Technologies for extrusion and plastic processing

From plasticising to the finished product: total process control

Excellence in Extrusion: the Bausano method

Bausano builds extrusion lines designed to ensure process stability, energy efficiency and production continuity. Its technological offering covers the entire plastic transformation cycle: from plasticising to forming, through to pelletizing and material recovery. Extrusion is a continuous industrial process that transforms thermoplastic polymers into products with a constant cross-section through melting, pressurisation and passage through the die. Bausano designs every stage of the line as an integrated system: feeding and dosing, plasticising, degassing, calibration, cooling, haul-off and cutting. The integration of mechanics, automation and thermal management keeps temperature, pressure and output constant even during extended production cycles. The lines are sized according to objective parameters: screw diameter, available torque, installed power, production capacity in kg/h and specific consumption in kWh/kg. This approach allows the customer to assess plant performance and operating costs over time in a measurable way.

Extrusion Process

Within the Bausano range, different technologies are developed and integrated into a coherent platform for design and process control.

Plastic extrusion

Complete lines for the continuous production of pipes and profiles, with control of diameter, thickness and dimensional tolerances. The single-screw or twin-screw configuration is defined according to the material and the required mechanical characteristics.

Multilayer
co-extrusion

Systems with multiple extruders operating in line to produce structures made of different functional layers. This technology makes it possible to optimise the use of raw material, integrate recycled material into the inner layers and maintain controlled surface characteristics.

Compounding and pelletizing

Lines dedicated to the production of technical granules through mixing, degassing and cutting. Screw geometry can be configured according to the percentage of mineral fillers, fibres or additives. The goal is to ensure mixture homogeneity and rheological stability of the compound.

Plastic recycling

Systems designed to transform post-industrial and post-consumer waste into reusable raw material. The process includes controlled plasticising, filtration and regranulation, with a focus on constant quality of the regenerated product.

Food Extrusion

Application of the mechanical and thermal control principle of extrusion to dedicated dies for the processing of doughs and mixtures intended for the food sector, with precise management of temperature and pressure.

MULTIDRIVE SYSTEM
IOT TECHNOLOGIES
ENERGY SAVING
INDUCTION SYSTEM

Multidrive System

The patented Multidrive system represents a technological evolution in the transmission of Bausano MD series parallel twin-screw extruders. Its principle is based on torque distribution across two or four counter-rotating motors, in 2×2 and 4×2 configurations, reducing stress on shafts, gears and screws. This solution ensures uniform mechanical load distribution, greater reliability and longer service life compared to traditional single-motor systems. Multidrive integrates high dynamic load capacity multi-stage thrust bearings and a single static inverter for synchronised motor control. The result is constant rotation, optimal power distribution and reduced energy consumption, with lower installation and maintenance costs.

IOT TECHNOLOGIES

Bausano extruders integrate Industrial IoT systems for real-time monitoring of production parameters. Sensors and digital interfaces collect data on consumption, temperature, torque and output, generating dynamic KPIs useful for performance assessment. Data analysis enables the application of predictive algorithms for process optimisation and anomaly prevention. This approach improves operational efficiency, reduces unplanned downtime and allows continuous control of the line’s energy performance.

ENERGY SAVING

Extrusion is an energy-intensive process. For this reason, Bausano designs each line starting from measurable technical parameters and specific production targets. In the MD series, the combination of optimised screw geometry, Multidrive transmission and latest-generation motors improves the overall efficiency of the machine. Precise control of torque distribution and thermal management reduces dispersion and optimises the ratio between installed power and power actually used. This translates into reduced specific consumption in kWh/kg produced, with direct benefits for operating costs and the economic sustainability of the plant.

Reduced consumption by up to 35% thanks to the induction heating system, which concentrates heat directly on the barrel, reducing thermal dispersion compared to traditional resistive systems.
Optimised torque distribution with the Multidrive system, which reduces mechanical losses and improves transmission efficiency compared to single-motor systems.
Energy monitoring through Industrial IoT, with real-time analysis of consumption KPIs to optimise the kWh/kg produced ratio.
dvanced thermal control of screws and barrel, with high-efficiency thermoregulation and cooling systems that stabilise the process and reduce energy waste during start-up and continuous production.

Induction heating system

The Smart Energy system is based on the principle of electromagnetic induction applied to barrel heating. By exploiting the heating effect generated in a metal when exposed to a variable magnetic field, this system can reduce energy consumption by up to 30–35% compared to traditional heating. The Smart Energy induction barrel heating system has been designed together with a special fan that cools the hot parts of the machine as effectively as possible. This new design, integrated with an openable coil system, also allows customers to retrofit the application on existing Bausano extruders.

Energy efficiency and objective performance comparison

Energy efficiency is a measurable design parameter. Bausano evaluates line performance in terms of specific consumption per kilogram produced, enabling a transparent comparison with other solutions available on the market.

A technical reference is the MD series counter-rotating parallel twin-screw extruder, model MD 130:

Installed power: 260 kW
Average consumption in production: 130 kWh/h
With patented induction heating system: 112 kWh/h
Average capacity: 1,000 kg/h
With a hypothetical energy cost of 0.20 €/kWh, the energy cost is approximately 0.0224 €/kg produced.

This method allows the customer to calculate operating costs directly and compare performance with alternative plants characterised by higher absorption or lower process stability.

The design also supports the use of recycled material and mineral fillers while maintaining production continuity and mixture uniformity. The reduction of start-up waste and consumption optimisation contribute to the economic sustainability of the investment.

Bausano technologies are used across several industrial sectors and are supported by an international network of specialised technicians operating in Europe, North America, Latin America, the Middle East and Asia. Assistance is active in countries such as Italy, Germany, the United States, Mexico, Brazil, India and China, and includes installation, start-up, training and after-sales support.

The main applications include:

PVC, HDPE and polyolefin pipes, for water, gas and sewage networks, with diameter and thickness control according to international standards.
Decking profiles, fencing and building components, also in WPC and composite materials, with the possibility of using regenerated material.
Window profiles, with complex geometries and dimensional stability in continuous production.
Technical profiles and corner profiles for construction, designed to ensure geometric precision, production continuity and waste reduction.