum and water flow in calibration tables
Haul-off tension and cutting intervals
These controls ensure the highest possible consistency and minimize human error, enabling operators to manage the line efficiently.
Industrial Applications
The EXTRUTEX Version 3 High-Capacity UPVC Extrusion Line is suitable for:
Construction Companies: Producing double-glazed window and door frames for commercial and residential buildings.
Industrial Profile Manufacturers: Creating reinforced, thick-wall profiles for specialized applications.
Interior Decoration Suppliers: Manufacturing trims, skirtings, panels, and decorative profiles.
Export-Oriented Businesses: Supplying high-volume UPVC profiles to regional and international markets such as the Middle East, Central Asia, and Europe.
Support, Installation, and After-Sales Services
EXTRUTEX provides comprehensive support for the Version 3 extrusion line:
On-site installation and commissioning
Complete operator training
Provision of custom die designs
Online troubleshooting for PLC and downstream systems
Rapid supply of spare parts and maintenance kits
These services ensure that the extrusion line is fully operational from day one, and maintenance or technical issues are addressed promptly, minimizing operational downtime.
Quality and Standards
All components used in the Version 3 high-capacity line are manufactured according to international standards, including:
CE (European Conformity)
ISO 9001 Quality Management
RoHS Compliance for material safety
Premium components include Siemens motors, Schneider PLC control systems, and Becker vacuum pumps for downstream calibration, ensuring reliability, precision, and longevity.
Economic Benefits
Implementing the Version 3 high-capacity UPVC extrusion line provides significant economic advantages:
Lower production costs due to energy-efficient operations
Higher operational productivity with minimal waste
Reduced scrap rates by up to 80%
Capability for multi-shift continuous operation
Rapid ROI through increased output and reduced downtime
Conclusion
The EXTRUTEX Version 3 High-Capacity UPVC Profile Extrusion Line represents a new benchmark in industrial UPVC extrusion. By combining advanced twin-screw extrusion technology, precision downstream calibration, and high-speed haul-off and cutting, it delivers superior quality profiles with high throughput, consistent dimensions, and minimal waste.
For medium to large production units seeking high capacity, flexibility, and precision, this line offers the ultimate solution to meet industrial and market demands. Its modular and energy-efficient design, combined with professional support services, ensures that manufacturers can maximize productivity, maintain product quality, and expand their product portfolio with confidence.
EXTRUTEX High-Performance UPVC Profile Extrusion Tooling – Version 4
Precision Engineering for Thick, High-Quality UPVC Profiles
The EXTRUTEX Version 4 UPVC profile extrusion tooling represents the pinnacle of modern extrusion technology, engineered for high-capacity, high-performance industrial lines. Designed specifically for thick profiles of 3 mm or more, this tooling enables production speeds exceeding 3 meters per minute and a remarkable output of 350 kg per hour, making it ideal for demanding manufacturing environments.
In any UPVC profile extrusion line, the extrusion tooling is one of the most critical components, serving as the initial point where molten material is shaped into its final profile. Well-designed extrusion tooling ensures dimensional precision, surface quality, structural stability, and uniform output, all of which are essential for modern industrial applications.
The Version 4 extrusion tooling is engineered to handle high-viscosity UPVC compounds, distribute material evenly across complex profiles, and maintain quality even under the highest-speed production conditions. Its design incorporates multi-channel flow systems, advanced heating controls, and modular adjustability, offering manufacturers flexibility, reliability, and efficiency.
Key Features and Advantages
1. Engineered for Thick, Reinforced Profiles
Profiles with greater wall thickness require careful control of material flow and uniform pressure across the cross-section to prevent deformation, double-layers, or weak points. The Version 4 extrusion tooling is designed with multi-channel flow paths, ensuring:
Even distribution of molten PVC throughout the profile
Prevention of delamination or “double-layering”
Enhanced structural integrity of the final product
This allows manufacturers to produce thick, high-strength window and door frames, industrial profiles, and multi-chamber designs that meet rigorous mechanical and thermal requirements.
2. Optimized Flow Channels and Pressure Distribution
The internal flow system of the Version 4 extrusion tooling combines conical and parallel channels, engineered to guide PVC evenly across all areas of the profile. The result is:
Reduced back pressure on the extruder, improving energy efficiency and prolonging machine life
Elimination of surface defects such as waves, bubbles, or cracks
Consistent color and surface gloss, critical for high-end architectural applications
By controlling the material flow and balancing pressures, the extrusion tooling ensures perfectly shaped profiles at high line speeds, supporting outputs of up to 350 kg per hour without compromising quality.
3. Wear-Resistant and Heat-Tolerant Tool Steel
EXTRUTEX uses premium tool steels such as 1.2316 and 1.2083 for extrusion tooling construction, selected for wear resistance, heat tolerance, and chemical stability. The material and heat treatment process provide:
Extended tooling life exceeding 50,000 operating hours under continuous production
High polishability, enabling glossy and defect-free surfaces
Dimensional stability even under repeated thermal cycling and high pressure
This ensures that the tooling remains precisely aligned and reliable throughout extended production cycles, minimizing downtime and maintenance.
4. Integrated Heating and Temperature Control
The extrusion tooling features dedicated chambers for heating elements and sensors across critical zones, enabling precise thermal management. Benefits include:
Prevention of PVC scorching or degradation
Uniform surface quality and consistent material flow
Faster line start-up with reduced thermal stabilization time
These systems allow operators to maintain consistent product quality even during extended high-speed runs, supporting industrial production requirements.
5. Adjustable Output Dimensions
The Version 4 extrusion tooling includes mechanisms for rapid adjustment of width and thickness, allowing operators to:
Modify profile dimensions without long line stoppages
Switch between different profile designs efficiently
Maintain tight tolerances at high speed
This flexibility makes the tooling ideal for customizable production lines, where multiple profile types are required, from reinforced window frames to industrial-grade ducting profiles.
Technical Specifications
| Feature | Specification / Description |
|---|---|
| Tooling Type | Modular multi-part extrusion tooling |
| Body Material | Hardened alloy tool steel (1.2316) |
| Profile Thickness | 3 mm |
| Profile Cross-Section | Customizable (window frame, sash, duct, etc.) |
| Production Speed | > 3.0 meters per minute |
| Output Capacity | 350 kg per hour |
| Maximum Inlet Pressure | 250 bar |
| Recommended Operating Temperature | 175–190°C |
| Heating Zones | 3–5 independently controlled zones |
| Tooling Change Time | ~20 minutes (Quick-Lock system) |
| Extruder Compatibility | Fully compatible with ATP 93 extruder from EXTRUTEX |
Industrial Advantages
High Productivity
The Version 4 extrusion tooling allows rapid start-up, quick adjustments, and high line speed, dramatically increasing throughput while maintaining surface quality.
Superior Surface Quality
Profiles extruded with this tooling exhibit no waviness, cracks, or surface irregularities, providing finished products that meet premium architectural and industrial standards.
Long Service Life
The combination of wear-resistant tool steel and advanced heat treatment ensures that the extrusion tooling withstands continuous production, abrasive fillers, and chemical stabilizers, delivering reliable performance over years of operation.
Flexibility
Modular components enable operators to:
Adjust profile geometry or cross-section
Integrate multi-chamber configurations
Swap tooling quickly for different production requirements
This allows manufacturers to meet diverse market demands without overhauling the extrusion line.
Compatibility with the EXTRUTEX Version 4 Extrusion Line
The Version 4 extrusion tooling has been fully tested and calibrated for use with EXTRUTEX high-capacity extrusion lines, ensuring seamless integration with downstream equipment:
ATP 93 Twin-Screw Extruder: Supplies consistent pressure and flow to the tooling for stable, high-speed extrusion.
ACT 11000 Calibration Table: Stabilizes the profile shape and ensures controlled cooling for thick, high-strength profiles.
APS 30 Haul-Off: Maintains uniform pulling force without stressing the freshly extruded profile.
SA1 Cutting Unit: Ensures precise cutting synchronized with extrusion output, minimizing scrap and handling damage.
This fully integrated system allows manufacturers to achieve maximum throughput with minimal defects, making it suitable for industrial-scale production and export-oriented operations.
Applications
The Version 4 extrusion tooling is ideal for producing:
Window and door frames for double and triple-glazed assemblies
Water-resistant, UV-stable door panels
Industrial thick-wall profiles for greenhouses, partitions, or ventilation ducts
High-load-bearing profiles for commercial and residential construction projects
The tooling supports multi-chamber designs that improve thermal insulation, structural strength, and acoustic performance, making it a versatile solution for modern UPVC applications.
Economic and Operational Benefits
High Output with Minimal Waste: Enables production of 350 kg/h with reduced scrap rates.
Energy Efficiency: Optimized flow and thermal management reduce extruder and downstream energy consumption.
Quick Adjustments: Modular design and Quick-Lock installation allow rapid tooling swaps or minor dimensional changes.
Durable Design: Reduces maintenance downtime, ensuring continuous high-volume operation.
Enhanced Product Quality: Uniform wall thickness, smooth surface finish, and high dimensional stability increase market value.
By integrating this tooling into a high-capacity extrusion line, manufacturers can maximize ROI, increase production flexibility, and meet stringent international quality standards.
Conclusion
The EXTRUTEX Version 4 UPVC Profile Extrusion Tooling exemplifies the perfect balance of precision engineering, advanced materials, and industrial expertise. Designed for high-capacity lines and thick, high-strength profiles, it delivers exceptional surface quality, structural stability, and production efficiency.
With its modular design, adjustable dimensions, and compatibility with EXTRUTEX downstream systems, this tooling ensures that every profile leaving the line meets strict quality standards, while enabling manufacturers to operate at maximum speed and throughput.
For industrial producers aiming for high-performance, high-capacity UPVC extrusion, the Version 4 tooling is an essential investment, combining technical excellence with operational efficiency to enhance product quality and profitability.
خط تولید پروفیل UPVC
تجهیزات پایینخطی پروفیل
مهندسی شده برای کیفیت – طراحی شده برای سبک
ساخت EXTRUTEX Austria
شرکت EXTRUTEX Austria با رویکردی نوآورانه، تمرکز خود را به جای حجم فروش بالا، بر کیفیت ممتاز و ارائه خدمات بینظیر معطوف کرده است. ماشینآلات پایینخطی این شرکت تنها در بازارهایی ارائه میشوند که تولیدکنندگان آن خواهان بالاترین سطح کارایی، دقت و قابلیت اطمینان هستند.
با بهرهگیری از سالها تجربه مهندسی، تحقیق و توسعه، آسترونکست تجهیزات پایینخطی پروفیل را به گونهای طراحی کرده است که علاوه بر عملکرد برتر، بهرهوری انرژی، ثبات فرآیند و کاربرپسندی را نیز در بالاترین سطح ممکن تضمین میکنند.
ویژگیهای شاخص تجهیزات پایینخطی EXTRUTEX
🔹 بهرهوری انرژی
مصرف انرژی بهینهشده در تمامی اجزای سیستم با حفظ عملکرد پایدار، از طریق استفاده از کنترلکنندههای سروو و طراحی مهندسیشده جریان آب و وکیوم.
🔹 ثبات فرآیند
با استفاده از سیستمهای تنظیم خودکار، مانند:
CVR: تنظیم وکیوم ثابت در نواحی مختلف کالیبراسیون
CWP: تنظیم فشار آب به صورت پایدار
CWT: تثبیت دمای آب در چرخههای خنکسازی
ثبات بالا در فرآیند تولید پروفیل تضمین میشود.
🔹 کاربرپسند و بدون نیاز به تخصص بالا
سیستمهای کنترلی با رابط کاربری لمسی و پارامترهای از پیش تنظیمشده، این امکان را فراهم میکنند که راهاندازی و بهرهبرداری بهراحتی توسط اپراتورها انجام شود، بدون نیاز به دانش تخصصی گسترده.
سیستمهای کلیدی و فناوریهای بهکار رفته:
✅ سیستم وکیوم با کنترلر سروو
طراحی اختصاصی پمپ وکیوم، همراه با کنترل دقیق میزان خلأ، سبب شده تا محصول نهایی از نظر ابعادی دقیق و باکیفیت باشد. بهرهگیری از سیستم کنترل زیمنس آلمان نیز موجب افزایش دقت عملکرد و کاهش خطاهای انسانی میشود.
✅ سیستم فیلتر Bypass
برای جلوگیری از ورود ناخالصیها و بهینهسازی فرآیند کالیبراسیون، سیستم فیلتر گذرگاه فرعی (Bypass) با طراحی پیشرفته تعبیه شده است.
✅ امکانات جدید کشنده (Haul-off Unit)
عملکرد کاملاً اتوماتیک
زنجیر سفتشونده برای انتقال یکنواخت قدرت
آرایش موتور مرکزی و گیربکس جهت انتقال گشتاور پایدار
طراحی بهینه برای دسترسی آسان به پدهای کشنده (POD)
این نوآوریها باعث کاهش زمان توقف خطوط تولید، افزایش سرعت تنظیم، و عمر طولانیتر قطعات مصرفی شدهاند.
چرخههای پیشرفته خنکسازی (Water Circulation Systems)
🔸 SWC – چرخه آب کالیبراتور خشک:
با مدیریت همزمان جریان، دما، کیفیت و حجم آب، بهرهوری خنکسازی در بالاترین سطح حفظ میشود.
🔸 SWC – چرخه آب کالیبراتور مرطوب:
تضمین یکنواختی در ساختار سطحی پروفیل و کاهش خطر انقباض یا تغییر شکل، بهویژه در خطوط سرعت بالا.
🔸 FBF – فیلتر مخصوص کالیبراتور مرطوب:
فیلتراسیون پیشرفته آبریزگاه پشت، برای دستیابی به سطح نهایی فوقالعاده در پروفیلهای حساس، مانند دربها و پنجرههای PVC.
🔸 DWD – سیستم تخلیه مستقیم آب:
جهت پاکسازی سریع و مؤثر چرخههای خنکسازی و کاهش رسوبات، با قابلیت اتوماسیون کامل.
مزایای راهبردی برای مشتریان
راهاندازی آسان: به لطف منوهای راهنمای ساده، سیستم لمسی، و تنظیمات ذخیرهشده، هیچ تخصص خاصی برای شروع کار مورد نیاز نیست.
تعمیر و نگهداری آسان: طراحی مدولار و در دسترس بودن اجزا، فرآیند تعمیرات را سریع و اقتصادی میکند.
کمترین فضای مورد نیاز: طراحی فشرده با حفظ کارایی کامل، مناسب برای سالنهای تولید با فضای محدود.
دو سال گارانتی رسمی از شرکت EXTRUTEX Austria، به همراه پشتیبانی فنی و تأمین قطعات.
دیدگاه ما در EXTRUTEX: فراتر از فناوری
EXTRUTEX تنها به ساخت تجهیزات بسنده نکرده است، بلکه ما در مسیر همراهی با مشتری از طراحی، مشاوره، نصب و پیادهسازی، تا آموزش اپراتورها و پشتیبانی پس از فروش گام برمیداریم. ما به هر پروژه به چشم یک همکاری بلندمدت نگاه میکنیم و متعهد به ارائه خدمات کلاس اول جهانی هستیم.
برای چه کسانی مناسب است؟
تجهیزات پایینخطی EXTRUTEX برای تولیدکنندگانی طراحی شدهاند که میخواهند:
پروفیلهایی با دقت ابعادی فوقالعاده تولید کنند.
در بازارهای رقابتی با بالاترین کیفیت سطح و ساختار حضور یابند.
هزینههای انرژی و تعمیرات را کاهش دهند.
بهینهسازی تولید را با تکیه بر فناوری روز انجام دهند.
نتیجهگیری
تجهیزات پایینخطی پروفیل شرکت EXTRUTEX Austria ترکیبی از فناوری پیشرفته، طراحی مهندسیشده، خدمات پشتیبانی سطح بالا و بهرهوری انرژی را در اختیار مشتریان قرار میدهد. در جهانی که رقابت در کیفیت و کارایی حرف اول را میزند، انتخاب EXTRUTEX یعنی انتخاب آیندهای پایدار و سودآور برای کسبوکار شما.
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