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

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.