WEG ADV200 liquid-cooled drives installed in the upgraded extrusion line.

WEG has strengthened its presence in the plastics processing industry through the supply of ADV200 liquid-cooled AC drives for the modernization of extrusion lines operated by Complastex, one of Italy's leading manufacturers of sealing systems for window frames and automotive applications. The automation project was developed by Gigapiù, a long-established Italian company specializing in industrial automation solutions.

Located in Lucca, Italy, Complastex has built its reputation on the production of high-quality extruded sealing profiles, while Gigapiù has extensive expertise in designing and integrating advanced automation systems. Together, the two companies partnered to modernize three strategic production lines, aiming to improve process flexibility, increase operational efficiency, and optimize the use of available installation space.

As part of the project, WEG supplied four ADV200-LC 55 kW liquid-cooled AC vector drives and one ADV200-LC 75 kW unit. The drives were installed to control the AC induction motors used in the extrusion process, delivering high-performance motor control with excellent precision, dynamic response, and reliable operation.

Each production line consists of one or two single-screw extruders, followed by a polymerization section and a final washing and cooling stage. Altogether, each line extends up to 40 meters and is designed to process different rubber compounds used in automotive sealing applications. The wide variety of materials requires highly accurate speed and torque control to ensure consistent product quality throughout production.

Gigapiù fully customized the automation system for Complastex, enabling the extrusion process to adapt to the different rubber formulations processed on each production line. In this application, WEG's ADV200 liquid-cooled drives play a key role by providing stable and reliable motor control while supporting the flexibility required for multiple production scenarios.

The liquid-cooled design of the ADV200 series was another important factor in the project's success. By removing heat through a dedicated cooling circuit rather than dissipating it inside the electrical enclosure, the solution reduces cabinet ventilation requirements, minimizes internal temperatures, and enables a more compact control panel design. This contributes to improved system reliability, better thermal management, and more efficient use of installation space—critical advantages for industrial retrofit projects.

In addition to their compact footprint, the ADV200 drives offer the performance and robustness required for demanding extrusion applications, ensuring smooth operation, consistent process control, and high system availability. These characteristics help manufacturers increase productivity while maintaining the quality standards required for automotive sealing products.

By combining advanced drive technology, efficient thermal management, and precise motor control, WEG continues to support the plastics industry with solutions that increase productivity, improve process quality, and help manufacturers achieve greater operational efficiency.