Highly Efficient Profile Extrusion Facilities
OMNIA’s new gearbox is space-saving. Its 98% rate of operating efficiency sets a new standard. The resulting saving of energy – amounting to more than 50% - joins with the calibrating table in enabling the achieving of the highest degree of operating efficiency.
The gearbox of the OMNIA extruder is mounted vertically, enabling the placement of the motor underneath it. This permits the profile extrusion line to be situated in an especially space-saving way in the profile manufacturing facility. This especially lean method of assembly allows, to provide an example, two OMNIA XTP 87 extruders engaged in the manufacturing of two window profiles to be placed nearly parallel to each other, with a center distance of only 500 mm. Another option is the mounting of the electronic control box on the left or the right of the frame. This provides customers with great flexibility of set ups.
Perfected: the Theysohn torque master gearbox
The proven torque master gearbox has been further developed and optimized. Thanks to a patented innovation, the new unit achieves a 98% rate of utilization. This results in significant savings of energy as compared to the current and horizontally-arrayed Theysohn torque master gearbox. The high factors of application shown by the torque master gearbox and the patented helical gearing of both screw drive shafts guarantee the gear components of having extremely long service lives. The screws’ evenness of torsion minimizes their abrasion.
Energy efficiency
Energy reduction is achieved by
- the newly-developed gearbox, which has a 98% rate of utilization
- axial flow fans used in cooling barrels (positive side effect: reduction of noise)
- insulating heating bands incorporated into the barrels’ heating systems
- no longer any need to cool water thanks to the placement of a newly-developed, thermically-insulated cooling flange on the barrel
- exclusively employed in OMNIA extruders are AC drives, dispensing with the need for maintenance-intensive carbon brushes and the incurrence of blind current. This results in a reduction of energy consumption.
- an innovative vacuum concept supplying the calibrating table with the precise amount of vacuum needed at the moment. Water pumps ensure the provision of water currently needed. The frequency-regulated vacuum pumps join with the controlled water pumps in giving rise to savings of more than 50% in energy and costs.
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