Technologies and advantages of PVC in extrusion

A versatile, high-performance and competitive material

A versatile, high-performance and competitive material for high-efficiency production

PVC extrusion (polyvinyl chloride) is one of the most established technologies in plastic processing, thanks to the material’s versatility and its ability to adapt to many industrial applications. Extruded PVC combines high mechanical performance, excellent processability and competitive costs, making it an ideal choice for the continuous production of pipes, profiles, technical components and medical applications. Bausano designs and manufactures PVC extrusion lines equipped with high-efficiency twin-screw extruders, developed to process rigid PVC (uPVC), flexible PVC, medical PVC and foam PVC with precision. Each configuration is defined according to the formulation, the rheological characteristics of the material and the performance required by the final application. Compared with other thermoplastic polymers, such as PE, PP or ABS, PVC offers an excellent balance of structural rigidity, chemical resistance, self-extinguishing behaviour and thermal and electrical insulation. These characteristics make it one of the most widely used materials in plastic extrusion processes, ensuring reliability, long service life and ease of processing. Each PVC extrusion line integrates feeding systems, gravimetric or volumetric dosing systems, extruder, extrusion head, calibration bench and cooling system. The entire process is designed to ensure high melt homogeneity, consistent surface quality and output up to 2,500 kg/h, while optimizing energy consumption. The digital control systems developed by Bausano enable continuous monitoring of the main process parameters, improving PVC extrusion stability, reducing waste and increasing production efficiency. The integration of Industrial IoT and advanced analysis tools also makes it possible to optimize plant performance throughout the entire production cycle. Bausano contributes to the transition towards a more sustainable industry by developing technologies compatible with formulations containing recycled PVC. The possibility of processing regenerated material supports the circular economy, reduces the use of virgin raw materials and improves the sustainability of the entire extrusion process.

All the advantages of PVC in industrial processes

PVC is one of the reference materials in plastic extrusion thanks to its combination of technical performance, application versatility and economic competitiveness. Its mechanical and chemical properties make it possible to produce products for the construction, medical, electrical systems and technical industry sectors, ensuring reliability even in the most demanding applications. With more than eighty years of experience in the design of PVC extrusion lines, Bausano develops customized solutions for processing rigid PVC, flexible PVC, foam PVC and formulations with recycled material. Each plant is configured to ensure production continuity, consistent product quality and maximum energy efficiency, providing a concrete contribution to customers’ sustainability and circular economy goals.

Durability
Easy to install
Cost-effectiveness
Nontoxic material
Fire resistance
Versatility

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From medical to construction, one material for multiple industrial sectors

Thanks to the exceptional flexibility of its formulations, extruded PVC is a reliable solution for highly diverse industrial applications. Bausano PVC extrusion lines are designed to process rigid PVC, flexible PVC, medical PVC and foam PVC, ensuring high product quality, process stability and production continuity in every sector.
In the medical sector, flexible PVC is used to produce tubing, bags and devices thanks to properties such as transparency, biocompatibility and resistance to sterilization processes. These characteristics make it possible to meet the high standards required by the healthcare industry, offering excellent dimensional stability even during the most complex processing operations. For construction, rigid PVC (uPVC) is one of the most widely used materials for the production of pipes, windows and doors, and technical profiles. Its high resistance to weathering, thermal and acoustic insulation, UV stability and long service life make it particularly suitable for outdoor and infrastructure applications.
In applications dedicated to flooring, decking and technical coverings, foam PVC provides lightness, mechanical stability and excellent aesthetic performance. In the electrical sector as well, PVC remains a reference material for the production of sheaths, ducts and cable coatings thanks to its self-extinguishing properties and high dielectric insulation. All PVC extrusion lines developed by Bausano are designed to ensure long-term reliability, easy maintenance and maximum adaptability to different formulations, including those containing recycled material.
Main applications of extruded PVC:

Pipes for the construction and infrastructure sector
Profiles for doors, windows and building components
Sheaths, ducts and coatings for electrical cables
Medical tubing, bags and certified flexible devices

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Customized PVC extrusion by Bausano

With Bausano E-GO Single Screw Extruders or MD Twin-screw extruders, various PVC products can be produced, and different types of additives are used depending on the product:

Fillers, usually mineral particles that can have the dual function of improving certain properties and making PVC more economically competitive.
Plasticizers, where flexibility is desired in the final product
Stabilizers, to prevent and counteract ageing and thermal degradation of the product
Lubricants, to facilitate processing.
Pigments, to give the desired color to the final product.

Thanks to gravimetric and volumetric dosing systems, Bausano lines ensure precise and constant feeding of additives and raw materials. Accurate formulation control improves finished product quality, reduces waste and maintains high performance throughout the entire PVC extrusion process.

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Extrusion plants designed for the material lifecycle

Bausano supports its industrial partners in the transition towards more circular production models through PVC extrusion lines also designed for processing regenerated materials. Technologies dedicated to mechanical recycling make it possible to process recycled PVC while maintaining high quality performance. Compared with other thermoplastic materials, PVC retains good chemical stability even after several processing cycles, making it particularly suitable for controlled material reintroduction processes and circular economy principles. Dedicated Bausano lines include MD series twin-screw extruders for processing rigid PVC (uPVC), compounds and technical formulations, E-GO single-screw extruders for producing pipes and other PVC products, as well as customized configurations for flexible PVC, medical PVC and foam PVC, with advanced management of rheological parameters. Thanks to dosing systems, digital control and the Sphera platform with Industrial IoT, each PVC extrusion line ensures continuous process control, waste reduction, greater energy efficiency and consistent quality of the extruded product. Compared with other polymers used in plastic extrusion, PVC continues to stand out for its balance between technical performance, durability, insulating properties and recyclability. This makes it an ideal solution for the production of PVC pipes, profiles, technical components, electrical and medical applications. All Bausano PVC extrusion lines comply with ISO 9001 standards and CE marking, guaranteeing quality, reliability and regulatory compliance. Since 1946, Bausano has developed complete PVC extrusion solutions that are scalable and designed to meet the evolving production needs of the market.

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Examples of Custom PVC Extrusion Applications

Construction sector: Pipes

From drinking water transport to drainage systems, irrigation networks and fire protection systems, PVC pipes are a widely established solution in modern infrastructure. This widespread use is linked to a combination of technical factors that are difficult to match with other materials, including operational reliability, long service life, cost efficiency and environmental sustainability. From a performance perspective, PVC pipes show a significantly lower failure rate compared with many polymeric and traditional alternatives, ensuring service continuity even under demanding operating conditions. In addition, when considering the total cost of ownership, PVC remains one of the most competitive solutions: not only because of the material cost, but also in terms of installation, maintenance and dismantling. These advantages are combined with the material’s strong environmental performance and recyclability, strengthening its role within production models oriented towards the circular economy.
To meet the production needs of this sector, Bausano offers a complete range of plastic extruders dedicated to the production of PVC pipes, designed to ensure process stability, consistent melt quality and dimensional accuracy even on large diameters. Among these, the MD 170 counter-rotating twin-screw extruder represents a high-performance solution for pipe applications, enabling the production of PVC pipes up to 1200 mm in diameter, with high reliability, process control and optimized productivity.

Examples of Custom PVC Extrusion Applications

Building sector: Windows

PVC is widely used in the production of profiles for windows and doors, cladding, flooring and wall coverings thanks to its high resistance to weathering, low thermal conductivity and no need for painting or protective treatments. Compared with other plastic or metal materials, PVC profiles provide an excellent balance between thermal and acoustic insulation, durability and energy cost reduction. In particular, PVC windows offer strong energy-saving potential thanks to their excellent thermal transmittance values, helping reduce heating and cooling costs. In addition, PVC profiles are more cost-effective than aluminium profiles, offering benefits for both suppliers and end users. Formulations based on rigid PVC (uPVC) make it possible to produce frames with high structural resistance and long-term dimensional stability, even under adverse climate conditions. To meet these application requirements, Bausano offers different plant configurations for rigid PVC profiles, including the MD parallel twin-screw extruder and the E-ON conical series. Both solutions ensure high melt quality, precise profile geometry and production stability, even with formulations containing recycled material or mineral fillers. In particular, the MD 75 model is ideal for complex profiles and high productivity, while the E-ON series, with capacity up to 300 kg/h, represents an effective alternative for compact, high-efficiency lines.

Examples of Custom PVC Extrusion Applications

Building sector: Flooring and decking

Bausano extrusion plants for rigid PVC and foam PVC are designed for the production of indoor and outdoor flooring and coverings, used in environments requiring hygiene, durability and safety, such as hospitals, sports facilities, hospitality structures, industrial kitchens and high-traffic public spaces. Thanks to their waterproof, fire-resistant and anti-slip properties, PVC flooring ensures high functional reliability even in demanding conditions. PVC decking, often produced with expanded formulations (foam PVC), represents a modern, lightweight and resistant solution for outdoor use, offering excellent resistance to weathering, UV rays and temperature variations. Plastic extrusion also allows maximum aesthetic customization, with a wide range of colours, textures and surface finishes. For PVC wall coverings as well, Bausano lines ensure high dimensional quality and melt homogeneity, which are essential for applications on large and complex surfaces. These materials are also ideal for renovation projects, thanks to their lightness, ease of installation and ability to improve the thermal insulation of existing structures.

Examples of Custom PVC Extrusion Applications

Building sector: Electrical cables

PVC for electrical applications stands out for its excellent dielectric insulation properties, making it the ideal choice for the production of electrical cables, protective sheaths and cable ducts. As a non-conductive material, PVC provides a safe and effective barrier against electrical leakage, ensuring protection even in critical environments. Specific PVC formulations for the electrical sector provide thermal resistance and self-extinguishing behaviour, preventing flame propagation while maintaining flexibility even at extreme temperatures. These characteristics make PVC cables particularly suitable for telecommunication systems, civil and industrial installations, as well as technical coverings for electrical panels and electronic components. In addition to performance, PVC is a safe and sustainable choice. It is non-toxic, compliant with the main international regulations on health, safety and the environment, and can be recycled at end of life while maintaining a low environmental footprint. Bausano plastic extrusion lines are configured to process PVC cable compounds efficiently, ensuring melt homogeneity, dimensional stability and production continuity.

Examples of Custom PVC Extrusion Applications

Healthcare sector: Medical tubing and bags

In the medical sector, PVC has become a reference material for the production of pre-sterilized single-use devices thanks to its unique combination of safety, flexibility and chemical resistance. It is used in approximately 40% of plastic devices used in hospitals, including infusion bags, tubing, masks and gloves. Its ease of processing also makes it suitable for architectural applications such as wall coverings and indoor flooring in controlled-contamination environments. For the production of medical fluid transport systems, Bausano lines with MD series twin-screw extruders offer maximum control over the melt profile and product quality, even with flexible formulations. To obtain the elasticity required by many applications, certified plasticizers are added to PVC, compliant with European Pharmacopoeia specifications and subject to strict pre- and post-market controls. An additional advantage is its versatility in sterilization methods: medical PVC can be safely treated with steam, ethylene oxide (EtO) and gamma or beta radiation, while maintaining its mechanical performance and biological compatibility. This reliability makes it the preferred choice in contexts requiring high hygiene standards, traceability and regulatory compliance.

PVC does not have just one formulation. That is why Bausano lines are designed to adapt with maximum precision.

A starting point to define the right solution together

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