PVC window production modernized at Eibel – New RAPID profile processing center in Malschwitz, Saxony

Eibel GmbH has modernized its PVC window production facility in Malschwitz, Saxony.
Herbert Eibel and Fabian Giefer are utilizing a modular design and fully automated precision technology from Rapid. Several production steps run in parallel, allowing individual modules to achieve maximum output and boost efficiency.

Combining the expertise of two long-established companies

In 1959, Karl Eibel passed his master craftsman examination in pattern making. Two years later, he took the step of becoming self-employed, thereby laying the foundation for the family business. Today, Eibel GmbH employs around 100 people and manufactures uPVC and aluminum windows and entrance doors at its facility in Malschwitz, near Bautzen.

The Eibel company embraced automation in PVC window manufacturing at an early stage and has firmly cemented the trust of both private customers and long-standing trade partners through the production of high-quality, innovative products.

Thanks to a high-performance machinery lineup, the company manufactures windows, doors, and sliding units in various installation depths and with a wide range of opening options and practical convenience features. For over 20 years, Eibel has relied on production systems from RAPID Maschinenbau, a company with a history spanning more than 90 years.

A new Rapid Ultratech processing line was commissioned in April 2024. The state-of-the-art machines from this long-established Swabian company handle profile cutting, all milling and drilling operations, and the screwdriving of reinforcements, thereby setting the pace for the entire production process. High process reliability is ensured by the robust construction of the Rapid precision machines and the use of advanced drive technology.

The specialist for high-quality windows and doors

Using the new production line, the window and door specialist processes the latest GEALAN-KONTUR® and GEALAN-LINEAR® profile systems, combining them with innovative elements from the versatile GEALAN S 9000 system platform. With an installation depth of 83 mm, the system is ideally suited for both new builds and renovations, offering a wide range of design possibilities.

Fabian Giefer, Operations Manager and Authorized Signatory at Eibel, emphasizes: "Our high-quality windows and doors offer a multitude of options that leave little to be desired—ranging from accessible and sound-insulating models to stylish design windows with slender sightlines." He adds: "The new Rapid machines meet all requirements and ensure the precise processing of high-quality profiles. Optimizing the cutting process and utilizing offcuts reduces waste, leading to cost-efficient production while simultaneously lowering the consumption of valuable raw materials in a sustainable way."

Flexible and high-performance combination

"The Ultratech production line consists of two main components: the Optima Evolution automatic saw and the MFC Evolution machining center," explains Mario Kruse. As Regional Sales Manager for Rapid, he developed the machine concept for the Malschwitz plant and oversaw the project's progress. "The key feature of the Ultratech system concept is its consistently modular design. Separating the sawing and machining modules—thereby making them independent of one another—enables significant increases in capacity."

For Eibel Fensterwerk, the Optima Evolution was supplemented with the MS module—a milling station for drainage slots, ventilation openings, and similar machining operations on the PVC profiles. All machining takes place on the full-length profile bar prior to cutting. Depending on the workload, these operations can be distributed efficiently and flexibly between the upstream milling station and the downstream MFC machining center.

The feed magazine is designed to hold 10 profiles, accommodating a maximum profile length of 6,500 mm. Integrated measuring systems automatically check the profile length and width before the bar is transported to the machining position. The MS module is equipped with four milling units; the orientation of these units is tailored to the specific machining operations required by the customer. After machining, the profile is conveyed to an under-table saw for 45°, 90°, and 135° cuts (intermediate angles are also available as an option). Finally, the cut parts can be labeled on the unloading table. Efficient, controlled waste disposal is ensured by a high-performance extraction system and a conveyor system comprising a horizontal waste belt and an inclined discharge conveyor.

Once the steel reinforcement has been inserted, the remaining machining operations can be performed on the RAPID MFC Evolution bar machining center. An upstream automatic screwdriving unit fastens the steel to the PVC profile. For a detailed video on this, please visit the Rapid YouTube channel:
https://www.youtube.com/watch?v=RRz8ms-1uhQ.