AI enters the extrusion line Bausano brings smart extrusion technology to Europe’s plastics fairs

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Bausano will present extrusion technologies and digital solutions at three major European plastics trade fairs in June. Highlights include twin-screw and multilayer pipe extrusion systems as well as Sphera, an AI-based ecosystem designed to support process monitoring, predictive maintenance and performance optimisation.

In June, Bausano will be participating in the three main European trade fairs dedicated to the plastics value chain: France Innovation Plasturgie (FIP), scheduled at Eurexpo Lyon from June 2 to 5; Equiplast, at the Gran Via exhibition centre in Barcelona on the same dates; and Plast, at Rho Fiera Milano, from June 9 to 12.

At Equiplast (stand 91, Hall 3), the company will present itself for the first time together with its partner Protecnic 1967, while at FIP (stand L02-M05), the exhibition space -developed in collaboration with Amineau — will become a true innovation hub. On display will be the MD 75/24 Plus parallel twin-screw extruder, designed for pelletizing applications in PVC processing. The screw geometry ensures homogeneous melting even when using recycled materials, the company states.

At Plast (Hall 13 E/F, stand 33-34), Bausano will showcase a highly customized pipe production line, combining the E-GO 45/37 single-screw extruder with an E-GO 45/30 co-extruder in an A/B/A layout for processing multilayer HDPE pipes. The extremely compact line architecture also includes a PO 3 63 multilayer die head with screen changer, connected to the co-extruder via an adapter equipped with a manifold for distributing and regulating the inner and outer layers of the pipe. The solution is completed by an HMI interface and a gravimetric dosing system with weight-per-meter control. Designed for pipe diameters from OD16 to 63 mm, the extrusion head features melt distribution divided into three spiral distributors with high-flow channels, ensuring uniform distribution of the three layers along the entire pipe wall, while offering high flexibility with material ratios of 5/90/5 and 33/33/33.

A key highlight at Plast will be Sphera, with which Bausano positions itself as the first company in the sector to introduce advanced integration of artificial intelligence into plastic pipe extrusion processes.

The digital ecosystem, marking the advent of a new production paradigm, consists of two native and complementary modules, Pharos and Ranger, presented for the first time in Italy at Plast and already operational in numerous field installations.

The Pharos IIoT architecture continuously acquires and processes machine and process data — from temperatures to pressures, from rotation speeds to energy consumption, as well as operating states and mechanical indicators. Ranger, the advanced AI platform, interprets this information in real time, in relation to actual operating conditions, integrating it with machine history, technical manuals, Bausano procedures, and specific customer documentation.

The platform is enriched with new functionalities: advanced parameter monitoring with an AI assistant, available on demand, evolves towards full interoperability between systems, with proactive operational suggestions via HMI, enabling dynamic interaction with artificial intelligence. The result of combining generative and agentic AI models, Ranger is now able to autonomously read data generated by Pharos and intervene in advance with corrective indications to prevent deviations and optimize performance. At the same time, sensor systems enable predictive maintenance logic, reducing downtime and improving overall plant reliability.

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