From Good Production to Good Production in Just 40 Minutes
How long is your extrusion line standing still during a tool change?
60 minutes? 90 minutes? 120 minutes? Longer?
And how many sellable meters of profile are you not producing during that time?
In many extrusion plants, long changeover times are still accepted as unavoidable. Yet this is exactly where one of the greatest opportunities to increase machine utilization can be found.
Watch the Proof in Time-Lapse:
At extrunet, we rethought the entire changeover process: from die preheating and quick-change technology to tubeless dry calibration systems and automated recipe management.
The result: From good production to good production in just 40 minutes.
Product recommendations for changing tools in 40 minutes:
Die Preheating & Assembly Station
The next die is already brought to operating temperature while production is still running.
With a heating capacity of 20 kW, the station heats the die to its nominal operating temperature of up to 200°C before the actual changeover begins.
Depending on the application, either:
the complete die including the heater cage
or only the circular die insert
can be preheated.
This provides maximum flexibility for different tooling concepts and production requirements.
Features
Remote-controlled lifting device
Ergonomic assembly cart
Integrated storage for assembly tools
Preheating during ongoing production
Benefit: No lost production time caused by heating up tooling.
Quick Change System
The extrunet Quick Change System is based on a standardized die interface.
Depending on the product, either a standard corner die or a product-specific die insert is used within the extrunet die housing.
As a result, the die housing remains on the extrusion line while only the product-specific components are exchanged.
Benefits
Significantly reduced changeover times
Standardized tooling concept
Less handling during changeovers
Higher process reliability
Faster transitions between different products
By separating the die housing from the product-specific insert, tooling changes become simpler, faster, and more repeatable.
Benefit: Less downtime, more productive manufacturing time, and a consistent standardization of extrusion tooling.
Tubeless Dry Calibration System (direct connect tooling system)
A key component of the quick-change concept is the (refurbished) direct connect tooling system.
All media are supplied directly through the base plate, eliminating the need to disconnect and reconnect tubes.
In addition, the calibration system can be changed without any special tools.
Benefits
Significantly shorter changeover times
No special tools required
No operator errors caused by incorrectly connected tubes
Higher process reliability and repeatability
Standardized changeovers independent of the operator
Another major advantage: Existing calibration systems can be retrofitted with the extrunet tubeless concept. Using a specially developed adapter plate, existing tooling can be converted to tubeless media supply.
This allows existing tooling assets to benefit from all advantages of the tubeless system without the need for complete replacement.
Benefit: Fewer operator errors, shorter setup times, and a cost-effective retrofit solution for existing tooling.
Recipe Management
One of the most underestimated factors after a tooling change is the time required to readjust the extrusion line.
With extrunet recipe management, extensive readjustments become a thing of the past.
By simply selecting the product recipe, all stored process parameters are automatically restored.
These include:
Temperatures
Vacuum settings
Speeds
Screw RPMs
Product-specific process settings
Benefits
Immediate adoption of proven process parameters
Faster start-up times
Reduced scrap rates
Higher repeatability
Less operator dependency
The Result
The difference is not made by a single feature.
It is created by the intelligent combination of:
Die Preheating Station
Quick Change System
Hose-Free Dry Calibration System
Automated Recipe Management
Your Benefits
Up to 75% shorter tool change times
Higher machine availability
Reduced start-up scrap
Fewer operator errors
Standardized processes
More productive hours per year
Produce more. Change over less.
From good production to good production in just 40 minutes.
More about Profile extrusion
automated tolerance control
With extrunet machines, you can save your profile specifications. With the help of the digital options, the extrusion system automatically takes measures to keep the profile within the tolerance range.
e:MAC-D
Air flow control in the die to automatically keep defined profile sections within the tolerance range.
inline machining centers
Precision meets flexibility!
The requirements for profile extrusion are becoming more and more complex – regardless of whether the profiles are to be milled, punched, embossed, formed, etc. afterwards.
Ideally, all this should be done inline in order to work cost-effectively and efficiently.
As a full-service provider in profile extrusion, extrunet is also your point of contact here and offers inline processing systems for many different areas.
A window system without a production concept? What a waste of time!
System development with extrunet – because your success does not end with the profile
Nowadays, a good window system alone is no longer enough. If the production line has not been taken into account, you lose time, money – and market opportunities.
Do you know your actual production costs?
Do you really know your cost per kg of profile?
Keeping an eye on energy and water consumption is good. But is that really enough to manage your production efficiently?
The crucial question is: Do you know all the influencing factors — or only some of them?
What Customers have to say about us.
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We want to extend our appreciation for the collaborative efforts on the recent project in which we were looking for a digital extrusion line that produces a stable profile quality. Your dedication and expertise were indispensable, and they played an important role in the success we have achieved.
The way Extrunet seamlessly integrated their experiances and ideas into our vision showcased a level of commitment that sets a remarkable standard.We have deeply valued the contributions of Extrunet and look forward to future collaborations.
Erik Kooistra
Directeur Polytech -
Extrunet ist es mit der EVO1 gelungen einen erfolgsversprechenden Schritt in die Zukunft zu gehen und somit ungeahnte Potenziale in der Fensterprofilextrusion aufzuzeigen.
Magnus Baumann
Global Head of operational technology and maintenance