Corrugated profiles extrusion line
In the field of thermoplastic extrusion lines, the production of corrugated polycarbonate (PC) profiles is one of the most complex technological challenges, especially when the market demands extremely reduced thicknesses and high optical quality. Historically, the 0.8 mm threshold has represented a difficult-to-surpass limit, due to the challenges associated with calendering PC at thinner gauges. It is precisely this concrete need that gave rise to the BG Plast line for corrugated profiles, designed to produce optically high-quality calibrated foil with thicknesses down to 0.5 mm, while maintaining dimensional stability, transparency, and production continuity.
The line is part of BG Plast’s established expertise in the construction of high-performance plastic extrusion systems, and combines precision calendering, controlled forming and advanced automation of the finishing stages.
Applications of the PC corrugated sheet extrusion line
The sheets and corrugated profiles produced by this profile extrusion line are primarily used in the construction and industrial sectors, where light weight, mechanical strength and optical quality are required. Typical applications include:
- Transparent and semi-transparent roofing
- Skylights and natural lighting systems
- Canopies and shelters
- Architectural cladding
- Industrial protective coverings.
The ability to process co-extruded polycarbonate with an anti-UV layer makes these profiles particularly suitable for outdoor applications, as they guarantee durability and performance stability even under demanding environmental conditions.
Technical specifications of BG Plast’s PC corrugated profile line
The technological hub of the line is a millimeter-precision calender, specifically designed by BG Plast for processing ultra-thin PC foils. The use of extremely robust rollers, equipped with an internal high-flow temperature-controlled fluid circulation system, enables accurate and uniform thermal control, an essential condition for producing thin foils free of internal stresses or surface defects.
Downstream of the calender, the extruded foil – already co-extruded with an anti-UV layer – passes through a temperature-controlled softening oven, which prepares the material for the next forming stage. The forming unit consists of a series of profiled metal alloy rollers, all temperature-controlled and designed to match the required corrugated profile. This solution allows for perfect and repeatable geometries, even at very thin thicknesses.
Another key feature of the line is its ease of reconfiguration: the forming unit is designed to be easily disassembled, facilitating rapid replacement of the forming rolls and reducing machine downtime. The line is therefore particularly flexible for diverse production runs and batches of varying sizes.
The system is completed by a special drive system, capable of adapting to the different geometries of corrugated profiles without causing deformation, and a cutting unit with an automatic stacker, which allows the sheets to be stacked directly onto pallets ready for shipment.
A performance-oriented solution from BG Plast
Our extrusion line for corrugated profiles exemplifies an advanced synthesis of mechanical engineering, thermal control and application expertise. It is a solution designed for manufacturers operating in the high-quality polycarbonate sheet segment, where precision, reliability and production flexibility are key factors for success.
As with all our extrusion lines, this configuration can also be customized to meet specific customer requirements, confirming the tailor-made approach that characterizes the design of BG Plast’s plastic extrusion systems.
Find the solution best suited to your production needs.