PREZ-MET PVC and aluminium window production line

PREZ-MET PVC and aluminium window production line is a state-of-the-art and comprehensive solution for the mass production of windows. The system enables complete machining of PVC and aluminium profiles within a single working cycle. The production includes all key stages – from precise profile cutting, through milling, drilling, welding to final cleaning of the elements.

The PREZ MET window production center is made up of three smaller integrated production lines – one line for the production of window frames and two lines for the production of window sashes. They consist of machines from renowned manufacturers from 2005-2016:
– ROTOX ZSA 263 cutting center
– PREZ-MET FS 50 end milling machine
– PREZ-MET 42 MP copy milling machine
– PREZ-MET ZGP 420 four-head welding machine (3 pcs)
– PREZ-MET ZGP 380E two-head welding machine (2 pcs)
– PREZ-MET ZG 940 single-head welding machine
– PREZ-MET COP 320/960 window sash machining center (2 pcs)
– PREZ-MET COP 420/960 window frame machining center
– PREZ-MET 460 S water slot milling machine
– PREZ-MET 960 C corner cleaning machine (2 pcs)
– PREZ-MET 960 CNC corner cleaning machine
– PREZ-MET 220 PA glazing bead saw
– BOMAR STG 230 DG band saw

Windows are made from quality PVC or aluminium profiles, which are characterised by high weather resistance and long-term durability. The first stage of production involves accurately cutting the profiles to the correct size with the ROTOX ZSA 263 cutting center. The machine is equipped with a cutting disc with a diameter of 550 mm, capable of cutting at angles of 45°, 90° and 135°. Inside the workspace, there are pneumatic clamps that guarantee a secure hold on the profile during machining. The entire process is performed fully automatically, with all parameters set via an intuitive control panel.

Glazing beads, i.e. finishing elements of the window sash that are responsible for the stable fitting of the glass in the window sash, are also cut. For this task, the powerful PREZ-MET 220 PA saw is used, which enables two PVC glazing beads to be cut at a 45° angle at the same time. The machine works in automatic mode and is operated via a control panel. Thanks to the use of additional cutting discs, it is also possible to undercut the clip nose, which significantly improves the subsequent installation of glazing beads. As steel components are also used in the window production process, the PVC window production line is also equipped with a BOMAR STG 230 DG band saw.

Once the profiles have been cut to size, all the necessary slots (for decompression, water drainage, handle and mullion connector) are made in the profiles, as well as milling the ends of the window mullions. Despite their inconspicuous appearance, the water drainage holes in the PVC window frame play a very important role. They are responsible for air exchange and also prevent condensation on the surface of the windows. The decompression slots, on the other hand, help with ventilation inside the profiles, reducing the potential risk of distortion and deformation due to high temperatures during the summer season.

PREZ-MET window production line is equipped with as many as three machining centres for making slots – one for window frames and two for window sashes. Each of the machines features components of renowned brands and units designed for specific operations. They are operated from an advanced BECKHOFF-branded control system, which offers intuitive operation and access to many advanced functions.

An important structural element of each window is the window mullion, dividing the window area into smaller sashes. To ensure a perfect fit of the mullion to the frame or sash, its ends are subjected to precise milling. For this task, the reliable PREZ-MET FS 50 end milling machine is used, which enables the mullion to be machined at angles of 45°-90°-45°. The machine also features a quick-change cutter system and pneumatic vertical and horizontal clamps, which ensure stable clamping of the workpieces during machining.

The PREZ-MET 42 MP copy milling machine works together with the end milling machine. The machine is used for copying and milling shapes based on a template or drawing on the copying table. Such a solution increases machining accuracy, speeds up production and enables more efficient use of material.

The profiles prepared in this way are then joined into a coherent whole using specialised welding machines selected depending on the type of window being produced. In the case of standard rectangular and square constructions, ZGP 420 four-head welding machines are used. For the production of non-standard shapes, such as round windows, a ZG 940 single-head welding machine is used. PREZ-MET line also includes two ZGP 380E double-head welding machines.

The welding process involves heating the profiles to a suitable temperature, which makes them soft and ductile. When welding, pressure and heat are applied evenly, ensuring a solid and uniform joint. The welding parameters can be set individually using the control panel. It is equipped with a temperature regulator and function buttons that allow convenient control of the entire process.

The final stage in the production of windows is cleaning the surface in order to achieve a perfect smoothness and aesthetic finish. It also removes flashings, i.e. excess material flowing out during the welding process. This task is performed by 4-axis, numerically controlled PREZ-MET 960 C and PREZ-MET 960 CNC corner cleaning machines. Each machine is equipped with a state-of-the-art control panel with software enabling the setting of operating parameters, process monitoring and error diagnostics. The operator has a constant overview of the cleaning process and access to all machine functions via an intuitive interface.

Technical specifications of the PREZ-MET aluminium and PVC window production line

ROTOX ZSA 263 profile cutting machine

• year of manufacture: 2006
• cutting angle: 45°; 90°; 135°
• cutting disc diameter: 550 mm
• cutting disc rotational speed: 2800 rpm
• hydropneumatic cutting disc feed
• profile feeding using NC axis
• profile transport either from the right or left
• pneumatic horizontal and vertical profile clamping
• working pressure: 7-8 bar
• power supply: 400 V; 50 Hz
• weight of the machine: 5200 kg

PREZ-MET FS 50 end milling machine

• year of manufacture: 2008
• milling angle: 45°-90°-45°
• maximum spindle horizontal stroke: 300 mm
• maximum cutter diameter: Ø 200 mm
• cutter collet Ø 32 mm
• four-position profile stop
• pneumatic horizontal hold-down Ø 50 mm
• vertical pneumatic hold-down Ø 40 mm
• quick-change cutter system
• quick and easy milling angle adjustment
• air filter and reducer
• workspace protection cover
• working pressure: 6-8 bar
• power: 1.1 kW
• power supply: 230 V
• weight of the machine: 160 kg

PREZ-MET 42 MP copy milling machine

• year of manufacture: 2005
• copying unit (1 pc)
• independent right and left carriage (2 pcs)
• drill with pilot (3 pcs)
• pneumatic hold-downs
• collet Ø 8 mm
• filter and pressure reducer
• sprinkler of the cutter
• compressed air gun
• working pressure: 6-8 bar
• power: 1.4 kW
• power supply: 400 V; 50 Hz
• weight of the machine: 190 kg

PREZ-MET ZGP 420 four-head welding machine for window frames

• number of machines: 3
• year of manufacture: 2008, 2008, 2011
• control system
• maximum welding dimensions: 2200×2650 mm, 2650×2650 mm, 3100×3300 mm
• minimum welding dimensions: 460×480 mm
• maximum profile dimensions (W x H): 170 x 40 mm
• number of heads: 4
• head drive: toothed gear
• individual head adjustment in X axis
• head positioning with manual insertion mode
• automatic cut profile length correction system
• measurement of welded profiles directly from the measuring bar
• automatic discharge system of welded workpieces
• electronic mirror temperature adjustment with read-out capability
• quick-change system for guides and foils
• ability to vary the operating pressure during the melting and profile welding phases

PREZ-MET ZGP 380E two-head welding machine for window frames

• number of machines: 2
• year of manufacture: 2005, 2005
• PLC controller with LCD display
• number of heads: 2 (fixed and movable)
• welding angle (fixed head): 90°
• welding angle (movable head): 30°-180°
• welding flashing control: 0,2-2 mm
• heated tabletop (4 pcs.)
• profile support arms
• working cycle: automatic
• working pressure: 6-8 bar
• power: 3 kW
• power supply: 400 V; 50 Hz
• weight of machine: 680 kg

PREZ-MET ZG 940 single-head welding machine for window frames

• year of manufacture: 2016
• PLC controller
• welding angle: 30°-180°
• maximum profile dimensions (W x H): 160 x 200 mm
• welding flashing control: 0,2-2 mm
• heating mirror dimensions (W x H): 350 x 300 mm
• heated tabletop (4 pcs)
• pneumatic hold-downs
• profile support arms
• working cycle: automatic
• working pressure: 6-8 bar
• power: 2 kW
• power supply: 400 V; 50 Hz
• weight of the machine: 250 kg

PREZ-MET COP 320/960 window sash machining center

• number of machines: 2
• year of manufacture: 2011, 2011
• control system: BECKHOFF
• maximum machining dimensions: 2650×2650 mm
• minimum machining dimensions: 440×440 mm
• maximum profile dimensions (W x H): 130 x 100 mm
• unit for drilling holes for hinges (2 pcs.)
• unit for water drainage
• unit for venting
• unit for box hole drilling
• unit for drilling holes for a handle
• unit for window mullion drilling
• possibility of simultaneous machining of two profiles
• clamping and locking of welded parts
• servomotor: BECKHOFF (6 pcs.)
• working pressure: 6-8 bar
• power: 15 kW
• power supply: 400 V; 50 Hz
• weight of machine: 2550 kg

PREZ-MET COP 420/960 window frame machining center

• year of manufacture: 2011
• control system: BECKHOFF
• maximum machining dimensions: 2500×2500 mm
• minimum machining dimensions: 440×440 mm
• maximum profile dimensions (W x H): 140 x 100 mm
• minimum cross mullion dimensions: 370 mm
• 6-spindle unit for drilling holes for hinges
• unit for drilling the tilt hinge
• unit for water drainage (top)
• unit for water drainage (bottom)
• two-spindle unit for drilling holes for mullions
• possibility of machining on all four profiles (top, bottom, left, right)
• marking of abutments
• clamping and locking of welded parts
• transport of welded profiles towards the cleaning machine
• servo motors: BECKHOFF (11 pcs.)
• working pressure: 6-8 bar
• power: 17 kW
• power supply: 400 V; 50 Hz
• weight of the machine: 3500 kg

PREZ-MET 460 S water slot milling machine

• electro-spindles (4 pcs.)
• collet Ø 8 mm with cutters (4 pcs.)
• pneumatic hold downs
• air filter
• working cycle: automatic

PREZ-MET 960 C corner cleaning machine

• number of machines: 2
• year of manufacture: 2011, 2014
• control system: BECKHOFF
• number of axes: 4
• maximum profile dimensions (W x H): 140 x 120 mm
• minimum workpiece dimensions: 480×480 mm
• disc cutter (1 pc.)
• head of seal groove (2 pcs)
• knife for shearing the upper surface of the profile
• knife for shearing the lower surface of the profile
• knife for shearing slanted and curved surfaces
• knife for shearing oval and curved surfaces
• automatic corner centering
• profile supports
• automatic chip evacuation from workspace
• servomotor: BECKHOFF (4 pcs.)
• working pressure: 6-8 bar
• power: 12 kW
• power supply: 400 V; 50 Hz
• weight of the machine: 1800 kg

PREZ-MET 960 CNC corner cleaning machine

• year of manufacture: 2008
• control system: BECKHOFF
• number of axes: 4
• maximum profile dimensions (W x H): 140 x 120 mm
• minimum workpiece dimensions: 480×480 mm
• disc cutter (1 pc.)
• head of seal groove (2 pcs)
• knife for shearing the upper surface of the profile
• knife for shearing the lower surface of the profile
• knife for shearing slanted and curved surfaces
• knife for shearing oval and curved surfaces
• automatic corner centering
• profile supports
• automatic chip evacuation from workspace
• servomotor: BECKHOFF (4 pcs.)
• working pressure: 6-8 bar
• power: 12 kW
• power supply: 400 V; 50 Hz
• weight of the machine: 1800 kg

PREZ-MET 220 PA glazing bead saw

• control system
• cutting angle: -45°/+45°
• automatic blocking of 45°, 90°, 45° angles
• cutting disc Ø 220 mm (2 pcs.)
• undercutting disc Ø 95 mm (2 pcs.)
• automatic, pneumatically controlled feed of cutting discs
• pneumatic horizontal and bottom hold-downs with position adjustment
• chip extraction with separator
• electric motor 0.75 kW; 2800 rpm (2 pcs.)

BOMAR STG 230 DG band saw

• cutting angle: -45°/+60°
• maximum cutting diameter: 230 mm
• saw blade dimensions: 2730 x 27 x 0.9 mm

(The technical parameters given may differ slightly from reality. A verification with the actual capabilities of the offered machine is required.)