The technology being implemented by the Wital company incorporates the process in which the polyvinyl chloride profiles are made.
The technology being implemented by the Wital
The extrusion of polyvinyl chloride profiles involves a range of applications. The most popular profiles are the ones used in the making of window and door frames. These profiles are made out of powdered feedstock. The mass is then extruded through the extrusion die thus moulding the profile into the desired shape.
Mieszanie kolumna lewa
The first phase of profile making is the preparation of the feedstock according to the specific formula. The formula has been created as a result of much research and many tests performed. There are a few compounds required to obtain a suitable mixture: PVC, the stabilizer, the impact modifier, filling material (chalk), titanium dioxide.All the compounds are fed in required proportions through the automated feeding system into a mixer, where they become indissolubly combined in the mixing process.
Mieszanie kolumna prawa
These compounds are provided by suppliers from Poland and Western Europe in big-bag wrappings or in bulks (tank trucks).
The mixing process is monitored by a specially designed computer system which superintends the operations of scales, feeders, pumps, engines and other elements of the mixing system. The high-rating equipment and very accurate scales provide opportunities for the production of a unique batch of the feedstock according to the rigidly determined formula.
The dry blend thus prepared enters the loading hopper of the screw extruder from where it is fed in to the feed zone of the extrusion screw where the material is initially heated to the temperature ranging from 150 up to 175°C, with the155°C being the optimum.
EKSTRUZJA kolumna lewa
Next, the material is condensed and transported by means of the rotary movement of the extrusion screw towards the extruder die. In the compression zone further thickening of the material takes place – the PVC mixture changes its state from solid to the plasticized one and is heated up to the temperature ranging from 160 to 170°C.It has been tested that the optimum temperature is 165°C.
In the feeding zone mechanical and thermal homogenization takes place as well as pressure elevation of the plasticized mass up to the level required to overcome flow resistance through the head. Moreover, it is in this area that the temperature of material increases up to 160 – 190°C. It has been tested that the optimum temperature is 180°C.From the feeding zone of the extrusion screw the material is transported to the die where - in the last geometrical element of the head`, the so-called extrusion die, the mass finally becomes formed and reaches – at the die’s output – the temperature ranging from 170 up to 190°C. It has been tested that the optimum temperature is185°C.
EKSTRUZJA kolumna prawa
From the extrusion die the plasticized and initially formed mass is passed on to the calibration cylinder. A set of calibrators (dry in the initial phase) cool the plastic mass by collecting heat from it and gives it the proper mould by means of pumps creating a vacuum. The initial cooling down of the mass is further treated „in a bath” performed by wet calibrators called water – tanks.The whole process is performed in a vacuum which permits the working tool to reflect its mould on the profile.
The outcome of the whole process is a window profile of a temperature being near the temperature of the environment.
The process is a continuous one; a set of saws or guillotines cuts the profile into desired sections. Additionally, every profile is protected by a film in order to prevent any damages during its transportation or manufacturing of windows.The finished profile bars (6, 5 metres long) are piled up on palettes which allows for secure storage and transportation.
Okleinowanie tytuł sekcji
The task of laminating is performed using the most reliable, high quality foils of the LG Hausys company, It is characterized by being highly chemicals-proof, weather resistant and durable in terms of temperature fluctuations.
Okleinowanie kolumna lewa
The complex process of laminating utilizes thermal sealing adhesives based on the latest technology which means it complies with all required standards. The decorative foil is attached on to a special decoiler and transported by means of rollers to a laminating device where an adhesive is applied (a glue substance melted in a specially designed „melting tool”).
A profile, at the input of being worked by the foil machine undergoes cleaning, degreasing and is preliminarily worked on with „Primer” stored in a tank. Using air heater or an infra-red lamps the profile is dried up in order to avoid any possible irregularities on its surface.
Okleinowanie kolumna prawa
Thus prepared, the profile is transported to the section with presses, where two substances meet (pre-prepared profile and film with the adhesive). By means of a cylinder press a permanent joint of both matters is formed, that is applying the decorative foil.
Before the profile leaves the production line it is overlaid with additional film to protect it from damage during further working with it. We have in store profiles with one- and two- sided foil available, in six standard colours. The completion to the offer is composed of custom-made profiles in over thirty colours.Having these adhesive foils in store available allows for a fast order execution with respect to non-standard-colour products.