ADVANTAGE-60® - NEXT-GENERATION COMPOSITE WINDOW MANUFACTURING TECHNOLOGY
ADVANTAGE-60® is a next-generation window manufacturing technology that combines PVC profiles, steel reinforcement, aluminium cladding and polyurethane (PUR) filling within a single composite structure. Rather than treating aluminium-clad PVC window production simply as a new profile or an additional cladding application, the system integrates profile design, composite structure and manufacturing processes into one complete production technology.
ADAPTABLE TO EXISTING PVC PROFILE SYSTEMS
One of the key features of ADVANTAGE-60® technology is its ability to be adapted to the existing window systems that PVC profile manufacturers have been producing for many years. A manufacturer's existing profile system can be adapted to ADVANTAGE-60® technology. This minimizes the need to develop an entirely new PVC window system and a completely new family of extrusion tooling. This approach enables manufacturers to preserve their established product portfolio while expanding into a new generation of aluminium-clad composite window systems.
PRODUCTION WITH THE EXISTING FABRICATOR MACHINERY
Another major advantage of ADVANTAGE-60® technology is that window fabricators and the manufacturer's dealer network do not need to establish an entirely new and dedicated window fabrication machinery setup. ADVANTAGE-60® composite profiles can be configured to work with the manufacturer's existing window systems. This enables dealers and window fabricators to continue manufacturing windows using the cutting and welding machinery already used for their existing systems. As a result, the technology can be introduced throughout an established fabrication network while keeping additional machinery investment for dealers and window manufacturers to a minimum.
ARCHITECTURAL COMPATIBILITY WITH EXISTING SYSTEMS
Because ADVANTAGE-60® can be adapted to existing PVC profile systems, a manufacturer's conventional PVC system and the aluminium-clad ADVANTAGE-60® system can be used within the same architectural project. A project that has already started, or has previously been completed in part using a conventional PVC system, can continue with the ADVANTAGE-60® aluminium-clad composite system when required. Because the architectural character of the existing profile system can be maintained, visual and architectural continuity between the conventional system and ADVANTAGE-60® applications can be preserved. This provides a significant practical advantage, particularly for residential developments, large-scale housing projects and commercial projects constructed in multiple phases.
INTEGRATED MANUFACTURING PRINCIPLE
In ADVANTAGE-60® technology, the steel reinforcement is positioned inside the PVC profile, while the aluminium cladding is positioned at the specially designed connection areas of the PVC profile. Polyurethane is introduced into the profile chambers, integrating the components as parts of a unified composite structure. Once the composite profile is ready for window fabrication, the PVC profile, steel reinforcement and aluminium cladding are processed within the same manufacturing flow.
This manufacturing principle integrates into the production flow the aluminium cladding operations that, in conventional aluminium-clad PVC systems, are typically carried out as separate processes after window fabrication. The objective is to reduce additional labour, simplify the manufacturing process and create an integrated system suitable for industrial-scale production.
FOUR COMPONENTS - ONE COMPOSITE STRUCTURE
ADVANTAGE-60® brings together the advantages of four fundamental components within one integrated structure:
PVC Profile
Provides the primary profile structure of the window system and contributes to its thermal insulation characteristics.
Steel Reinforcement
Contributes to the mechanical strength and structural performance of the system.
Aluminium Cladding
Provides the architectural appearance and surface advantages of aluminium on the exterior.
PUR Filling
Fills the profile chambers and contributes to thermal insulation and the integrity of the composite structure.
TURNKEY ADVANTAGE-60® MANUFACTURING TECHNOLOGY
ADVANTAGE-60® is not offered merely as a profile design or an aluminium cladding system. FULL WINDOWS approaches the industrial implementation of the technology as a complete turnkey manufacturing solution. Each project is developed after evaluating the manufacturer's existing window systems and production infrastructure. Depending on project requirements, the production system can include: slotted steel reinforcement production technology, PUR profile filling line, FULLMACHINE®, aluminium cladding installation technology, required PVC and aluminium extrusion tooling, process monitoring systems, manufacturing know-how, training, testing procedures and production-line integration. The ADVANTAGE-60® manufacturing system is an integrated technology package incorporating patented technologies and specialized production processes.
FULLMACHINE® AND PUR PROFILE FILLING TECHNOLOGY
Industrial polyurethane profile filling is one of the key technologies integrated into the ADVANTAGE-60® manufacturing system. FULLMACHINE® is a profile filling technology developed for the industrial filling of PVC and aluminium profiles with polyurethane. The system enables PUR filling processes for long profiles of 6 metres and above to be integrated into the ADVANTAGE-60® production line. FULLMACHINE® technology is presented in detail in the dedicated FULLMACHINE® section of this website.
PATENTED TECHNOLOGIES AND MANUFACTURING KNOW-HOW
The ADVANTAGE-60® manufacturing system has been developed as a continuation of research and development activities in composite profile technologies, polyurethane profile filling and specialized manufacturing processes. The technologies incorporated into the system are supported by patents and intellectual property development. Within this project, patents are not presented as standalone products. They form part of the technological foundation and originality of the complete ADVANTAGE-60® turnkey manufacturing system. The production technology is delivered as an integrated combination of specialized equipment, process knowledge, application experience and manufacturing know-how.
KEY ADVANTAGES FOR MANUFACTURERS
Rather than requiring manufacturers to completely replace their existing systems, ADVANTAGE-60® is designed to transform existing production infrastructure into a platform for a new generation of products.
- ADAPTABLE TO EXISTING PVC PROFILE SYSTEMS
- MINIMIZES ADDITIONAL TOOLING INVESTMENT
- ENABLES PRODUCTION USING THE EXISTING FABRICATOR MACHINERY
- ALLOWS CONVENTIONAL AND ALUMINIUM-CLAD SYSTEMS TO BE USED WITHIN THE SAME PROJECT
- PVC PROFILE + STEEL REINFORCEMENT + ALUMINIUM CLADDING ARE PROCESSED WITHIN THE SAME MANUFACTURING FLOW
- PUR FILLING CREATES AN INTEGRATED COMPOSITE STRUCTURE
- PROVIDES A TURNKEY INDUSTRIAL MANUFACTURING TECHNOLOGY
WHO IS ADVANTAGE-60® DEVELOPED FOR?
ADVANTAGE-60® is designed for PVC profile extrusion manufacturers, aluminium profile extrusion manufacturers, window system companies and industrial manufacturers seeking to develop next-generation aluminium-clad PVC composite window systems. The objective of FULL WINDOWS is not to sell finished windows, but to establish technology partnerships with manufacturers and enable industrial production of the ADVANTAGE-60® system in different international markets.
INTERNATIONAL TECHNOLOGY PARTNERSHIP
ADVANTAGE-60® is a manufacturing platform open to international technology partnerships. Because every manufacturer has different existing profile systems, production infrastructure, fabrication networks, target markets and technical requirements, each project is evaluated according to the manufacturer's existing industrial structure. The objective is to combine FULL WINDOWS technology and manufacturing know-how with the manufacturer's existing industrial capabilities to enable serial production of next-generation aluminium-clad PVC composite window systems.