Door and window profiles

Bausano extrusion lines for PVC profile production

PVC extrusion lines for door and window profiles

Profile extrusion is the process of making continuous shapes of plastic, of various types and one of the major applications in the plastic industry, and for us, is the extrusion of doors and windows. For us the production process of doors and windows profile mainly includes a Bausano Twin screw extrusion process. The raw materials used in the processes are the mixed powder prepared in the previous process according to a certain formula. The Bausano Twin-screw extrusion process can be directly molded with powder, with large production capacity, especially suitable to produce large quantities of conventional profiles and large specifications of different profiles. Naturally, also pellets can be used to extrude profiles, like window and door profiles.

Materials and co-extrusion in PVC profiles

In the window and door sector, the extrusion process starts from PVC dry blend, a mixture of PVC powder and specific additives dosed according to the required performance. Control of the dry blend feeding and plasticizing phase is essential to obtain a homogeneous melt and a stable section throughout production. Co-extrusion is a widely used technology for integrating multiple functions directly into the profile, while maintaining geometric control and reducing downstream operations. This solution makes it possible to combine materials with different properties within the same extruded section. Typical configurations in window and door profiles:

profile body in PVC-U, obtained from dry blend, for rigidity and dimensional stability
co-extruded gaskets in PVC-P or TPE, to ensure elasticity
sealing performance functional or decorative surface layers, integrated directly in line

Co-extrusion integration ensures constant gasket positioning and greater repeatability compared to solutions applied at a later stage.

Geometric control and cutting operations in the extrusion line

In window and door profiles, even minimal dimensional deviations can affect assembly and final performance. The main critical points concern the control of the internal chambers, which must maintain constant shape and dimensions, and the profile flatness, required to ensure correct welding and coupling. The cutting phase is a critical step in the process. Profile length must be repeatable to allow proper corner welding and window or door assembly. Cutting that is not perfectly synchronised with the haul-off can generate inaccuracies, burrs or end deformations, increasing scrap and line stoppages. Coordination between calibration, cooling, haul-off and cutting is therefore essential to final quality.

Configuration of Bausano extrusion lines for PVC profiles

Bausano designs complete extrusion lines for door and window profiles, configured to process PVC-U from dry blend and support continuous production with high stability. The solutions are based on MD series parallel counter-rotating twin-screw extruders or E-ON series conical twin-screw extruders, selected according to profile section and required productivity. MD extruders are available with screw diameters from 52 to 130 mm, L/D ratios up to 30 and installed power up to 260 kW, making them ideal for complex and multi-chamber profiles. E-ON extruders, with screw diameters from 53 to 80 mm, ensure stable PVC-U outputs indicatively ranging from 50 to 300 kg/h, making them suitable for both new installations and revamping of existing lines.
The downstream integrates:

vacuum calibration benches up to 8,700 mm long, to stabilise the section immediately after extrusion
modular cooling systems with vacuum and water control
haul-off units with adjustable speed up to 120 m/min, according to mass per metre
vertical or horizontal cutting systems, with minimum cutting lengths from 200 to 500 mm and strokes up to 1,250 mm

This configuration makes it possible to maintain tight tolerances, reduce process instability and ensure consistent profile quality, even in high-volume production and with complex multi-chamber geometries.

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To identify the extrusion solution best suited to your production and application requirements, you can request a personalized consultation with Bausano technicians specialized in the design and manufacture of extrusion lines for door and window profiles.

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