Process testing and analysis for real application

Applied research for industrial extrusion

Applied engineering for extrusion: from formulation to production process

Bausano engineering stands out for its integrated and experimental approach to the design of extrusion lines, placing process reliability at the centre even before plant design begins. Each line starts from in-depth analysis carried out in the internal chemical and technological laboratory, where materials, additives and operating parameters are tested to ensure compatibility, stability and repeatability on an industrial scale. Thanks to advanced characterisation tools and pilot plants, real processing conditions can be simulated with precision, melt quality can be measured, recipes can be optimised and every phase of the production cycle can be validated. This drastically reduces the margin of error in the execution phase and makes it possible to propose already optimised technical solutions, accelerating time-to-market and increasing investment security. The result is a data-driven decision-making process, where every design choice comes from tangible tests and objective measurements. Continuous customer support, from experimentation to commissioning, is an integral part of the Bausano method, designed to transform material knowledge into production efficiency.

Experimental material characterisation

The characterisation of thermoplastic materials is carried out in the Bausano laboratory through plastograph analysis, based on the use of a Brabender system to study material behaviour during melting and mixing. Equipped with torque measurement up to 150 Nm, rotor speed control and direct melt temperature monitoring, the system subjects the material to controlled shear stress under reproducible conditions. The torque measured over time makes it possible to obtain Brabender curves that describe the rheological evolution of the material, highlighting phenomena such as gelation, viscosity variations or the onset of degradation. The data are compared with an internal test history and used for the data matching required to design screw geometries and define thermal profiles, improving the predictability of material behaviour on an industrial scale.

Flow simulation and design optimisation

The rheological data obtained in the laboratory are integrated into specialised software for the simulation of molten material flow, an essential tool for modelling real conditions inside the plasticising unit. The goal is to identify operational criticalities in advance, such as flow instability, uneven thermal distribution or pressure imbalances. Numerical analysis makes it possible to predict thermal build-up, identify localised pressure drops and study the distribution of shear gradients. This approach enables targeted optimisation of screw and die head design, ensuring efficiency, stability and final product quality. The ability to compare simulated data with experimental data makes every line designed by Bausano a validated and highly customised system, already tested under real operating conditions before construction begins.

Experimental material characterisation

Flow simulation and design optimisation

Advanced testing and analysis to transform every line into a scientifically tailor-made solution

Rheological analysis: real data for designing tailor-made plants

Designing a tailor-made plant means starting from data. This is the principle behind the Bausano method: a technical-scientific approach that integrates rheological analysis into the development cycle of every extrusion line. Unlike many competitors, who rely on generic parameters or standardised tests, Bausano uses advanced tools such as capillary rheometers and plastographs to analyse the rheological behaviour of materials directly under simulated operating conditions. This means designing on the basis of real data, minimising uncertainty and increasing the expected performance of the plant. Within rheological analysis, each material has its own complexity, studied through a set of physical and chemical parameters that are essential for the correct design of the extrusion line. The main indicators analysed include:

Shear Rate
Molecular Wight
Molecular chain structure
Type and concentration of additives
Temperature
Pressure
Viscosity

The collection and interpretation of rheological data make it possible to model the melting and homogenisation phase of the material with precision, adapting each plant component – in particular screw geometries, thermal profiles and torque curves – to the specific behaviour of the polymer to be processed. This experimental process takes place inside the Bausano internal laboratory and enables every technical request to be transformed into a reliable, efficient and scalable plant solution.

Concrete advantages for the customer:

Tailor-made design based on measured rheological data.
Preventive identification of critical issues, such as degradation, instability and inhomogeneity.
Optimisation of screw geometry and temperature profile.
Reduced start-up times and maximum predictability of performance.
Lower waste, machine downtime and maintenance costs.
Greater energy efficiency and reliability in continuous production shifts.
Possibility to test customer recipes before industrial production.

Use of a proprietary technical database to compare materials and plant solutions. In the field of extrusion technologies, Bausano stands out because it offers not only plants, but a true scientific design method. The integration of experimental analysis, numerical simulations and plant engineering know-how creates a tangible competitive advantage, with lines that respond precisely to customer needs and maintain performance over time. This approach, based on precision, repeatability and continuous innovation, is now one of the most recognised assets of the Bausano brand in the global market.

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Test plant available to customers for laboratory trials

The integration between the experimental laboratory and the technical department makes it possible to design extrusion lines based on real data, collected under controlled operating conditions. Before industrial-scale production, the proposed technologies can be validated through practical trials carried out on the MD30 Twin Screw Extruder , specifically configured to reproduce the main process dynamics on a reduced scale. During the test, the specific material is processed according to the intended formulation, enabling accurate simulation of real production and immediate identification of the optimal parameters. The data collected make it possible to:

select the most efficient configuration according to the product to be manufactured
precisely define the most suitable machine size
identify any mechanical or process optimisations

This approach enables the development of perfectly sized plants, reducing error margins and ensuring full consistency between project design and production output. The availability of extruded material samples, combined with technical analysis of the results, provides the customer with an additional evaluation tool before final production start-up.

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Industrial and Pilot plant testing

Inside its Test Room, Bausano provides customers with industrial pilot plants to test materials and formulations under real production conditions: a unique opportunity in the extrusion sector. This infrastructure makes it possible to accurately simulate process dynamics, providing concrete performance data and real samples for internal quality checks before proceeding with the investment. Tests are carried out on twin-screw or single-screw extruders configured ad hoc, replicating the exact operating conditions of the future production line. The customer can choose to attend the trials in person, working side by side with Bausano technicians and engineers, or follow them remotely, receiving data, analyses and material samples afterwards. Thanks to this approach, Bausano drastically reduces uncertainty during the pre-sales phase, offering tangible technical validation of the project. It is a real decision-making support tool, integrating the development of tailor-made solutions with the reliability of experimental data, in a perspective of continuous innovation and customer centrality. Providing customers with the best extruders on the market for real trials before purchase is a distinctive element of the Bausano method. Unlike what is offered by most competitors, the tests are not carried out on small laboratory machines, but on fully equipped industrial pilot plants designed to manage complex productions.
The Test Room includes:

an MD75 twin-screw extruder, for filled materials and high-viscosity technical formulations,
an E-GO R 60/37 extruder, designed for high output and precision,
an E-GO single-screw extruder for pipes, dedicated to the processing of polyolefins and PVC.

Thanks to these plants, customers can test productivity, melt quality and real process dynamics, with the certainty of investing in an already validated solution. The result is a truly tailor-made extrusion line, with guaranteed performance and start-up times reduced to a minimum. A service that only Bausano, with over 80 years of innovation and a data-driven engineering approach, is able to offer.

Material testing: the first step towards the right line configuration

By completing the form, customers can request a test on their material. Bausano will analyse melt behaviour, assess formulation stability and provide guidance on process parameters, temperature, pressure and optimal screw design for the future line.