Profile Extrusion Lines

Modular solutions for the production of technical and industrial profiles

Complete extrusion lines for profile production

Bausano’s profile extrusion lines are available in configurations with E-GO single-screw extruders, MD parallel twin-screw extruders, and E-ON conical twin-screw extruders, depending on the material to be processed and the application requirements. Solutions based on single-screw extruders are ideal for processing low-filled thermoplastics, such as PE, PP and ABS, and are particularly suitable for the production of simple profiles that do not require intensive mixing. In contrast, lines equipped with parallel twin-screw extruders are designed to optimally process rigid and plasticized PVC as well as WPC, ensuring high material homogenization and consistent melt quality. Each line can be configured with different technical solutions, including screw diameter, L/D ratio, transmissible torque, and extrusion speed, to match the profile type and the required production output. The integration of the patented Multidrive system reduces mechanical stress on components, improving process stability and overall energy efficiency. The integrated digital control system enables real-time monitoring of key operating parameters, including temperature, pressure, and line speed, with the possibility of remote management across all stages of the process.

Modular downstream accessories

Bausano’s profile downstream systems complete the extrusion process with constant haul-off, controlled cooling, and precise cutting, ensuring dimensional stability even for complex geometries. The integration of modular accessories, such as calibration tables, closed-loop cooling tanks, and vertical or horizontal cutting units, ensures high productivity, consistent quality, and application flexibility.

Fully temperature-controlled dies, both internally and externally
Calibration and cooling tables
Haul-off units equipped with local and remote PLC control
Vertical cutter: suitable for profiles up to 300 mm
Horizontal cutter: designed for wide profile production

Plastic profiles for technical, civil and industrial applications

Bausano’s plastic profile extrusion lines enable the production of a wide range of solutions, from rigid PVC profiles for windows and doors to high-performance technical profiles for industrial sectors. Depending on the configuration, it is possible to manufacture WPC profiles for decking and cladding, as well as skirting boards, guides, ducts, furniture profiles, and construction components.
Thanks to the modular design of the line, each system can be adapted to different geometries, cross-sections, and materials, including PVC, PE, PP, ABS, PMMA and wood-plastic composites, ensuring precise process control across all stages: extrusion, calibration, cooling, haul-off, and cutting. The extrusion dies are engineered to guarantee dimensional stability and melt homogeneity, even for complex or multi-channel profiles.

Technical Profiles

Technical profiles are used across a wide range of industrial sectors, from automotive to electronics, as well as furniture and mechanical engineering. Bausano lines are designed for the extrusion of thermoplastic materials such as PE, PP, ABS and PMMA, ensuring precise geometries, high dimensional stability, and excellent mechanical resistance.

Doors & Windows Profiles

Extrusion lines for window and door profiles are optimized for the production of rigid PVC profiles with high structural strength and tight dimensional tolerances. These profiles are used for frames, rebates, glazing beads, and accessories for doors, windows, and curtain wall systems, including multi-chamber

WPC Profiles

Bausano solutions for WPC (Wood Plastic Composite) profiles are ideal for the production of outdoor decking, cladding, fencing, and technical furniture components. Processable materials include PVC or PE compounds blended with wood flour or natural fibers, ensuring weather resistance and long-lasting aesthetic

Custom profile extrusion lines with modular accessories

Bausano’s profile extrusion lines are engineered to deliver maximum configuration flexibility. Each system can be equipped with modular downstream components, including vacuum calibration units, cooling tanks, haul-off systems, and vertical cutting units with capacities up to 500 mm profile width. Depending on the final application, it is possible to integrate embossing, marking, or winding units. Lines dedicated to door and window profiles include supports for wide sections with shape control, while WPC profile lines feature dies and dosing systems optimized for high-viscosity, fiber-filled materials. To support every production requirement, Bausano offers operating leasing and customized financing solutions, designed to make the initial investment more accessible and facilitate plant expansion. The cost of the lines varies according to the technical configuration, processed materials, and automation level. Each project is developed through a consultative approach, supported by detailed technical datasheets, profitability analysis, and return on investment (ROI) estimation. This flexibility makes Bausano a reliable partner for manufacturers seeking high-productivity and cost-efficient profile extrusion lines.

Materials, technological innovation and sustainability

Bausano profile extrusion lines are compatible with a wide range of thermoplastic materials, including PVC, WPC (Wood Plastic Composite), PE, PP, ABS and PMMA, also in recycled or filled formulations. Each system can be configured to meet different application and production requirements, thanks to customizable screw diameter, L/D ratio, transmissible torque, and output capacity. The integration of proprietary technologies, such as the Multidrive System and induction heating, enhances process stability, reduces mechanical stress, and enables energy savings of up to 30%.
Control is managed through digital systems with IoT and artificial intelligence, allowing real-time monitoring of temperature, pressure, and line speed. Each line is designed according to eco-design principles, with long-life components, compatibility with recyclable materials, and waste reduction, actively contributing to a sustainable and circular production model. All production is Made in Italy and complies with international standards of quality and traceability.

Accessible investment and global support

To make even high-complexity projects accessible, Bausano provides operating leasing and customized financing solutions, supporting both new line installations and the expansion of existing plants. Each proposal is structured according to the selected configuration, processed material, and automation level, with full support including technical documentation, ROI analysis, and engineering consulting. With a network of specialized technicians and a commercial presence in over 60 countries — including the United States, Germany, Poland, Turkey and India — Bausano ensures continuous technical support, both on-site and remotely, across all phases: start-up, maintenance, and upgrades. The reliability of its after-sales service, combined with over 80 years of industry experience, makes Bausano a global reference partner for plastic and composite profile extrusion, delivering solutions designed for long-term performance and adaptability to evolving production needs.

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Application sectors

Thanks to the design flexibility of the lines and compatibility with various thermoplastic materials, profiles produced with Bausano extrusion lines are used across numerous industrial sectors and technical applications, with customizable geometries and tight dimensional tolerances:

CONSTRUCTION AND INFRASTRUCTURE – profiles for window frames, structural elements, skirting boards, ducting, architectural cladding, and structural components
FURNITURE AND DESIGN – profiles for doors, frames, decorative panels, technical furniture, and modular accessories
TECHNICAL INDUSTRY – guides, protective elements, sliding profiles, spacers, and structures in engineered plastic materials
AUTOMOTIVE AND MOBILITY – profiles for seals, cable ducts, protective components, and interior finishes in ABS or specialty polymers
URBAN FURNITURE AND WPC OUTDOOR – WPC profiles for decking, fencing, cladding, and high-resistance outdoor structures

Efficient solutions

Thanks to the integration of proprietary engineering technologies, Bausano profile extrusion lines are designed to increase overall process efficiency, reduce specific energy consumption, and ensure consistent quality across all profile geometries, even in high-intensity continuous production cycles:

ENERGY SAVING – induction heating system applied to the barrel, reducing energy consumption by up to 30% compared to traditional resistance systems
PROCESS STABILITY – precise melt temperature control, internal pressure management, and consistent dimensional tolerances, even for complex profiles
CONSISTENT PRODUCTIVITY – configurations with high-torque extruders, high throughput even with filled materials, and stable performance over extended production shifts
OPERATIONAL EFFICIENCY – optimized cycle times, waste reduction, digital control of line parameters, and compatibility with remote supervision systems

Materials

Bausano profile extrusion lines are compatible with a wide range of thermoplastic materials, including rigid and plasticized PVC, polyolefins such as PE and PP, ABS, PMMA, and WPC composites. Each material is selected based on the final application and the required properties, such as mechanical strength, dimensional stability, transparency, or outdoor durability. The lines are also designed to process virgin, recycled, or filled formulations, ensuring consistent quality and continuous production, even during extended operating cycles. Process parameters — including melt temperature, torque, pressure, and line speed — can be precisely adjusted to match the specific behavior of each compound. This versatility enables the production of profiles for technical, aesthetic, or structural applications, maintaining high quality standards even when using recycled materials or compounds with a high natural fiber content. The design of screws and extrusion dies is optimized according to the viscosity and rheological properties of different polymers, ensuring optimal melt homogeneity. In combination with digital control systems, each line can accurately manage formulation variations and ensure full traceability of the final product. The goal is to provide a flexible, efficient, and sustainability-oriented industrial solution.

Technical consulting for profile extrusion lines

Do you need technical consulting to design a profile extrusion line optimized for energy efficiency, process stability, and high hourly output? The Bausano team is available to analyze your application and production requirements and configure a tailor-made solution, aligned with your plant objectives and the specific characteristics of the profile to be produced.

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A starting point to define the right solution together

By filling in the form below, it is possible to describe specific technical or production requirements. The technical team will carefully evaluate the request in order to propose the most suitable extrusion line or extruder.