Technical Profiles

Bausano extrusion lines for high-precision functional profiles

Technical profiles for industrial applications

Plastic technical profiles are extruded components used in industrial applications where the profile geometry performs a specific function. They are used as guiding, support, protection, insulation or coupling elements within mechanical and structural systems. In these contexts, profile quality is not linked to appearance, but to dimensional stability, process repeatability and the ability to maintain constant tolerances throughout continuous production. Used in sectors such as technical construction, automation, transport and plant engineering, technical profiles must integrate with other components without requiring reworking. This makes control of the entire extrusion process essential, from material plasticization to final cutting.

Materials used and co-extruded profiles

Bausano offers extrusion solutions configured for a wide range of thermoplastic materials, selected according to the performance required from the final profile. Material choice affects rigidity, chemical resistance, elastic behaviour and surface quality. When a profile needs to combine multiple functions, co-extrusion provides an effective technical solution. It makes it possible to combine different materials within the same profile, reducing subsequent assembly operations and increasing production repeatability. Commonly used materials:

PVC-U for rigid profiles with good dimensional stability
PVC-P, TPE, TPV for elastic areas and sealing functions
PP and PE for industrial and chemically aggressive applications
ABS for technical profiles requiring strength and surface finish

Co-extrusion can be used, for example, to produce rigid profiles with integrated soft lips, surfaces with different friction levels or dedicated functional layers.

Dimensional control and cutting in the extrusion process

In the production of technical profiles, maintaining tight tolerances is one of the main critical factors. Process challenges are often linked to complex sections, variable thicknesses and materials with different rheological behaviours. The main issues include deformation during cooling, multi-axis instability and differential shrinkage in co-extruded profiles. Another sensitive stage is cutting. The final profile length must be precise and repeatable, as it directly affects subsequent assembly or processing steps. Cutting that is not synchronised with haul-off can generate burrs, crushing or dimensional variations, increasing scrap and downtime.

Bausano extrusion lines for technical profiles

Bausano designs extrusion lines for technical profiles by considering the entire process as a single integrated system. Depending on the material and section, the lines use E-GO single-screw extruders or MD counter-rotating twin-screw extruders, with screw diameters indicatively ranging from 52 to 130 mm and power up to 260 kW. The downstream includes vacuum calibration benches, modular cooling, high-stability haul-offs and vertical or horizontal cutting units with electronic length control. Line speeds can reach high values on lightweight profiles, but production capacity is always assessed according to the mass per metre, which can range from a few grams to several kilograms per metre. This approach helps maintain precision, reduce waste and ensure consistent quality.

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