FULLMACHINE^® - INDUSTRIAL PUR PROFILE FILLING TECHNOLOGY

WHY PUR FILLING INSIDE PROFILES?

Filling suitable chambers in PVC and aluminium profile systems with polyurethane is one of the solutions used to improve the thermal insulation performance of profile systems. However, transforming PUR application in long profiles from laboratory or individual sample production into an industrial serial-production process requires specialized machinery and process technology. FULLMACHINE^® has been developed to meet this requirement.

DEVELOPED FOR LONG PROFILES OF 6 METRES AND ABOVE

One of the fundamental features of FULLMACHINE^® technology is its ability to fill commercial-length profiles of 6 metres and above, as commonly used in the extrusion industry, with PUR. Instead of first cutting the profile into short pieces for filling, the process is designed to fill the profile while it remains at commercial length. This allows the PUR filling process to be integrated into the profile manufacturer's industrial production and logistics structure.

APPLICABLE TO PVC AND ALUMINIUM PROFILES

FULLMACHINE^® is not a technology developed for only one profile system. By evaluating the geometry and dimensions of the chamber to be filled together with the required process conditions, the system can be adapted to PVC and aluminium profile applications. This allows the technology to be considered not only for window and door systems but also for other profile applications where PUR filling is required.

BATCH-ORGANIZED PROFILE FILLING FOR SERIAL PRODUCTION

One of the important features of the FULLMACHINE^® production system is that the production organization can be based on profile batches instead of handling and filling profiles individually. Profiles can be prepared in groups of 4-5. Approximately 25 such groups can be organized into a production batch of around 100 profile lengths. The prepared profile batch can be transferred to the filling platform by forklift, and the filling process can be managed by a single operator. This production organization facilitates the PUR filling of large quantities of long profiles under serial-production conditions.

LABOUR AND PRODUCTION EFFICIENCY

Handling, positioning, filling and restacking long profiles one by one requires considerable labour and time. In the FULLMACHINE^® system, organizing profile batches on the production platform reduces material handling and operator operations. Instead of the additional personnel that may be required for individual profile filling, the batch-based production organization is designed so that the process can be managed by a single operator. This approach can reduce labour requirements in serial production while enabling more controlled production planning.

CONTROLLED 2K PUR FILLING PROCESS

FULLMACHINE^® is designed for the controlled application of two-component polyurethane into profile chambers. Preparation, mixing and application of the PUR material into the profile are carried out according to defined process parameters. Application parameters are determined by evaluating profile geometry, chamber dimensions, PUR material properties and production conditions. For this reason, FULLMACHINE^® consists not only of machinery and equipment but also of PUR application process knowledge and manufacturing know-how.

APPLICATION TO DIFFERENT PROFILE CHAMBERS

The dimensions and geometries of chambers requiring PUR filling can vary significantly between profile systems. FULLMACHINE^® technology allows processes to be developed for different profile sections and chamber structures. Within this scope, filling trials have been carried out on PVC Passive House profile applications involving narrow chambers such as a 13 mm frame chamber and an 8 mm sash chamber. These applications demonstrate the importance of the correct PUR material, process parameters and application know-how in addition to the machine technology itself.

INTEGRATION INTO EXISTING PROFILE PRODUCTION

The objective of FULLMACHINE^® technology is not to replace the profile manufacturer's existing production system. The PUR filling process can be integrated into the manufacturer's existing extrusion and profile production organization as an additional industrial process. An appropriate production organization can be developed by evaluating the manufacturer's existing production capacity, profile range, factory layout and targeted filling volume. This enables manufacturers to retain their existing PVC or aluminium profile systems while adding PUR-filled profile technology to their product portfolio.

INTEGRATED TECHNOLOGY FOR ADVANTAGE-60^®

FULLMACHINE^® is also one of the core manufacturing technologies within the ADVANTAGE-60^® composite window production system. In ADVANTAGE-60^®, PVC PROFILE + STEEL REINFORCEMENT + ALUMINIUM CLADDING + PUR FILLING are combined within a single composite structure. FULLMACHINE^® enables the PUR profile filling process within this structure to be carried out on an industrial scale. ADVANTAGE-60^® technology is explained in detail in the dedicated ADVANTAGE-60^® section of this website.

PRODUCTION TECHNOLOGY WITH REAL-WORLD APPLICATION EXPERIENCE

FULLMACHINE^® is not a system developed only at a theoretical or laboratory scale. Production applications for filling long PVC and aluminium profiles with PUR have been carried out, creating process experience with different profile geometries and industrial production conditions. The technology development process has combined university and R&D studies with experience gained from real production applications. This accumulated experience forms the basis of the manufacturing process and application know-how supplied together with the machine technology.

TURNKEY PUR PROFILE FILLING TECHNOLOGY

FULL WINDOWS does not consider FULLMACHINE^® technology merely as the delivery of a machine. Each project is developed after evaluating the manufacturer's profile systems and production requirements. Depending on the application, the project scope can include profile analysis, identification of chambers to be filled, development of the PUR process, machinery and filling equipment, production organization, process settings, operator training, commissioning and manufacturing know-how. The objective is not simply to install a machine in the factory, but to establish a functioning production process that enables the manufacturer to produce PUR-filled profiles on an industrial scale.

WHO IS FULLMACHINE^® DEVELOPED FOR?

FULLMACHINE^® has been developed particularly for PVC profile extrusion manufacturers, aluminium profile extrusion manufacturers, window and door system companies, manufacturers developing thermally insulated profiles, and companies seeking to manufacture PUR-filled long profiles on an industrial scale. The technology can be engineered according to the manufacturer's existing profile systems and production capacity.

KEY ADVANTAGES FOR MANUFACTURERS

• PUR FILLING FOR LONG PROFILES OF 6 METRES AND ABOVE
• TECHNOLOGY APPLICABLE TO PVC AND ALUMINIUM PROFILES
• CONTROLLED INDUSTRIAL 2K PUR FILLING PROCESS
• BATCH-ORGANIZED PROFILE PRODUCTION
• SINGLE-OPERATOR PRODUCTION ORGANIZATION DESIGNED TO REDUCE LABOUR REQUIREMENTS
• PROCESS ADAPTABLE TO DIFFERENT PROFILE CHAMBERS
• INTEGRATION INTO EXISTING PROFILE PRODUCTION INFRASTRUCTURE
• FULL INTEGRATION WITH ADVANTAGE-60^® MANUFACTURING TECHNOLOGY
• MACHINERY + PROCESS + TRAINING + KNOW-HOW

INTERNATIONAL TECHNOLOGY PARTNERSHIP

FULLMACHINE^® is an industrial technology platform that can be adapted to the different profile systems and production requirements of PVC and aluminium profile manufacturers worldwide. Each project is evaluated according to profile geometries, production volume, PUR application requirements, factory infrastructure and targeted production capacity. The objective of FULL WINDOWS is not merely to sell machinery, but to combine machine technology, the PUR application process and manufacturing know-how so that manufacturers can establish industrial PUR-filled profile production within their own facilities.