NWUD SERIES

Perhaps the most versatile film laminating system

Like the vast majority of laminating companies, you are probably faced with the challenge of having to process a wide range of different profile geometries. Several different profile types are required for the production of a single PVC or aluminium window alone. In addition, there are several window systems with different profile sizes, different coloured PVC profiles and, finally, an almost infinite number of decors and foils that are laminated on one or both sides. In the various combinations, the possibilities multiply ad infinitum and you are wondering how to cope with this variety?
Fortunately, there are versatile laminating systems, such as the NWUD series, which can make your work much easier. You can have them customised to your exact requirements so that nothing is left to be desired.

Double-sided foil lamination
The NWUD system series has the special feature that the decorative films are applied to the profile from two sides simultaneously. To achieve this, it is equipped with two complete laminating systems on one and the same machine bench. Firstly, the film is applied to the top side, as with all other laminating machines. However, a second system with a slot die and film holders is integrated in the belly of the machine so that the continuous profile can also be laminated from below at the same time. This means that all double-sided laminated profiles can be laminated in a single pass without any additional retooling. Depending on requirements, it is also possible to laminate only from above or only from below, which characterises the versatility of this machine series. Profile lamination on both sides is also particularly suitable for the efficient production of two-colour windows (bicolour). Profiles that are fully wrapped (360°) can also be processed more easily with film application on both sides. No matter what challenge you are facing, a double-sided wrapping system offers you all the possibilities.

Customise your system according to your requirements
Every company, including yours, offers a specific product portfolio that sets it apart from its competitors. This should also be reflected in the configuration of your laminating systems. An ‘off-the-shelf’ system will not support you with your very specific requirements and will not give you any advantages in production. Therefore, take the time to discuss your requirements with the experts at WPR to ensure that you achieve your goals with your system.

Let’s take a look at a few important aspects together:

Materials
The NWUD double-sided laminating system can process a wide variety of materials, depending on the design and equipment. This system is most frequently used for the film lamination of PVC and aluminium profiles, usually for window profiles, windowsills, sliding doors or conservatories. With the appropriate surface pre-treatment, other plastics such as ABS, polystyrene or polypropylene as well as glass fibre profiles can also be laminated.
In the version for the furniture industry, the NWUD can also process real wood and wood-based materials such as MDF, for example for door frames, drawers and furniture elements. Which materials do you process?

Profile and panel sizes
An NWUD profile wrapping machine can foil almost any shape of profile. From small profiles such as glazing beads, mullions, as well as decorative and skirting boards, to window profiles, door frames, sliding doors, facade panels, and large-format sheets and panels, such as windowsills, door skins, or even floors. WPR manufactures the special slot nozzles for applying PUR hot melt adhesive in various sizes, so you can cover the widest possible range of sizes.

Working speed
Are you looking for a machine that can laminate large production volumes in the shortest possible time? Then ask us about a high-speed, high-performance machine that meets or even exceeds your working speeds. We ensure that the machine is designed for the required line speed. The length of the machine frame must be appropriately dimensioned, as must a sufficiently long primer application and drying zone. Otherwise, at high working speeds, you risk producing a lot of waste. There is a suitable machine for every requirement. You wouldn’t take a family car to a race track, would you?

Optimized setup
Due to the variety of profile, colour, and foil combinations, you need to set up your profile wrapping machines in the lamination department very often. This takes up valuable time during which the machine is not producing. If you want to reduce these downtimes, we offer a variety of technical features that you can integrate into your system. Particularly popular are pre-assembled setup cassettes that can be quickly exchanged, movable machine shoulders that can switch between different profile widths in seconds, and transport wheels with quick adjustment as well as profile guides at the machine infeed and outlet. How much time do you usually need for a complete profile change?

Foil change
As mentioned earlier, the NWUD allows for multi-colour lamination of profiles in a single pass. If you process particularly many films, it is advisable to integrate several foil holders so that you can switch between colours without stopping the machine. The most advanced solution is an automatic foil changer that allows you to change foils during operation at full working speed and without profile wastage. This way, you can process all orders of a profile in all colour variants in one production batch and from both sides of the profile without additional setups. Efficiency doesn’t get much better than this.

Configurable to your needs
As you can see, the NWUD machine series offers all possibilities for your specific lamination requirements. The modular configuration of the system with many technical options helps you design a lamination system that supports you in your strengths and weaknesses. Besides the possibilities, the system configuration also extends beyond the lamination process itself. Optionally, you can also integrate an automatic foil cutter at the outfeed of the system, which cuts the foils between the profile bars on both sides even at high speeds. Especially for high-performance systems, it is advisable to consider semi-automatic loading and unloading systems, as operators reach their limits at high working speeds.
It is important to discuss your ideas and wishes with our experts from WPR. They will be happy to provide you with competent and non-binding advice to ensure that your new double-sided lamination machine meets your expectations.

Is double-sided lamination more difficult than single-sided lamination?
The lamination process with all its parameters is exactly the same, but you need to pay attention to a few points when foiling the underside of the profile. You might wonder if the primer application with felts also works on the underside of the profile. Sure, with the right setup, the felt application works from below as well, but the application control is a bit more difficult. Usually, mirrors or webcams help to make primer control under UV light possible from below.

Can the primed profile underside travel over the transport wheels of the system? No, that is not recommended, as it could impair the profile priming. Therefore, the transport wheels are removed in the primer application and drying zone, and the profile is supported by lateral profile guides.

Is setting up and laminating from below more complicated? Of course, laminating from below is more complex and harder to see. Therefore, lamination companies usually run the simpler profile side below and the more complex profile side above. Especially with PVC or aluminum window profiles, there is usually a flat side that is suitable as the underside. Alternatively, you might want to look at our NWD series, where the profiles are laminated laterally from the side.

When should you choose a machine from the NWUD series?
If one of the points mentioned above has piqued your interest, you are already on the right track. There are generally two types of customers who decide to purchase an NWUD.

Firstly, there are lamination companies with few wrapping lines, maybe even looking for their first system. They need a versatile double-sided lamination machine to cover the widest possible range of profiles and foils with a single machine. They particularly benefit from the various design options and features to run the majority of their product portfolio on one profile wrapping line.

On the other hand, there are customers looking for a high-performance lamination machine with maximum production output. They usually have many double-sided foiled profiles in their program and, thanks to the NWUD, can produce these profiles in large quantities in a short time. These systems are usually designed for maximum speed, so large orders or inventories of standard profiles can be processed quickly and efficiently.

Double-sided lamination from above and below is also particularly suitable for inline lamination. Here, the lamination system is directly integrated into the extrusion line of the PVC profiles.
What are your challenges? Write to us using the contact form below, and we will get back to you shortly to discuss your ideas. We look forward to hearing from you!