Orquestra 4.0 Software

What does Industry 4.0 mean when it comes to Extruders?

The world is facing the 4th industrial revolution, in which computers and automation will come together, in an entirely new way, with robotics connected remotely to computer systems equipped with machine learning algorithms, that helps us identifying production inefficiencies.

The approach to transforming the process industry into a 4.0 model, or “smart factory”, is based on synergistic work between plant manufacturers and the companies that use them. Your company is in good health, runs, invests, and needs a control system that keeps pace with its new requirements.

In this regard, Bausano supports its customers with the implementation and the integration of systems aimed at supporting the new digital industrial revolution, providing to the plastic manufacturers a complete and integrated range of solutions, industrial softwares and technologies.

It means equipping your own extrusion systems with a centralised control system that allows the calculation of the performance indices and the analysis of Real Time production data.

Benefits:

Reduce unscheduled production stops
Reduce the Costs Of Spare Parts
Reduce the costs of the technical service labor
Increase revenues
Increase security
Increase maintenance efficiency

New 4.0 solution with ORQUESTRA
Prevent asset failure by analyzing production data and predicting issues before they happen: Intelligent Diagnosis and Predictive Maintenance.

Why analysing data?

The integration of IoT systems and Bausano extrusion lines provides a short time-to-market production
and compatibility with existing plants (revamping applications).

Perform continuous and real-time monitoring of production;
Generate immediate reports and intuitive graphs on production performance (machinery status, waste, hours worked);
Intelligently connect all the machines in the field and integrate them with the company management systems (ERP, MES, CRM ..) to automatically govern the start-up processes (production recipes);
Collect raw data and transform it into ready-to-use information;
Have certified and correct data on which to set the analysis of its business and R&D activities.

Predictive Maintenance

Predictive maintenance for industry 4.0 is a method of preventing asset failure by analyzing production data to identify patterns and predict issues before they happen.

Until now, factory managers and machine operators carried out scheduled maintenance and regularly repaired extruders parts to prevent downtime.

Implementing industrial IoT technologies to monitor asset health, optimize maintenance schedules, and gaining real-time alerts to operational risks, allows manufacturers to lower service costs, maximize uptime, and improve production throughput.

Innovative technologies are bound to become a model to be followed for the entire sector, designed to raise the quality standard of processes and of the final product, offering important strategic resources and new development opportunities.

Extrusion fully traceable

Which are the parameters to be monitored?

Termoregulation Zones
Temperture
Screws Rpm
Energy Consumptions
Thrust Pressure (Ton)
Extruder Pressure (Bar)
Extruder Motors Speed
Extruder Melt Pressure
Extruder Melt Temperature
Alarms Management
Production Recipe

Are you ready to Imagine the future of extrusion together?

Connected production is not an option, but a must. Only with open cooperation and the exchange of ideas and solution approaches will Industry 4.0 concepts find their way to practical solutions.

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