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Bausano also innovates profile production with E-GO
Bausano, a leading international player in the design and production of customised extrusion lines for the transformation of plastic materials, has recently completed the installation of a custom-designed production plant to make profiles for roller shutters, covering swimming pools. Bausano has skilfully combined state-of-the-art technological solutions and high customisation capabilities, starting from the client’s specifications. In this sense, from the profile sector to the recycling sector, with the E-GO and E-GO R series, Bausano becomes a spokesman for constant innovation.
Specifically, the project envisaged a solution capable of producing an ideal profile for roller shutters up to 60 mm wide and composed of three layers of polycarbonate: a challenge that Bausano successfully met by setting up an integrated and fully automated system, characterised by the presence of three single-screw extruders of the E-GO series - two E-GO 50/30, positioned orthogonally, and one E-GO 30/25, positioned in piggy back - each dedicated to the processing of three types of polycarbonate. In detail, with a complete dosing system at hopper level for the dye master, the E-GO 50/30 accommodate black polycarbonate for the bottom layer and semi-transparent polycarbonate for the middle layer, respectively. A very thin layer of polycarbonate with a UV-resistant polymer extruded in E-GO 30/25, specially selected for its properties, is applied to the latter. Unlike other thermoplastics, the latter is, in fact, resistant to all weather conditions,
a fundamental factor in guaranteeing a quality and long-lasting finished product in swimming pool covers.
Bausano has also equipped the extruders with an in-line dehumidification system, a fundamental plus both to perfectly preserve the material during processing and to guarantee the transparency of the top layer of the profiles. A further advantage comes from the fully customised calibration and cooling bench, consisting of vacuum pumps installed laterally, which eliminate the production of vibrations and consequent imperfections, thus safeguarding the integrity of the profile. In addition, the system includes a water temperature control unit to keep the temperature constant during the post- calibration cooling phase, guaranteeing homogeneity, finished product quality and improved ease of cleaning and maintenance of the entire line. The
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installation is completed by a pulling system with belt pull, an automatic milling system to remove condensation bubbles and moisture in the profile, and a hot-blade cutting system for maximum efficiency and precision. Lastly, thanks to Digital Extruder Control 4.0, the operator is able to synchronise the three extruders with the drive unit, for production of up to 2 m/min of profile, for higher speed.
“The recently completed profile production system is the perfect example of Bausano’s ability to customise extrusion solutions for any industrial application”, says Massimiliano Fenili, Technical Manager, who concludes: “Constant innovation and digitisation are Bausano’s assets. This is why our lines are designed with Industry 4.0 in mind, in order to guarantee maximum efficiency, safety and ease of programming, for high performance in terms of energy and production, in the long term”.
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