Hollow profile PC

The essential factor contributing to the production of hollow profiles meeting all present market requirements is the line’s ability to perfectly distribute the extruded material, resulting in increasingly extreme tolerances of profile thickness, gramweight and width.
Only this way can an unquestionably optimized product be obtained.
The new generation of Omipa TPPC dies for hollow profiles offer you assured success.
This is because it was designed and realised to guarantee perfect and optimal distribution without the need for any operator adjustment and through an easy, stable and repeatable process.

We can guarantee this standard of excellence because we have paid attention to every single detail. In an Omipa line all the elements operate in perfect synergy, like a team that works well together:

• the dosing unit, flexible and precise, ensures perfect polymer dosing
• the screw, specially studied to guarantee constant melt temperatures, gives the flow homogeneity and stability
• the filter changer, for melt filtering, can be oleodynamic or, upon request, of the continuous-flow type, guaranteeing continuity of production when processing high percentages of reground materials
• the polymer feed pump, whose function is to stabilize flow at die inlet, thereby keeping output and process stable even at high output rates.

Our experience is at your disposal. For you, this means unequalled technical support and customised design for a perfect sizing of the installation on the basis of your individual needs. The result?

The production of profiles in PC, UV/PC, PMMA, ABS:

• From 4 mm (lightweight) to 60 mm and more of thickness
• From 2 to 13 walls and more
• From 600 to 2400 mm and more of width

This was an unthinkable objective until recently.

At the die exit, the sheet passes through the calibrator, whose fundamental role is to form the profile. All the essential physical properties (thickness, structure, surface) depend on this delicate phase of the process. This is why Omipa has developed a research field expressly devoted to optimising calibration. The result is an international state-of-the-art patent, strengthening Omipa’s leadership. FLOATING PLATE and AIR CUSHION system® applied to our machines sets unparalleled quality standards.

• Better surface quality and gloss, with considerable advantages also for the subsequent profile working stages
• Excellent increase in output, thanks to a higher line speed
• Better manageability, more control, more adaptability to the different productions
• Better stability of the machine, practically insensitive to process variations.
• Improvement in the process management simplicity with high automation and repeatability.

1. The Omipa calibrator incorporating FLOATING PLATE and AIR CUSHION system® consists of more sets of calibrating plates. Equipped with pneumatic control for upper plate opening for maintenance, cleaning and start-up purposes. Each plate incorporates independent circuits: one for thermoregulation fluid circulation (which keeps the plate at the correct temperature), the other for vacuum adjustment. PP hollow profile lines are integrated with an automatic system to adjust the gap between the plates for product thickness changes.
2. The profile is extracted from the calibrator using a take-off unit equipped with more couples of rolls with high pull force. The balanced closure system guarantees perfect adhesion to the profile, thereby allowing its extraction without any deformation. Thermal shock due to rapid cooling in the calibrator can cause internal tension in the profile.The passage through a conditioning unit, inside which the profile is heated by means of infrared rays, makes the sheet perfectly flat and free from tension.

Extrusion of PC, a material that is very sensitive to UV rays, normally requires coextrusion on one side or on both sides of a PC layer containing anti-UV filters.

This operation prevents yellowing of the profile, and its loss of transparency and mechanical resistance.

Omipa has developed a revolutionary coextrusion system named UV-SAVE SYSTEM. PC profiles are normally coextruded with a 50-micron thick UV-PC layer. Even though this layer is so thin, it has a considerable incidence on the total cost of the finished product.

Omipa, thanks to its unique technology, allows you to save up to 30 % of the UVPC usage, with a consequent reduction of production costs. Indeed, our system, unlike traditional systems, eliminates the “triangle effect”, thereby allowing the resin layer to follow the profile surface perfectly, without penetrating inside the ribs and filling them.

Are also available:

1. Bilateral film protection unit. Second take-off complete with blade trimming system and bilateral film coupling unit for the application of a PE protection film on upper and lower side of the profile.
2. Cross cutting unit. Hot blade cross cutting unit for profiles up to 50 mm thick.
3. Stacker. Unilateral stacker for hollow profiles up to 12 m long, complete with taping unit.

No matter what material you are processing, the different combinations of longitudinal trimming systems and cross cutting systems provided by Omipa will always offer you the utmost respect for product integrity, thereby combining the elimination of rejects due to inaccuracy with the highest quality.

The same attention is devoted to designing the best technical solutions for in-line stacking. If you have any special stacking requirements, our engineers are always at your disposal to study the solutions most suitable to you.

The Corona treatment unit prepares the surface for printing, and the second take-off, equipped with a trimming system and a creasing unit, when required, completes the process.

The highly precise and fast shear, for profiles up to 15mm in thickness and up to 3 m in width is suitable for double in-line cutting, whereas for thicker profiles a hot blade cross cutting unit is used.

The double pallet stacking unit for hollow profiles is only an example of the different storage configurations offered by Omipa.

When you choose Omipa you are sure you will always have the best process qualities: stability, simplicity and customisation.
All Omipa lines are supplied with a supervision system controlled by PLC.
The software, produced internally, is always tailored to individual needs.
The use of a PLC allows you to record and monitor all the line process parameters: speeds, revolutions, temperatures, absorptions, outputs, pressures and alarms.
Designed for the central control of the entire line and of each single equipment, the system guarantees precious advantages as it makes line management more practical and functional.
Each alarm (the system can manage up to 400) can be connected with a control procedure, enabling the operator to solve problems by consulting stored instructions.
Codified recipes can be stored and recalled in real time, whenever necessary, thereby making it possible to modify line parameters easily and quickly, with the possibility of immediately repeating the desired production, without slowing it down in any way.

All the data provided during line operation are, in turn, stored to create an overall historical record of all the production parameters, such as:

• graphs of pressures, motor speeds, line output trends
• automatic starts
• line values
• alarms (date, time etc.)
• product management, stacking systems etc.

In addition, the software will allow you to manage:

• automatic start-ups
• pre-heating by means of a timer
• line maintenance program.

Although this is a complex system, it was studied to offer the operator extreme simplicity of use. The entire line management is concentrated in a single work station, and a graphic display of all the functions allows direct action at every point of the line from a single control site.
The system can be interfaced with the main corporate data management software, for global and integrated control of production (orders, purchasing, stocks).
The digital control system is the “mind” of every Omipa extrusion line.
For the operator, everything becomes easier, safer and more manageable. For the company, practical advantages result in better overall control of production with a consequent higher profitability of the line.