Processes

At the heart of our product is extrusion, a process from which we get a cylindrical profile in technopolymer that constitutes our core business. From this profile then derives every other process of rework to cut it of the desired length, assemble it in bundles, thermoform it, strengthen it with textile braid, incur it and possibly regenerate it for re-entry into the production cycle.
Each product in Mebra comes from the design or research and development department that works closely with the customer for the development of the most suitable solutions to meet the needs of a dynamic market.

Extrusion and co-extrusion

All plastic processes made by Mebra Plastik Italia S.p.a. have in common a production phase called extrusion.
Extrusion is an industrial production process of plastic deformation that allows to produce pieces in constant section, which in our case translates into the process by which fusion-led thermoplastic materials are pressed continuously through matrices to create a profile that in most cases is cylindrical in shape.
Our extrusion lines are equipped with innovative and cutting-edge technologies and allow us to create single-layer, multi-layer and co-extruded tubes. In this way, the use of raw materials of excellent quality, is enriched by the possibility of combining them taking advantage of their peculiar advantages and satisfying every type of need for each type of application at medium-low pressure.
Among our special extrusions are cover rework with single tube sheaths or pipe assemblies, the production of calibrated coaxial tubes, the production of non-cylindrical profiles.

Discover more product services and customizations

estrusore coestrusione macchina lavorazione materiale plastico

Bespoke cutting

In addition to the realization of standard rolls, spools and coils, according to the customer's needs we make both custom-made matasses and custom-made straight bars cut to very low tolerances. The bars can then be cut either standard 90° contact or cut on one or both sides at 45°. On request we can then cyanide the tube to make catchers.

Produzione di tubi a barre di varie dimensioni tramite processo di tagliatura

Heat sealing

Heat sealing is a delicate process for which, pipes of materials that lend themselves to this type of processing, are welded together in the number and configuration established by the customer. What makes this solution extremely interesting is the reversibility of the process. The pipes welded together, in fact, can still be separated and used with push-in fittings, without welding residues causing leakage. Over the years Mebra has refined the technique of heat-welding by developing internally machinery that allows us to produce high quality heat-sealed pipes.

Configurazioni tubi e multitubi termosaldati di Mebra Plastik

Braiding

In order to increase the pressure seal or the protection of the underlying pipe, a tube can be coated by special braiders from a mesh made around it. In most cases, a second step is provided in an extrudor that completes the top layer. If the braid has been made in a wide mesh, the sublayer in contact with the upper layer welds and the product can only be used as a single tube. In the event that the braid is dense meshed or in the event that the upper layer is extruded with a material that has a melting temperature much lower than that of the sublayer, the two layers remain separate and it is possible to unseath the product.

Thermoforming

The thermoforming process exploits the ability of thermoplastic materials to "memorize" the shape imprinted when exposed to heat. Some materials have a better "memory" than others and for this reason Mebra has selected the best performing polymers of each family for the realization of our standard spirals. On request, however, we are able to produce spirals to design with any material of our workmanship.
The production of spirals is accompanied by a solid and consolidated production of parts on design. We are able to three-dimensionally model our tubes even exceeding the flexibility limits of the product used, through the use of techniques learned in years of experience. With our process technology and know-how, development quickly moves from prototypes, series 0 to mass production.

Stringing

Added value to our inguainate multi-tube products, since 2016 we have been using a special machine to combine three or more pipes and twist them. This device is widely used in the cable world to improve the flexibility of products that would otherwise be difficult to manage. So even for us and the roped products can therefore be allowed bending radii far narrower than the same un roped article, especially when the number of tubes in the whole becomes important.
The standard stringed product series is accompanied by the possibility of a completely custom configuration, not only combining pipes of different material, but also of different diameter and color and leaving the possibility to add electrical cables as well. The limit in the number of pipes to be combined has not yet been reached and the current record stands at 34 tubes collected in a single beam.
The tube beam contained by a transparent film is then coated with a protective sheath that depending on the type of application can be standard in ether PU, PE or PVC (on request also in other materials, even antistatic or self-extinguishing). In addition to maintaining the assembly, the sheath, depending on the material, can protect against atmospheric agents, abrasion, chemical agents, aggressive environmental elements (sparks, welding slag, oils, creeping currents, ...) as well as to ensure more or less flexibility.