Scientific design of extrusion lines

Engineering intelligence behind every system

A scientific approach to custom design

At Bausano, every extrusion line is developed through a structured engineering process, based on in-depth technical analysis carried out from the earliest stages by a highly specialised multidisciplinary team. The design process begins with systematic data collection, aimed at defining the production context, identifying critical variables, and analytically outlining performance targets. This scientific approach makes it possible to anticipate real operating conditions, laying the foundation for tailor-made solutions driven by efficiency, reliability, and process parameter optimisation.

Rheological analysis and process testing for guaranteed performance

The design of each extrusion line is developed through experimental analysis carried out in the Bausano testing and simulation laboratory, a controlled environment designed to accurately reproduce the real behaviour of thermoplastic materials. Experimental activities rely on high-precision instrumentation, including a capillary rheometer, plastograph, optical microscope, precision balance, densimeter and laboratory extruder. These tools provide essential rheological, thermal and mechanical data, supporting the definition of geometries and process parameters, and ensuring customised design and high production performance.

Flow simulation: rheological data supporting design

Experimental data obtained from rheological analysis are processed using advanced polymer flow simulation software, enabling precise modelling of operating conditions within the plasticising unit. The integration of laboratory data and numerical modelling allows the analysis of key parameters such as viscosity, shear rate distribution and thermal profile along the screw. The comparison between experimental and simulated data makes it possible to identify:

Flow instability zones and non-uniform filling
Localised thermal build-up and temperature imbalances
Excessive or uneven pressure drops
Potential material degradation
Opportunities to optimise screw and die geometries

Rheological analysis and process testing for guaranteed performance

Flow simulation: rheological data supporting design

Flow instability zones and non-uniform filling
Localised thermal build-up and temperature imbalances
Excessive or uneven pressure drops
Potential material degradation
Opportunities to optimise screw and die geometries

Integrated approach to the custom design of screws and extrusion dies

Rheological analysis and flow simulation enable the design of screw geometries, pelletizing dies and pipe heads—whether single-layer, multi-layer or crosshead—based on the actual behaviour of the polymer. Each functional parameter, from pitch to compression profile, is optimised according to experimental data. The result is a tailor-made configuration that ensures plasticising efficiency, process stability and final product quality, even when processing complex materials.

Maximized productivity

The optimisation of screw and die geometries enables higher throughput while maintaining consistent melt quality, even at high speeds. A precisely engineered design allows the extruder to operate at its full potential, delivering measurable improvements in process stability and hourly output.

Scrap reduction

Accurate design of geometries ensures a stable and balanced material flow, reducing dosing errors, pressure fluctuations and final product defects. The result is a significant reduction in scrap and more efficient use of raw materials, improving both production efficiency and operating costs

Scientific validation

The integration of theoretical modelling and experimental data enables a fully customised design approach, where each component is defined based on measurable parameters. This scientific method ensures design consistency, operational reliability and full alignment with the customer’s application requirements.

Bausano Patents and Technologies

Bausano’s technical design is based on a tailor-made approach, where every component, from the screw to thermal management, is developed according to the actual behaviour of the polymer. This expertise has led to the development of two proprietary patents: one focused on energy saving in heating systems, and the other designed to increase the durability and reliability of the extruder. Concrete solutions engineered to ensure operational efficiency and long-term sustainability.

Testing and simulation laboratory

Bausano’s in-house laboratory is designed to perform rheological testing and process simulations on an industrial scale, reproducing the real behaviour of thermoplastic materials under controlled conditions. The analysis integrates data acquired from capillary rheometer, plastograph, optical microscope, densimeter, precision balance and laboratory extruder. These tools allow each design solution to be validated before production, ensuring reliability, functional consistency and high performance, even under complex operating conditions.

MORE INFORMATION

Thermoplastic polymers

During melting and gelification, each thermoplastic material, such as PVC, PE, PP, PS, PETG, EVA, TPU, ABS, PC/ABS and WPC, exhibits a specific behaviour linked to its chemical and mechanical structure. For this reason, a deep understanding of polymer composition and its response to thermal and mechanical stress is essential to design systems capable of ensuring stability, efficiency and consistent performance over time.

Co-design: a shared approach to engineering development

Within the design process, Bausano offers the possibility to activate a co-design approach, supporting the customer during key phases of plant development. This collaborative method integrates the application expertise of the end user with Bausano’s engineering know-how, with the goal of delivering solutions fully aligned with production objectives.

The co-design process includes:

Direct involvement during development phases to ensure alignment between technical specifications and the operating context
Shared technical validation based on experimental data, numerical simulations and application testing
Structured knowledge sharing to support decisions on materials, processes and configurations

This approach, available on request, reduces design uncertainty and accelerates the engineering of customised, efficient and scalable systems.

Ranger: integrated artificial intelligence tailored to the line

Within the customised design process, Bausano extends its tailor-made approach to the digital domain by developing Ranger, an artificial intelligence system integrated and trained on the specific data of the customer’s line. The model is built starting from the machine’s technical documentation, operating logic and real process parameters, ensuring full consistency with the installed system.
Once integrated into the control system, Ranger is able to:

Provide technical support in case of line downtime, guiding the operator through diagnosis
Deliver structured and contextualised information on manuals, diagrams and procedures
Respond to requests related to process parameters and real-time alarms

This digital infrastructure represents an extension of the machine itself, designed to reduce downtime, support the operator and enhance technical knowledge on a continuous basis.

A starting point to define the right solution together

By filling in the form below, it is possible to describe specific technical or production requirements. The technical team will carefully evaluate the request in order to propose the most suitable extrusion line or extruder.