Window Profile

Classic Line Machines

Classic Line machines are specially designed for profile extrusion combining economical production of window profiles with maximum product quality.

The WEBER extruder range starts from a 72mm diameter screw with a 22L/D ratio for production of window profile from 20 kgs/hr through to a 116mm diameter screw with a 32  L/D ratio for production of window profile upto 650kgs/hr.

There are 6 machines sizes within this range with differing L/D ratios available.

 

Extruder	Max.output
	PVC profile kg/h
DS72.22P	180
DS8.22P	230
DS9.25P	330
DS11.22P	430
DS11.27P	480
DS12.28P	600

Flexxtrusion

Weber are proud to announce the “New” generation of extruders “Flexxtrusion”.

This series of machines offers the customer the highest flexibility available in today`s market place.

The “Flexxtrusion” extruders are designed with one machine frame, gearbox and motor in each series and allows for different sizes of Barrel & Screws to be fitted.

The Weber extruders have traditionally allowed for upgrades in the size of Barrel and Screws. Many old Weber DS85 extruders have been upgraded to a DS88 which gives the customer a higher output and reduces the need to buy a larger extruder.

As an example of the new “Flexxtrusion” concept, the new DS9.32 series has a processing unit with a 32 L/D ratio, on the same frame a DS9.25 Barrel & Screws can be fitted  (25 L/D). It is also possible to fit the DS8.22 Barrel & Screws (87mm screw diameter, 22 L/D).    

The “Flexxtrusion” machines are offered  in 3 ranges :-

• DS7.32 Series
• DS9.32 Series
• DS12.32 Series

This flexibility allows the customer to buy only one machine to run many more tools than currently possible and as the size of product and output changes he only has to change the processing units.

Duo Line

Space saving ideas, WEBER invented the  “DUO” technology concept as an alternative to double strand extrusion, this new development allowed for separate controls for each machine, independent melt flow for both strands and simultaneous extrusion of different  profile geometries.

Co-Extrusion

The WEBER Co-Extruders are widely considered the world`s  best with very high load levels sustainable during the co-extrusion process.    

The range starts with a CE3z capable of production from 10kgs/hr to 25kgs/hr and ends with the CE8.2z giving  an output from 80kgs/hr to 270kgs/hr.

There are 4 machine sizes in this range, each having the option of a .2 version which gives in general a 10% increase in output.

The .2 version processing units  (Barrel & Screws) can generally be fitted to existing machines allowing customers to achieve higher outputs on their current WEBER co-extruders.

Extruder	Max.output PVC    Profile
	Co-Ex Application    kg/h
CE3z	25
CE3.2Z	30
CE5	70
CE5.2Z	80
CE7z	170
CE7.2Z	190
CE8Z	250
CE8.2Z	270

Pipe Extrusion

Classic Line – for PVC Pipe

The  classic line extruders have been used successfully for many years.  Despite having introduced new machines Weber will continue to offer these classic models to ensure compatibility with existing equipment.

Extruder	Max. output    PVC Pipe kg/h
DS72.22	240
DS9.25	450
DS11.27	850
DS12.28	1000
DS13.27	1100
DS15.22	1800
CE5.2	100
CE7.2	250
CE8.2	300

 

New  DS 32 D Series : maximum performance for PVC Pipe Production

The  new extruder series DS 32 D is equipped with powerful drive technology and an innovative screw design.

Weber have developed a brand new screw design which produces extremely high plastification, it is especially advantageous for the extrusion of uPVC pipes. It generates earlier plastification and thus allows for greater throughputs with smaller L/D ratios than currently on the market today. On top of that it produces such a good dispersion that the Calcium Carbonate  filler can be dosed and mixed directly on top of the extruder and then fed directly into the screw flights and is homogenized  and plasticised in the barrel. As the filler content in dryblend is limited because of segregation, the direct dosing of additional filler and processing by means of the new screw design is the answer to achieve a stable and reliable process and an excellent quality of  highly filled PVC pipes.

As an example, a 90mm twin screw extruder DS9.32 can produce 110mm diameter pipe  with a *filler level of 20 parts at upto 800kgs/hr.

With this screw geometry Weber have also proved that it can process with *filler  levels of 50 parts at an output of upto 650kgs/hr.

The dispersion of the filler  is exceptional which means this pipe passes all of the standard tests of lower  filled pipe.

* CaCO3

This new screw geometry allows for :-

• Higher output
• Improved product quality
• Lower raw material costs
• Cold mix – directly dosed into extruder
• Longer lifetime of screws and barrel.

The new design surpasses the performance of the larger L/D ratio extruders currently in today`s marketplace.

This new screw design is also advantageous for applications like WPC extrusion as well as other difficult to plasticise materials.

Extruder	Max.output PVC Pipe kg/h
DS7.32	550
DS9.32	800
DS12.32	1400

 

High  Performance NE40 Series for Polyolefin Pipe

A unique High Performance range of  single screw extruders has been developed by Weber especially for HDPE and PP pipes.

This range has 5 models with screw  diameters between 50mm and 130mm. The lower energy consumption has rightly  earned this machine range the label “WEBER GREEN TECHNOLOGY”

Advantages of High Performance NE40 Series Machines:

• Long effective life of the grooved bush and processing unit through lower grooved bush pressure
• Constant outputs  across the entire speed range
• Lower melt  temperature compared to older machine concepts
• Output increase by upto 40% compared to older series
• Reduced energy  consumption
• Reduced water cooling of the grooved feed bush and new drive concept
• Barrier screw with shear and mixing part
• Direct coupling motor – gearbox as an option
• Heat exchanger designed to divert the excess heat from the heater bands to any number of  applications

Extruder	Max.output	Max.output
	PE-HD kg/h	PP kg/h
NE5.40	350	280
NE6.40	700	550
NE7.40	1100	800
NE9.40	1400	1000
NE12.40	2000	1450

 

Extrusion  of PVC Foam Core Pipes

Multilayer pipes with compact PVC  layers on the outer and inner walls and a centre layer produced from either virgin or recycled foamed material.

Manufactured using the Weber FBL2 Feedblock, lightweight pipes with foamed core layer have been produced for non pressure applications especially used in waste water and sewer pipes (KG pipes).  

Extrusion  of Corrugated Pipes and Double Wall Corrugated Pipes

In co-operation with renown manufacturers of corrugated pipe forming machines, Weber are able to offer  suitable extruders for PVC, PE and PP corrugated and double wall corrugated pipes.

Advantages of Weber double wall  corrugated pipe lines (co-extrusion)

• Low friction, floating suspension as a customised solution for balancing thermal expansion
• Optional screw  removal from the back of the extruder for cleaning and inspection, meaning the injection head and corrugated pipehead does not need to be removed
• The entire extruder system is controlled by the Weber WPS3 control

Extruder for	Extruder for	Max.output
Corrugated Wall	Plain Inner Wall	PE-HD kg/h
NE6.40	NE5.40	850
NE7.40	NE6.40	1450
NE9.40	NE6.40	1700

Corrugated  and Double Wall Corrugated PVC Pipes using the Weber FBL2 Feedblock

The core element of double wall corrugated PVC pipes is always the Weber feedblock. This feedblock has been  used in industry for over 10 years.

Constant optimisation and further development have made the current FBL2 better than ever with output capacities of upto 1,000kgs/hr and pipe diameters of upto 200mm extruded directly from the  FBL2 without the need for an additional pipehead.

 Weber provides customers with individual advice regarding the suitable machine combinations.

Advantages of the Weber Feedblock

• Very good wall  thickness distribution
• High process reliability
• Minimum pipe weights achievable with high percentage of chalk
• Space saving extruder arrangements

PO  Single and Double Wall Corrugated Pipes using the Weber PKM Pipe Head

Constant optimisation and further development have made the current PKM pipe head better than ever with pipe  diameters from 20mm  upto 800mm.

 Advantages of Weber PKM Pipe Heads

• Good wall thickness distribution through rheologically optimised flow channels
• High flow rate capacities
• Internal water cooling of the pipe head reduces the sagging effect for pipes with thick walls
• Piped air cooling, cools from the inside and reduces the cooling path length
• Low shearing forces acting on the material

 

WEBER  offer Extruders for all pipe applications

WEBER can offer complete Lines for  PVC Solid Wall Pipes upto 630mm diameter (Including pipehead) with outputs upto  1,800 kgs/hr  

WEBER can offer complete Lines for  PVC Foam Core Pipes upto 200mm diameter (including feedblock) with outputs upto  1,000kgs/hr

WEBER can offer complete Lines for PE/PP Pipes upto  800mm  diameter (including pipehead) with  outputs upto 2,000 kgs/hr  with HDPE  and1,450 kgs/hr with PP with their new “High Performance” extruders.

 WEBER can offer complete lines for 3  layer, single & double wall corrugated pipe.

PEXa pipe extrusion line

A  high quality pipe with exceptional properties. The peroxide cross linking of  HDPE makes PEXa pipe one of the best of its kind.

Application:

Mainly for heating, sanitation pipes, in geothermal plants, for air-conditioning  (area cooling), for gas installation, for offshore and industrial applications.

Infrared cross linking technology can be used to multiply the previously achieved output capacities of the ram process. This economical manufacturing method lends new impetus to PEXa pipes.

Weber have developed a special  processing technology for this method and can offer extruders and pipe heads with a capacity of upto 350kgs/hr and pipe diameters upto 160mm.

Crosslinking polyethylenes achieves a considerable increase in :-  Creep strength, resistance to stress cracking, low temperature impact strength,  long-term pressure resistance.

 Advantages of the Weber  PEXa extruders

• High output capacities
• Maximum process reliability
• Good melting homogeneity at very low compound temperatures

WEBER co-extruders and WEBER double wall coating heads allow for the production of  PEXa pipes with oxygen diffusion barriers. WEBER offer both conical and parallel screw extruders for this application

Technical Profile  & Super Edition models

Technical Profile & Pipe Extrusion

WEBER  offers:

• Extensive process engineering expertise.
• Fully developed extruder designs.
• Effective, user-friendly automation and control technology.
• Tailor-made,  space-saving layout.
• Wide range of extruders for differing output requirements
• Complete systems formanufacturing PA, TPU, PC/ABS and POM pipes

Fields  of Application

Extruder Series	PVC		PO	Technical    Profiles
	Powder	Pellets	Polyolefins	Polyamide	Thermoplastic Elastomers	Styrol Polymers	P/acrylate	Polyacetate	Polycarbonate
	PVC-U	PVC-U	PE,PP	PA6, PA6.6,     PA12	TPO,TPV, TPS, TPU	SAN,    ABS, ASA, PS	PMMA	POM	PC
DS₁	+	+	ₒ	–	–	+	–	–	–
CE₂	+	+	ₒ	–	–	+	–	–	–
ES₃	ₒ	+	+	+	+	+	+	+	+
ES N₄	–	–	+	+	+	ₒ	ₒ	ₒ	ₒ
NE₅	–	–	–	ₒ	+	ₒ	ₒ	ₒ	ₒ

Keys   + : Suitable            ₒ  : Limited Suitability           – : Not Suitable

1 = Cylindrical twin screw extruder  (DS)

2 = Conical twin screw extruder (CE)

3 = Single screw extruder (ES)

4 = Single screw extruder with  grooved feed (ES N)

 5 = Single screw high performance  grooved bush extruder (NE)

The variety of polymers, compounds and compound systems allow for application specific and individual solutions in the extrusion of technical profiles. The selection and mixture of materials  used influence the strength and ageing properties, UV resistance, elasticity,  geometric design and many other aspects The following machines have been designed for the increasingly demanding market place.

Single  Screw Extruder Series ES, Single Screw Co Extruders Series ZE

WEBER offer a range of single screw  extruders and co-extruders for the technical profile and pipe sectors, these  are the ES and ZE series machines and are built to order according to the  customers specification. WEBER offer two different designs in  this range, these are built with either a plain feed bush or a grooved feed  bush dependent upon the material to be processed :-

Plain  Feed Bush Extruders

*ES20, ES30, ES45, ES60, ES80,ES100,  *ZE20, ZE30, ZE45 and ZE60.   These machines are all suitable for  processing PP, PS, PE, TPE PA, PS, PPVC, UPVC and PC

Note : *ES20 & *ZE20 are not suitable for PC.

Grooved  Feed Bush Extruders

ES30 N, ES45 N, ES60 N, ZE30 N, ZE45 N and  ZE60 N   These  machines are all suitable for processing PP, PS, PE, TPE PA, PS and PPVC

The “Super Edition” series (except ES80 and  ES100)

The Super Edition series are manufactured in batches and are normally supplied from stock, these machine are built to one specification. The only options available are:

• Standard heater bands or high capacity heater bands (for processing high  melting plastics, e.g.PA)
• Melt pressure and melt temperature measuring unit
• Tool connection flange in execution according to customer requirements

The  single screw extruder “Super Edition” is designed for the economic  extrusion of technical profiles and small pipes made from thermoplastics, especially technical plastics.

Characteristics include:

• Proven Weber quality “Made in Germany”
• Optimum price / performance ratio
• Modular design
• Motor / gearbox unit with energy efficient AC drive
• Microprocessor control with touch screen
• Compact, space saving design
• High range of processing
• Extruder speed control with ergonomic potentiometer
• Screw geometry according to application
• Generally delivered from stock

 

WPC

The perfect mixture of thermoplastics and natural fibres

The advantages of plastics combined with the best of natural fibres:

WPC is the material which uses renewable raw materials to limit the use of depleting resources. This is not just good for the environment but also for the end product, for example “Decking Boards”. The material properties are clearly improved and the design options for classic timber products are multiplied. The result is a solution for perfect products that also respect nature.  

Not all countries are alike, for this reason Weber have continually optimised WPC extrusion to allow customers to combine classic plastic materials with natural fibres which are common to their region and therefore less expensive.

Whether wood, sisal, hemp, coconut fibre or rice hulls – the result is always perfect.

Advantages of WEBER WPC extrusion:-

• Low shear rates and moderate melt temperatures
• High torque
• Self cleaning function, therefore very little distribution of dwell
• Processing of different material types – loose fibres, compounds, pellets etc.
• High constant output across the entire speed range
• Outgassing
• Optimised wear protection

Together with the extruder Weber are able to supply the calibration table, haul off, brushing/cutting stations and ejector tables.

This means Weber can supply the ideal system solution without any interface problems.

Weber offer both conical and parallel screw extruders for this application.

Ancillary Equipment

uPVC Pipeheads

• upto 315mm diameter
• Including die and pin

Weber can supply pipe heads for processing uPVC upto 630mm diameter in co-operation with leading toolmakers

uPVC Feedblock

• upto 200mm diameter
• Including die and pin

PE/PP Pipeheads

• upto 315mm diameter
• Including die and pin

Weber can supply pipe heads for processing PE/PP upto 800mm diameter in co-operation with leading toolmakers

Granulator Head KG7 & KG 7 FE

• For the production of PVC pellets
• Hot beading principle
• Cut by rotating knives
• Individual arrangement of circular holes and hole diameters
• Continuously adjustable cutting speed
• Suitable for all DS and CE extruders

Belt Dosing Units for volumetric dispensing

• Available in three sizes
• Continuous material feed
• Infinitely adjustable motor
• Easy to attach to the existing sliding hopper base plate
• For all DS and CE extruders

Forced Feeding Unit

• Suitable for materials with poor flow characteristics
• For materials with low bulk density (eg soft PVC powder)
• Optional pressure-dependent control

Breaker Plates