Komplast is strengthening its leadership in the recreational vehicle component sector with a year of major investment: a new 3,000-square-metre production facility, new machinery and a fully automated in-house regranulation system that enables the density of Kombiplast profiles to be precisely calibrated
Founded in Lucignano, in the Italian province of Arezzo, by Francesco Lucaroni and Luca Rossi, the Tuscan company is attending the Caravan Salon Düsseldorf with a wide range of developments: a new production building, latest-generation machinery, an industrial automation system and a technological partnership set to open up entirely new possibilities for the motorhome sector. Komplast is no longer simply a manufacturer of profiles and roller shutters. It is an expanding technology company with a forward-looking, systemic vision encompassing everything from material circularity to the integration of nanotechnology into its products.
The new facility
and production automation
Komplast is already operating from its new facility, which covers approximately 3,000 square metres and is located next to its existing premises. The new building is largely dedicated to the high-volume production of Kombiplast structural profiles. It houses ten extrusion lines entirely devoted to this product, representing a step change not only in terms of capacity but, above all, in technological capability. At the heart of the new facility is a centralised system for distributing and dosing re-granulated material. The system radically transforms the production process. Rather than preparing a single compound to be supplied to all machines, each individual extrusion line can receive a customised formulation in real time, managed by precision gravimetric dosing units.
“If I want to use 30% recycled material on one line, 20% on another, virgin material on a third and 100% recycled material on a fourth, the system can manage this independently for each individual machine. It is a level of control and customisation that was previously unimaginable,” explains Francesco Lucaroni.
The benefit for customers is direct and measurable: more reliable production scheduling, reduced variation between batches and, above all, the ability to meet specific density and composition requirements without compromising production continuity.
Kombiplast:
an autonomous circular system
With the complete in-house integration of the regranulation process, Kombiplast has taken another major step forward. The company’s system consists of structural expanded-PVC profiles designed to replace timber in the sandwich panels used for the walls, floors and roofs of recreational vehicles. Until recently, production waste was sent to an external supplier for recycling. Komplast has now acquired the machinery required to regranulate 100% of its production offcuts in-house, giving the company direct control over the size, geometry and density of the resulting granules. This may appear to be a purely technical development, but its implications are significant. “Granule morphology is fundamental,” says Lucaroni. “Previously, we obtained irregular shapes that did not guarantee uniformity during mixing. Today, the recycled granules have the same weight, density and geometry as virgin material. They flow into the machines with the same consistency, process with the same fluidity and deliver the same performance.”
In practical terms, this has resulted in a much broader and more controllable range of densities. Kombiplast profiles can now be manufactured with densities ranging from 380 to 600 kg/m³, compared with the previous reference density of 450 kg/m³. For applications where minimum weight is essential, such as non-structural components or internal frames, the density can be reduced to below 400 kg/m³. Where greater strength and mechanical performance are required, higher-density formulations can be used. Komplast has also simplified its colour-coding system. The previous three-colour system – orange for virgin material, grey for recycled material and light blue for polystyrene – has been replaced by a single colour, within which the different material blends are managed. Polystyrene has been temporarily discontinued due to a lack of market demand. This new unified colour system reflects the maturity of the process and its fully integrated management.
Commercial expansion:
Northern Europe and France
Komplast’s growth is not limited to its industrial operations. The company has consolidated and expanded its commercial presence across Europe, with significant developments in two strategically important regions. In Northern Europe, Komplast has entered the Scandinavian markets, where it previously had no direct presence, through a new distribution network, with the first supply agree ments already in place. At the same time, the company has strengthened its partnerships in several Baltic markets. These regions have specific requirements in terms of resistance to low temperatures, low weight and durability – characteristics that are inherent strengths of Kombiplast profiles. In France, where the recreational vehicle market is one of the most dynamic in Europe, Komplast has recorded significant commercial growth since March and April 2026, securing major supply contracts with leading manufacturers.
Roller shutters:
Kimera enters the premium segment
Roller shutters are Komplast’s long-established core business. The company is now one of Europe’s leading manufacturers of sliding systems for recreational vehicles, producing more than 50,000 sliding doors each year for the RV sector alone. In terms of production volumes specifically dedicated to recreational ve hicles, this places Komplast among the world’s leading manufacturers in the segment. Previewed at the Caravan Salon Düsseldorf and now in full-scale production, Kimera is the flagship product in the range and is beginning to be installed in premium vehicles. Comprising two profiles with contrasting finishes, Kimera creates sophisticated textural effects. It also features a patented flexible joint that allows for extremely tight – even reverse – bending radii, while ensuring smooth and quiet operation at all times. A high level of customisation is also available, with dimensions, finishes and digitally printed decorative designs developed to meet the individual requirements of each manufacturer. Komplast is also changing the way it presents itself at trade fairs. In Düsseldorf, the company is showcasing an almost entirely redesigned stand and communication concept, including a virtual vehicle tour operated through touchscreen software. Visitors can enter the motorhome virtually and select different points of interest to access product information and image galleries relating to the Komplast solutions used in each area of the vehicle.