Intelligent Automation for Plastic Extrusion

The integration between Gefran and Bausano focuses on developing plastic extrusion systems based on distributed automation, industrial artificial intelligence, and real-time data analysis. The solution is intended for the plastics processing industry, where process stability, product quality, and operational continuity are essential requirements.

Combining Expertise for Extrusion Process Control
Gefran provides the automation platform and digital infrastructure for the production line, while Bausano integrates these technologies into its extrusion systems and adapts them to specific process requirements. The cooperation addresses the increasing complexity of plant operation, characterized by large volumes of process data, the need to reduce unplanned downtime, and a growing shortage of skilled operators.

The objective of the integration is to transform plant-generated data into operational information that supports continuous production control and operator decision-making.

Technical Architecture and Partner Responsibilities
Gefran's automation platform combines process control, Industrial IoT, and artificial intelligence capabilities within a modular and scalable architecture. At the core of the system is the G-Mation P6 controller, which combines PLC and edge computing functions.

The system supports cycle times of up to 250 µs, multiple EtherCAT network topologies, and industrial communication protocols including MQTT, OPC UA, and Euromap for interoperability with machines and external systems. The infrastructure also incorporates an integrated web server, VPN support for secure remote connections, and a Docker-based architecture that enables new applications to be deployed without affecting machine control performance.

By integrating control, visualization, application management, and cloud connectivity into a single device, the architecture reduces the number of exposed interfaces and simplifies compliance with emerging industrial cybersecurity requirements.

Bausano uses this architecture as the foundation for integrating machine learning algorithms and process-specific optimization tools for plastic extrusion.

System Deployment
The platform is deployed directly on Bausano extrusion lines and integrates with existing machine infrastructure. Machine learning algorithms continuously analyze operational data, enabling real-time monitoring of production conditions, early detection of process anomalies, and dynamic optimization of operating parameters.

Each partner contributes according to its expertise. Gefran supplies the automation hardware and software platform, while Bausano develops the application-specific functions for extrusion control and AI-assisted operator support.

Industrial Applications and Use Cases
The solution is designed for manufacturers operating plastic extrusion lines. Primary applications include continuous monitoring of production KPIs, Overall Equipment Effectiveness (OEE) measurement, predictive diagnostics, historical data analysis, and operator decision support.

The SPHERA ecosystem incorporates the PHAROS analytics engine for real-time performance monitoring and predictive analysis, while RANGER combines generative and agentic AI models to automatically interpret operational data and provide contextual recommendations that assist operators in optimizing process performance.

Expected Operational Impact
Plastic extrusion lines generate thousands of operational data points every second. Continuous analysis of this information enables process deviations to be detected before they affect product quality, reduces unplanned maintenance activities, and supports more stable operating conditions.

The integration of industrial automation, artificial intelligence, and digital infrastructure also facilitates operator onboarding, improves equipment maintainability, and contributes to more efficient production management through data-driven process optimization.

Edited by Evgeny Churilov, Induportals Media - Adapted by AI.

www.gefran.com