the profilers 1-2013 - Greiner Extrusions Technik

April 2013
THE
PROFILERS
Information by Greiner Extrusion
Trend-setting extrusion technology:
Follow us into a successful future

2 THE PROFILERS | April 2013
INNOVATION & MARKET FOCUS
Ing. Michael Schleiss, MBA
CEO Greiner Extrusion/Greiner Tool.Tec
Mag. Martin Etzlstorfer, MBA
COO Greiner Extrusion
Dear Business Partners!
Welcome to the future of extrusion! With our new, additionally optimized tooling and
machinery systems we have decidedly taken an innovative direction in profile extrusion.
In this hot-off-the-press issue of our customer magazine, THE PROFILERS, we are more
closely examining some of these innovations for you.
What makes the next-generation toolings and machinery so special? We have been
closely listening to our customers’ feedback, and as result, we have found the answer:
the RED.LINE system! In this edition, we will begin highlighting the benefits of our new
product line in detail.
The RED.TOOLING system is composed of a variety of individual components, and as
a complete and intricate system it delivery a significantly improved extrusion performance.
On the following pages, you will learn more about three of the new components:
the “centralized plug”; “flow.control”; and the “keep.clean.unit”.
The development of the new downstream unit, Greiner – RED.LINE, occurred in tandem
with the improvement of the haul-off unit, RED.COM. In this current issue, you will gain
insight into these revolutionary components, RED.PUL (haul-off) and RED.CUT (cutter).
To mention here just a few of the benefits, we would like to point out that by using these
new products the changeover time is reduced by half, pad marks are eliminated, and the
cutting quality is improved; knives can be changed out with no production downtime.
Efficient extrusion
The Greiner FX-LINE offers an attractive price-performance ratio, thus becoming a costeffective
choice for an energy-saving extrusion downstream situated in the mediumpeformance
category. With the FX-LINE, we are demonstrating that not just the high-end
models can achieve profitability along with the highest level of technical performance.
Focusing on window profiles
Expertise within Greiner Tool.Tec has been centralized and consolidated into two divisions
– Window Profiles, and Technical Profiles. As a result, you – our valued business
partner – will experience a multitude of benefits. With the integration of the Gruber product
brand, and the integration of Gruber’s valuable workforce knowledge and expertise
into Greiner Extrusion, we can provide all our customers with total continuity in offering
customized service.
Please enjoy reading our information-rich magazine, THE PROFILERS. We look forward
to being your reliable business partners again this year!
TRADE SHOWS:
SAVE THE DATE!
In 2013, Greiner Extrusion will attend
the following trade shows:
Plastpol 2013
Hall A, Stand A22
May 7 – 10: Kielce, Poland
Chinaplas 2013
Hall 9.2, Stand A67
May 20 – 23: Guangzhou, China
K 2013
Hall 16, Stand A57
Oct. 16 – 23: Düsseldorf, Germany
CONTENTS
Pioneering:
The RED.LINE system on the test stand ..........3
Innovation details:
RED.TOOLING – examined carefully ................4
Development force: The benefits of
the new haul-off combination, RED.COM ........5
Michael Schleiss
Martin Etzlstorfer
FX-LINE: The energy-saving,
next-generation extrusion downstream ...........6
Centralized expertise: Successful integration
of Gruber into Greiner .....................................7
Used machinery: The independent
extrusion platform, Extrudia ............................7

THE PROFILERS | April 2013 3
The future of extrusion has started!
Two years ago, Greiner Extrusion set out to completely change the
future of profile extrusion. A great number of project details were worked
out and a lot of prototype testing was necessary before development of
the complex tooling and machinery system was completed.
RED.LINE system – on the road to success
Performing a continuous run, our partner in terms of
first-run batches, Schüco, put the new RED.LINE system
through its paces. The question to be answered by
Schüco was: Does the RED.LINE system have sufficient
potential to contribute to the future success of the company?
Schüco is a leading provider of energy-efficient building
envelopes. The company is known for global expertise
in windows, doors, facades and solar solutions. Founded
in 1951 as a metal fabrication company, Schüco is
now active as a systems supplier in 78 countries with
more than 5,000 employees and 12,000 partner companies.
Headquartered in Bielefeld, the company generated
a revenue of €2.23 billion in 2011. The company’s
international headquarters of SchücoPWS, Plastics
Division, is based in Weißenfels/Saxony-Anhalt. From
here, all processes within the Plastics Division are controlled:
raw material purchase, development, production
(in Weißenfels and in Haan/near Düsseldorf), distribution
and complete logistics. Schüco counts on innovation
in order to constantly retain a competitive edge in the
market. In addition, Schüco was also one step ahead
when it became Greiner Extrusion’s first-run partner for
the RED.LINE system (main tooling and machine).
The RED.LINE system offers significant benefits
During these testing series, both companies were very
much interested in determining the benefits and weaknesses
of the new system. After an intensive test phase,
the results were critically discussed. In the end, it was
interesting to find out the impression that was created
by the new system.
Stefan Valerius, Head of
Operations at Schüco Kunststoff-Produktionen
in Weißenfels
and Haan, described the
impact the system had upon
him, “The benefits are convincing:
A single, central plug
connection between the die and extruder prevents
confusion of connections, and in addition provides
for a clear overview. Due to the heater cage having a
central plug connection, handling is made fairly easy
and connecting errors are eliminated. Because of the
fast and extremely precise material flow control system
– flow.control – it’s possible to keep the production
weight of the profile low, saving considerable amounts
of material.”
For quite some time now, Greiner Extrusion has been
dealing with the subject of saving energy in production.
With the RED.LINE system, the company has been
successful in proving that its energy savings are both
substantial and sustainable. This was also confirmed by
Marko Betz, Head of Process Engineering at Schüco/
Weißenfels and Haan: “The new RED.LINE system with
RED.LINE and RED.TOOLING are precision tuned, and
as an optimally combined unit the system consumes
81% less vacuum energy than an existing line of the
same profile geometry. In comparison to the existing
line, get.CAL, that uses Power Tooling and consumes
23.7kW, the new RED.LINE with RED.TOOLING consumes
4.5kW while producing the same profile in the
same performance range.”
Marko Betz continued:
“In an existing unit without
a closed water circuit, water
consumption is 35m³/h,
which decreases by 17m 3 /h
with the new RED.LINE system.
This is a reduction of
approximately 52%. Since
incorporating a complete
changeover to the closed-water circuit system, the
quality of water and consequently the quality of profiles
has significantly improved.”
An essential issue for every extrusion company is the
reduction of reject units. “Using the RED.LINE system,
“The benefits of the
RED.LINE system are
impressive”
Stefan Valerius, Head of Operations at
Schüco Kunststoff-Produktionen
start-up time and therefore start-up scrap, has been
substantially reduced. In addition, during the production
process there are fewer rejects being seen in comparison
with Power Tooling; furthermore, the smooth running
of the system is recognized as a positive feature,
and the simplified design of the calibration significantly
shortens preparation time for coating,“ said Jens Martin,
Head of Toolmaking at Schüco.
“The simplified calibration
design offers another benefit:
shorter cleaning times.
The new cyclone technology
of RED.LINE in combination
with the new multi-hose is
impressive with its fairly high
vacuum smoothness in the
tooling tank, and the noise
level is very low, too,“ explained Jens Nöhring, Team
Leader of Operators at Schüco.
Greiner Extrusion is oriented toward future
The performance of the new system is impressive, indeed.
This was also confirmed by our first-run batches
partner, Schüco, and the company has decided to use
the RED.LINE system in the future. At Greiner Extrusion,
innovation and development are being realized. With the
RED.LINE system, a future-oriented standard in window
profile extrusion is being set.

4 THE PROFILERS | April 2013
to date
The benefits of the RED.TOOLING centralized plug:
So far, 14 plug connectors were required; now, with RED.TOOLING,
a single plug connector is used.
flow.control:
Significant material savings using
flow.control developed by Greiner.
keep.clean.unit:
Reduces material deposits during dry
calibration.
RED-TOOLING – Innovation details
The next-generation RED.TOOLING system is made up of
a variety of precision-tuned and complex components
proven to deliver optimum performance.
The benefits of tooling innovations
In this edition of THE PROFILERS, three individual components
are examined in depth:
centralized plug connection
low.control
keep.clean.unit
These three components also provide an additional
benefit: they can be retrofitted independently with
other existing tooling systems or with your current
RED.TOOLING system.
What are the benefits offered to an extrusion
company when using the central plug?
Dangling cables between the die and the extruders
do not comply with modern requirements in extrusion.
The centralized plug connection was developed
in cooperation with our partner, Krauss Maffei, and
the benefits are impressive. A single, centralized plug
connection between the die and extruder prevents
hazards and confusion, and in turn it provides for orderly
arrangement and a
clear overview. By using
a heater band testing
device, proper functioning
of the heating zones
can be easily and quickly
determined. As a result of
incorporating a centralized
plug, assembly and
disassembly procedures
are performed faster and
easier – it simplifies handling overall. Retrofitting on
existing extruders and dies is fairly straightforward; it
allows for rapid and incremental upgrading, thus entering
the security class.
How much material is saved when using
flow.control?
The flow.control system (material flow control) is an
in-house development by Greiner Extrusion. Firstly,
material is saved due to Co-Extrusion, and secondly,
flow.control is now the next step toward a substantial
reduction of material usage. With the development of
the flow.control system, Greiner Extrusion is setting new
standards in the control of material flow. In particular,
within seconds it allows for the precision-controlled correction
of material flow through the individual sections.
Using hot air or cold air in the smallest of quantities,
the flow in critical profile sections can be either slowed
down or accelerated. A reduction in material consumption
is achieved through the production of profiles
whose weight is kept to a minimum yet which are able
to maintain control through critical sections. In addition,
the flow.control system has the ability to compensate
for material fluctuations that occur during the course of
extruder changeover, while at the same time increasing
the production flexibility and the process window.
Example:
A wall thickness of 2.5mm (main walls) can be reduced
by 0.05mm using flow.control = 1.5% reduction in material.
How significant is the reduction of rejects when
using the keep.clean.unit?
The keep.clean.unit was also developed in-house. During
the first dry calibration process, wax-like deposits
affect the profile surface and are often the reason for
production downtime. The best remedy is prevention.
Use of the keep.clean.unit prevents the occurrence of
such material deposits. The specifically designed unit
can be retrofitted to existing toolings, preventing the
buildup of deposits during calibration.
Without KCU
With KCU
Shutdowns/annually 20 16
Production downtime intervals are reduced by 25%
when using the keep.clean.unit.
Amortization KCU ≤ ½ year
The best bet is to try it out with your extrusion company
– this provides the safest and most efficient means for
establishing your decision-making basis! During the
development of these three product solutions that were
created in-house, the issues of saving material, greater
flexibility, and easier handling were the primary considerations.
In continuation of this subject, Greiner Extrusion
will report on further benefits of RED.TOOLING in
the next edition of THE PROFILERS – i. e. dry calibration,
PDC tank, and vacuum tank. RED.TOOLING –
Highly Intricate Innovation will be continued.

THE PROFILERS | April 2013 5
RED.COM – Haul-off combination
composed of RED.PUL and of RED.CUT
RED-PUL – wide pads and tool-less pad changing
During the development of the new RED.LINE downstream
unit, significant improvements to the haul-off
combination, RED.COM, were made at the same
time. The guidance system on both sides of the
RED.PUL caterpillar unit provides for parallel alignment
of the upper and lower caterpillar. As a result,
no tension in the profiles occurs. An evenly distributed
contact force along the entire length of contact area
is exerted via the tried-and-true Greiner lever system.
The contact force can be exerted onto the profile on
demand using a contact force and counterpressure
control system. As a result, balancing processes
can be initiated to completely avoid excess loads on
the profile.
New, wide pads reduce changeover times
One of the essential benefits are the significantly
wider pads. Now for RED.PUL, the pads have double
the width in comparison to other pads currently on
the market. Using wider pads, and as a result of toolless
pad changing ability, retrofitting time is reduced
by half. An additional benefit of wider pads is the fact
that displacement
of the pads is prevented
by a high haul-off
force; therefore, pad marks on
the profile are now a thing of the past.
In addition, special pads up to 100mm high can easily
be used with the RED.PUL system without any
drawbacks. The existing Greiner pads can be pushed
over the pad bases of the RED-PUL and still further
used. If required, the caterpillar carrier can be entirely
equipped with the existing pads that had been in use.
An adjustable speed range of 0.5m-10m per minute
allows for a wide assortment of production capabilities:
from slow-running, larger profiles to fast-running,
smaller profiles; ability to perform multi-strand production;
and a maximum haul-off force of 30kN.
Right: the new, wide pads. Left: the old, narrower pads. Using wider pads, and as a result of easy and tool-less pad
changing ability, retrofitting time is reduced by half.
Benefits:
Half the time to retrofit
Tool-less pad changing
Wider pads (98mm instead of 50mm)
No pad marks
RED-CUT – improved cutter impresses with precise cutting of profiles
The focus during development was the ongoing refinement
of the cutter. The new RED.CUT unit impresses
with its excellent cutting quality that provides for the
precise cutting of profiles. The PLC-controlled length
measurement system offers 10 pre-set modes via the
touch panel, from which its variable cutting-speed
adjustment can also be controlled. Utilizing the optional
pulse generation from the measuring wheel, even
higher repetitive accuracy of the cutting length can
be achieved. The downhold cylinder can be swiveled,
which allows for a smooth and easy knife changing
process. A simplified clamping system and free access
to the cutter from the operator side make it easy to
quickly change the knife without tools.
Three convincing aspects of RED.CUT:
Fast and tool-less knife changing
PLC-controlled knife heating
Variably adjustable cutting speed
Regardless of external influences, the PLC-controlled
knife heating feature maintains constant knife temperature.
The special blade cut contributes to reduced
deformation of profiles and provides consistent cutting
quality, thus avoiding burr formation with each cut. The
use of a crank drive achieves a long life span with low
maintenance needs.
Benefits:
Improved cutting quality
Knife changing without production downtimes
PLC-controlled knife heating
Variably adjustable cutting speed
Downhold cylinder
Tool-less knife changing
Controlled knife heating

6 THE PROFILERS | April 2013
FX-LINE
A sophisticated downstream unit
offers high-level functionality at an
attractive price-performance ratio.
EFFICIENT EXTRUSION – in a performance category all of its own
Through using the tried-and-true GESS system along
with the integration of new options, the new FX-LINE
is now the state-of-the-art choice in its performance
category.
Benefits of the FX-LINE
Modular
GESS – Greiner Energy Saving System
Anti-corrosive parts that come in contact
with water
Highly-efficient and energy-saving
Compatible with existing toolings
FX-LINE Calibration table
Several features of the FX-LINE have been optimized.
All parts that come in contact with water are noncorrosive,
including the clamping frame. The parallel
height adjustment stretches along the total length of
the clamping frame. In addition, the GESS – Greiner
Energy Saving System – is integrated into the FX-LINE,
saving up to 80% in energy costs.
The vacuum pumps of the dry calibrators are connected
to each other, enabling vacuum adjustments
that make the supply of false air unnecessary. As a result,
not only is energy consumption reduced, but the
noise level is lowered as well. A relatively high-volume
cyclone tank creates a stable vacuum.
The direct recirculation of water from the dry calibrator
into the cooling water system prevents contamination.
The ergonomic control panel is mounted onto a swivel
boom, making for easy adjustment to achieve optimum
operating position.
The base frame is
powder-coated and
the unbreakable, soundabsorbing
covers are made of
durable, colored ABS plastic.
FX-LINE Haul-off combination
The tried-and-trusted haul-off is equipped with
two motors and a regulator drive system. It is designed
for the production of a variety of profiles. The
haul-off force is designated to 16kN and therefore
perfectly meets the requirements of profile production.
A self-actuating skid-control system prevents
displacement of profiles under increased haul-off
force. Pad width is 140mm. Precision adjustment
options for the contact force and counterpressure
control system regulate the contact force exerted on
Cutter Control panel – Haul-off and cutter Pads Haul-off
Option: Filter system with by-pass Touch panel Swing door
GESS – Greiner Energy Saving System

THE PROFILERS | April 2013 7
Next steps
Successful integration of Gruber into Greiner
Centralized expertise – new growth markets
The last edition of The Profilers was about
the reorganization of Greiner Tool.Tec. Its
expertise in profile production has been consolidated
into two divisions – Window Profiles
and Technical Profiles. In the business area
of window profiles, Greiner Extrusion took
over the product brand, Gruber. Previously
called Gruber Extrusion, it has been renamed
Greiner Tech Profile and it focuses on technical
profiles (cable ducts, roof gutters, etc.)
and growth markets such as wood composites,
for instance.
benefits in terms of supporting existing Gruber
Extrusion window profile customers (operating
Gruber tooling systems and downstreams).
With employee experience covering both
product brands, Gruber and Greiner, customers
benefit from the fact that the knowledge
and expertise of the two brands have been
united within a single corporation. Thus, appropriate
product solutions in regards to tooling
and downstreams can be provided completely
in line with customer requirements.
The Greiner Extrusion FX-LINE provides for high-performance
and energy-saving profile extrusion at an unmatched
price.
As of January 2013, a part of the Gruber Extrusion
workforce was integrated into Greiner
Extrusion. The integration of Gruber Extrusion’s
employees from Pettenbach involved all
departments – Toolmaking, Construction, and
Product Management – to ensure the retention
of the product know-how of Gruber tooling
systems and downstreams.
In the Purchasing Department, too, Gruber
Extrusion employees were retained by Greiner
Extrusion in order to maintain the continuity
of customer service. This, in particular, offers
the profile. Due to improved profile in-feed, the profile
is taken directly to the front of the caterpillar carrier,
thus making for an easier starting process. Large
swivel doors allow improved access for effortless
maintenance and operation.
FX-LINE Cutter
The FX-LINE cutter and the FX-LINE saw are
equipped with an easy-to-operate length measurement
system equipped with pre-set modes for cutting
lengths. Two different cutting speeds can be selected
when operating the cutter, and the knife is heated to
prevent deformation of the profile during cutting. Due
to reduced resistance on the knife during the cutting
process, burr formation is greatly reduced. The
knife’s unique blade cut contributes to less deformation
occurrence. Clamping is made simple, and easy
accessibility facilitates the time-saving changeout
of knives. The clamping force of the downhold cyclinders
is adjustable via the control panel and can
be adapted to the specific requirements necessary
on a per-job basis.
FX-LINE Saw
The saw design is similar to an underfloor saw. A
high-performance saw motor drives the DM400mm
saw blade (optionally up to DM500). The cutting
stroke is actuated by pneumatic cylinders, and their
speed is adjusted from the control panel. There is
a wide variety of saw blades available for optimum
improved cutting quality on complex profiles. An integrated
suction unit for fragment removal offers an
additional performance benefit.
Used machinery
on the Extrudia platform
Worldwide database of used machinery
Knowledge-exchange in regards to profile extrusion
is the priority on the independent and
cost-free platform, Extrudia.
In cooperation with inter-branch partners, an
internet platform concerning profile extrusion
was created, from which foremost the extruders
themselves will benefit. In addition to a
knowledge database, forums and recent news
from the branch, the Extrudia portal maintains
a worldwide database of available used profile
extrusion machinery – and it is accessible for
free. The range of used machines listed includes
extruders and toolings. Extrudia brings
together offers of – and requests for – used
extrusion equipment.
Visit us today at:
www.extrudia.com

PARTNERS FOR
SUCCESS.
Owner/Publisher: Greiner Extrusion GmbH, Responsible for content:
Greiner Extrusion GmbH, Friedrich-Schiedel-Straße 1, 4542 Nußbach, Austria,
www.greiner-extrusion.com, Headquarters at Kremsmünster, District court of Steyr, Austrian
Chamber of Commerce Number FN 285487 i, UID ATU 62967347, Design: COMO GmbH,
Photos: Greiner Extrusion, www.fotolia.com, Printer: Friedrich VDV, Total circulation:
900 copies, Subject to alterations, errors and misprints.