Technology

The first stage of profile production is preparing the raw material according to a specific formulation. This formulation was developed through extensive trials and research. Several components are needed to obtain the proper compound: PVC, stabiliser, impact modifier, filler (chalk), and titanium dioxide. All ingredients are dosed in appropriate proportions by an automated weighing system into the mixer, where they are permanently combined in the mixing process.

These components are supplied by suppliers from Poland and Western Europe, delivered in big-bag packaging or in bulk (tank trucks).

The mixing process is monitored by a dedicated computer system, which controls the operation of scales, feeders, pumps, motors, and other installation components. High-quality equipment and highly accurate scales ensure the production of consistent batches of raw material according to a strictly defined formulation.

Next, the material is compressed and transported by the rotational movement of the screw towards the extrusion die. In the compression zone, further compression of the material takes place – the PVC compound transitions from a solid to a plasticised state and is heated to a temperature of 160–170°C, with the optimal temperature being 165°C.

In the metering zone, mechanical and thermal homogenisation occurs, and the pressure of the plasticised mass is increased to a level necessary to overcome the flow resistance through the die. In this zone, the material temperature rises to 160–190°C, with the optimal temperature being 180°C.

From the screw metering zone, the material is fed into the die head, where in the final geometric element of the die, known as the extrusion nozzle, the mass is ultimately shaped and reaches an exit temperature of 170–190°C, with the optimal temperature being 185°C.

From the extrusion die head, the plasticised and pre-formed material enters the calibration unit. The calibrator set (initially dry calibrators) cools the plastic mass by removing heat and precisely shapes it to the required profile using vacuum generated by pumps. The pre-cooled material then enters the “bath”, which is carried out by wet calibrators known as turbo tanks. Throughout the entire process, the profile is subjected to vacuum, allowing the tool to reproduce its shape accurately. The result of this process is a window profile product with a temperature close to ambient temperature.

The process is continuous, and a set of saws or guillotines cuts the profile into appropriate lengths. Additionally, a protective foil is applied to the profile to protect it from damage during transport or window production. The finished profile bars (6.5 meters in length) are stacked on pallets to ensure safe storage and transport.

In the complex foiling process, hot-melt adhesives based on the latest technologies are used, meeting all required standards. The decorative foil is mounted on a special unwinder and fed through rollers to the coating head, where adhesive (melted in a dedicated melter) is applied to it.

At the entry to the foiling machine, the profile is cleaned, degreased, and pre-treated with primer contained in a dedicated tank. Using hot air heaters or infrared (IR) radiant lamps, the profile is dried to avoid any irregularities on its surface.

The prepared profile is transported to the press zone, where the two materials (the pre-treated profile and the foil with adhesive) come into contact. Using a press roller, the two materials are permanently bonded, applying the decorative foil.

Before leaving the installation, the profile is additionally covered with a protective film to safeguard it during further handling. In our warehouse, we have profiles foiled on one side and both sides in six standard colours. The offer is complemented by profiles in over thirty colours made to order. Having these foils in stock enables us to quickly fulfil orders in non-standard colours.