COMBIROLL

in-line assembling machines for pvc roller shutters

For the production of roller shutters ready for packing

For the roller shutter industry we manufacture special high productivity machines dedicated to the production of PVC roller shutters in single and dual strand, directly in the PVC extrusion line, with a productivity of up to 2 x 12 m/min, in case of dual strand extrusion. These are automatic modular plants complete with punching, interlocking, cutting and assembly units. They are available in the pneumatic version and with brushless motors for high speeds.

The single units are equipped with the necessary accessories (punch tool sets, interlocking tool sets and guillotine die blocks), which are designed and manufactured according to the customer’s roller shutter profile.

Advantages
Technical features
C1/TL-6 and C1/TL-10
With notch or pin interlocking system

Automatic roller shutter machines in pneumatic version for an extrusion speed up to 6 m/min, or with brushless motors for a speed of up to 12 m/min.

C2/TL-6 and C2/TL-10
With notch or pin interlocking system

Automatic roller shutter machines for dual strand extrusion lines. Available in a pneumatic version for an extrusion speed of up to 6 m/min, or with brushless motors for a speed of up to 12 m/min.

Combiroll-Pack

Automatic roller shutter machine for the simultaneous production of roller shutters and 6.5 m long slat packs. It is available as a pneumatic unit for an extrusion speed of 6 m/min and as a servo-aided unit for an extrusion speed of 12 m/min.

Its dedicated software allows the operator to easily switch production from roller shutters to slat packs and back again according to production needs. The Combiroll-Pack is equipped with two mechanically independent lines and an innovative system “that” includes extractable supports, tilt steel rollers and automatic mobile roller shutter supports.

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Turn-Key Plants

Baruffaldi, with its extensive experience in the field of plastic profiles and pipes extrusion, forging partnerships with its customers, designs and manufactures turn-key plants. From the raw material formulation and the profile optimization right up to the regrinding system to recycle the waste material, Baruffaldi is proud of realizing the full project requested by the customer.

The company reliability, the services offered, the quality of the materials and the advanced level of technology used on the machines are recognized by the leading plastic extrusion manufacturers from around the world.

The combination of the technical knowledge and the dynamic and flexible structure of the company makes Baruffaldi the ideal partner for manufacturing the plant that is best suited to maximize the return on the investment in the equipment.

Baruffaldi is the perfect partner for investors who are new to this sector, thanks to the value-for-money products, a comprehensive consultancy service included in the price and on-site specialist technicians during the start-up phase of production plants.
The efficient customer service and the technicians support guarantee worldwide assistance, including Baruffaldi training service for operators.

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Extrusion Tools

For plastic profiles

Since its establishment in 1953, Baruffaldi has created a solid reputation at an international level as a manufacturer of extrusion tools and extrusion lines, downstream equipment and processing machines for plastic profiles.
 
Extrusion tooling is the heart of the production technology of any type of profile. In this sector we distinguish ourselves for the high productivity, versatility and production speed up to 25 m/min for roller shutters.
 
Our company philosophy in this field is based on a constant investment in research and development that allows us to reach our customers’ production goals through the application of innovative solutions that meet the highest market standards.
The know-how of our team, coupled with a complete in-house production process, gives us the possibility to customise our tooling and satisfy any specific customer need.

From the machining and boring centers to the wire erosion process, all frames and small components are “home-made” and accurate. We manufacture extrusion tools using only certified steel of the highest quality. Production is performed with the support of a state-of-the-art CAD/CAM system.

Every Baruffaldi branded element that leaves the factory is professionally tested in our quality department, which is equipped with three-dimensional measuring machines such as Faro CAM2 Platinum arm and DEA-HEXAGON measuring machine.

Project designers and tuning technicians work side by side in synergy with the customer to achieve continuous improvement aimed at obtaining effective, competitive and innovative solutions that are the key to our customers’ success as well as our own.

In-House Fine Tuning

Our testing department is equipped with 3 complete extrusion lines to cover the broadest possible spectrum in testing extrusion tooling, special customized equipment and our special end-of-line machines. There are a Baruffaldi single screw extruder L/D 60-28, with an output of 90 kg/h, a Cincinnati conical twin-screw extruder type C-55 with an output of 100 kg/h, a Reifenhauser parallel twin-screw extruder capable of extruding 80-210 kg/h, a single screw co-extruder (25 kg/h), a Piovan drying plant for hygroscopic polymers, and a calibrator thermoregulator for special plastic materials (PC/ABS etc.). After the internal tests, our technicians fine-tune the extrusion tool at the customer’s site until the profile meets the agreed technical requirements and acceptance criteria and the tool can be put in production.

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Single Screw Extruder

Single screw extruder mounted on a machine bed made of sectional steel and steel plate. It is available with a 45 mm, 60 mm, 75 mm or 90 mm diameter plastification screw made of normalized, hardened and tempered steel that can be fitted with a temperature control system and a nitrided steel cylinder with 4 independent temperature control zones.

The extruder is also available with different length/diameter ratios.

Technical features
Electrical Equipment

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OMNIA 0.1

Extrusion Line

ADVANTAGES
CALIBRATION TABLE – OCT SERIES
TECHNICAL FEATURES
OPTIONS

Omnia can also be used for the extrusion of pipes up to Ø 63 mm by mounting our sizing tank on the calibration table.

HAUL-OFF – OP SERIES
TECHNICAL FEATURES

The quick-change pads allow the user to fit different types of rubber or contoured pads or to carry out maintenance with a generous time saving.

COMBO POSSIBILITIES
CUTTING UNITS – OC/H – OC/V – OC/D SERIES
TECHNICAL FEATURES

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Calibration Tables

Our new generation modular calibration tables are conceived with energy recycling circuits for the maximum reduction of energy consumption.

They are available in different lengths (from 3 to 20 m) and with a number of pumps according to the specific applications. They stand out for their sturdiness, solidity and quality of materials, being entirely made of steel.

They are equipped with a (stainless steel) water collection bath of the same size as the frame, modular (stainless steel) water and vacuum distributors with manifolds., vacuum on pumps fixed to independent frames, extractable sideways and mounted on a different rails system to avoid the transmission of vibrations.

They are equipped with a stainless steel tank of the same size as the frame, modular water and vacuum stainless steel distributors, pumps assembled on anti-vibration frames, extractable on the side and independent from the frame.

Motor-driven longitudinal movement on rails and vertical movement. Manual or motor-driven plane translation and tilting movements (optional).

Motor-driven transversal adjustment. Baruffaldi has developed two different kinds of calibration tables suitable for a wide range of profile sizes and geometries.

Calib

The whole calibration table moves longitudinally on rails. The vacuum pumps are assembled onto independent frames, that can be extracted sideways, to avoid the transmission of vibrations during the process.

OCT

This type of calibration table is part of our standard Omnia extrusion line. Its longitudinal movements affect only the tank with the calibrators.

The frame, resting on feet, is fixed, and only the water bath moves longitudinally.  Our calibration tables are made according to the specific production needs of our customers: they are equipped with independent energy saving systems and are available also with a built in heat exchange unit.

Functionality, manufacturing accuracy and customisation are the distinctive features of our machines.

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Haul-offs

 

We manufacture haul-offs of different types and sizes for small, medium and large profiles. They are available with rollers, pads or belts, with a contact length from 0.75 m to 3 m and a variable contact width depending on the specific application. Our haul-offs stand out not only for their robust and sturdy structure, that eliminates vibrations and discontinuity of traction, but also for their construction criteria and quality components, that guarantee reliability and long life.

The quick pads change over system allows the easy replacement of the pads and routine maintenance can be carried out with a considerable time saving as well.

TRAXI

Our customisable haul-offs of the so called TRAXI range, with upper caterpillar tilting movement on both sides, are suitable to complete both standard profile extrusion lines as well as lines for special applications like for automotive and big size profiles (for example building industry).
Thanks to their solid and sturdy frame they can also be used in extrusion lines for fiberglass and composite profiles, as they can guarantee a pulling force up to 10 tons.

OP

The OP haul-off is part of our standard Omnia extrusion line and is equipped with a central tilting movement system. It is perfect for small and medium size technical profiles, but it can also be used for complex and articulated profiles. Just like all Baruffaldi units it can be customized according to profile size and geometry.

P-C

Our production program also includes the highly versatile combined puller and cutting units, which are available in different versions: either with belts or pads haul-off and vertical guillotine (P-C/V), or with belts or pads haul-off and transversal cold or hot blade guillotine (P-C/H) with die block, according to profile thicknesses and geometry.
Thanks to our technical know-how and our steady investments in the R&D department we always manage to find the best technology to meet every specific production need.

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Milling Machines

for Extruded Plastic Profiles

Vertical Milling Machine: MM

The technology applied to these automatic vertical milling machines is engineered for slotting double wall rigid PVC profiles of up to 600 mm in width, directly on the extrusion line.

The machine is positioned between the haul-off and the guillotine and carries out the slotting process using a milling unit composed of independent modules mounted on a suitably dimensioned cooled bearing plate, which can house up to 44 milling tool holders.

The multiple milling head is mounted on columns and moves up and down to carry out the milling on the profiles. Carriage movement is controlled and driven by a brushless motor designed to synchronise the milling with the profile speed.

The machine is also equipped with an external suction unit to remove dust and milling swarf so that the profile is clean and ready for the next working process.

The choice of materials, such as the electro-welded box section steel, the painted frame, the anodised aluminium structures that support the moving parts, and the stainless steel used for parts in contact with the profile are all hallmark signs of a top-quality machine.

Applications

This type of machine finds its main application field in the extrusion industry of perforated double wall cable trays – For single wall ducts have a look at our punching machines!

The production of customised milling tools allows extremely precise and clean holes/slots. This machine is designed to be extremely versatile and manufactured according to different production needs. It can be used for different profiles formats and multiple drilling/milling patterns, for example, for double wall PVC cable trays.

Advantages
Technical features
Horizontal milling machine: MILL8

This machine reflects a new concept in modular milling systems to process large-scale multi-wall PVC profiles up to 355 mm in width.

Its modularity gives the possibility to add extra milling units, up to a max. of eight, depending on type of profile, extrusion speed or milling pattern. Moreover, Baruffaldi R&D department developed this new concept of a machine that can be used both in-line and off-line by adapting the thanks to its special software solution.

For the off-line use of the machine, both clamps are necessary: the infeed one, to be found at the machine entry, and the one placed on the carriage for the movement of the profile through the unit.

In the in-line use, the brushless motor (for the longitudinal movement of the carriage along the extrusion axis) and the encoder guarantee the perfect synchronisation of the carriage with the extrusion speed of the profile.

The milling unit makes round holes, all placed at the same distance one from the other, along the 6 profile walls, with the flexibility of managing different punching patterns, that can be set on the operator panel. The special milling tools complete with the related inserts are designed obtain a clean cut without burrs and minimise the material removed. The milling heads have a multiple movement that is repeated at each milling cycle: during their return stroke they hold the disk and release it at the end of the cycle.

The powerful aspiration system sucks the scraps of the milling process, while the milled disks fall into the special collection channels from where they are conveyed on the belt that drops them in the special container placed at the exit of the cabin, for the subsequent recycling.

Thanks to the Baruffaldi scrap-collection and recycling system, our milling machine MILL8 guarantees the cost reduction of the material used in production.

Scrap discharge belt and dust suction system

Baruffaldi always takes into consideration the need to safeguard a safe and healthy working environment. The two (inlet and outlet) tunnels and the soundproof safety cabin comply with the safety regulations, as the noise is much lower than the requirements of the current regulation on this issue. The MILL8 has a user-friendly operator panel and its routine maintenance is easy. Moreover, the remote assistance system allows Baruffaldi to give customers immediate assistance, as Baruffaldi is always on their side.

Baruffaldi always takes into consideration providing a safe work environment. The two tunnels (in and out) and the soundproof safety cabin comply with safety regulations, as the processing noise is much lower than the requirements of the related regulation admitted on working environments. The MILL8 has a user-friendly operator panel and its routine maintenance is easy. Moreover, the remote assistance system allows Baruffaldi to give customers immediate assistance, as Baruffaldi is always on their side.

Advantages
Technical features

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POVI 10000, POVI 5000

Off-line Punching and Coining Systems for Plastic Cable Ducts

The cable duct punching systems POVI 5000 and POVI 10000 are the only plants in the world designed to reach process speeds of up to 12 m/min. with the highest quality standards.

They are designed and manufactured to produce PVC and PC/ABS electrical cable ducts according to the standard punching patterns required by the market.

Advantages of our punching and coining systems for cable ducts

POVI 10000 and POVI 5000 are modular systems that can be customized according to the specific production needs of the customer. Baruffaldi Plastic Technology is the only partner capable of designing and manufacturing the most suitable plant to secure the maximum capital return on your investment.

POVI 10000 and POVI 5000
They are high technology and high productivity systems, designed to punch and coin cable ducts on three sides, off-line.
With the same plant it is possible to punch all sizes: from the smallest one (15×15 mm) to the biggest one (100×150 mm). The punching process can also be combined with the so-called embossing process, which consists in making a “fingerprint” on the outer profile surface, to facilitate manual removal of the pre-punched part during installation.
Coining is a special technology developed exclusively by Baruffaldi, that adds an important plus to the product, eliminating swarf and sharp edges caused by the punching process on the cable duct side walls.

Moreover, POVI 10000 and POVI 5000 are equipped with an innovative cable duct transport system inside the various units of the plant, which leaves no visible mark on the bottom of the duct.
The POVI 5000 has a lower cost, both in terms of investment and maintenance, but guarantees the same quality as the POVI 10000 thanks to the same technical characteristics.

The soundproof cabin guarantees low noise levels and reduction of acoustic emissions for a safe and healthy working environment.

Technical features
Other units in the Baruffaldi POVI systems

Feed-in table: IT/CD
Frame with motorized height adjustment, manageable by means of two buttons and numeric display, with conveyor belt feeding table for the manual operator loading of the cable ducts.
A special device inserts the ducts one by one in the punching machine and the profile presence sensors verify the alignment with the axis of the machine, to avoid jamming. The feed in table is also equipped with a special unit to heat ducts feet, in case of high product thickness or low ambient temperature, in order to avoid breaking them during the punching process. The temperature is set according to the thickness of the product to be processed and the ambient temperature.

Scoring unit: SML/2
Independent, stand-alone unit positioned at the exit of the punching machine and before the feed out table, complete with motorized devices for the advancement of the duct at constant speed and its expulsion on the feed out table at the end of the process. In the standard version, the unit makes two continuous incisions (score lines) on each internal side wall, one at the base of the slots and the other at the base of the wall respectively to facilitate breaking of the fingers and of the side wall itself. Position and depth of the score lines are easily adjustable based on the size and thickness of the cable duct.

Printing unit
All POVI systems can include a cable duct printing system to print the necessary production data on the product. Depending on the customer’s request, we can therefore include an inkjet printer, a laser printer or any other marking device chosen by the customer (optional).

Brushing machine: BM/CD
The POVI systems guarantee a high-quality punching and coining process, that normally leaves no residual burrs. However, in some cases (particular materials, critical geometries and complex punching schemes), it may be necessary to brush the “critical” area of the product, that is the feet. For this purpose we therefore designed ad hoc brushing machines, which have the same characteristics of versatility and flexibility as the other units of the plant.

Our standard cable duct brushing machine consists of 2 heads, each equipped with 2 motorized brushes, with independent adjustment in width, height and inclination. The special carters positioned above the brushes have the function to convey the dust to the suction device of the unit or the centralized suction system of the customer’s shop floor.

Feed-out table: TT 4.0
Solid and sturdy unit with adjustable feet, complete with extraction device and tilting supporting surface, pneumatically operated. From here the operator can easily pick up the cable ducts and place them in cardboard boxes or transfer them into containers. It is available in two standard lengths.

For customers who wish a different solution , we can also manufacture a horizontal out table with conveyor belts (size approx. 2 x 2.5 m) with a pneumatic device to release the punched and coined cable ducts on underlying belts.

Palletizers and stackers
Automatic unit with two octagonal axes, that deposits the cable ducts in an orderly manner on a pallet or inside special boxes. customizable system based on customer needs.

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POVI 6000

Hydraulic In-line Punching Machines for PVC
Cable Ducts and Single Wall Perforated Cable Trays

These stand-alone and compact punching machines are ideal for the in-line punching of “U”-shaped plastic profiles that need punching on all three sides, such as cable trunking, ducts for floor conditioning systems and single wall cable trays with a width of up to 600 mm and a thickness of up to 5 mm.

They are latest generation units, designed and built to work at high speeds, up to 10 m/min., and to be extremely flexible and versatile according to the different and specific production requirements. The three punching heads are independent, i.e. they can work both together and individually. They can also be equipped with proportional valves, which allow you to control their movement precision, reduce mechanical stresses and guarantee a high quality punching standard on all thicknesses.

The punching process can also be combined with the so-called embossing process, which consists in making a “fingerprint” on the outer profile surface, to facilitate manual removal of the pre-punched part during installation.

The punching machine is equipped with a carriage that slides on prismatic linear guides, on which the three punching heads with the relative cutting sets are assembled. The horizontal movement of the carriage is operated by a brushless motor with ball & screw, controlled by a PLC.

Advantages
Technical features

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