Enhancing Extrusion Efficiency with Data-Driven Process Control

Extrusion companies face major challenges. An Italian company lost 2400 kg of material due to a blockage in the suction system. By implementing digital solutions by RE: they saved thousands of Euro.

Extrusion companies face significant challenges, from high scrap rates to inconsistent product quality. For example, an Italian customer of RE: GmbH lost 2400 kg of material due to a blockage in the suction system. By implementing real-time monitoring, such issues can be detected and addressed promptly, resulting in substantial cost savings.

The Importance of Data Integration and Real-Time Monitoring

RE GmbH’s c.Hub Middleware allows for seamless data integration from various sources without extensive IT implementation. This real-time data monitoring is crucial for preventing waste and optimizing material usage. For example, the aforementioned blockage issue was resolved early due to real-time data alerts, preventing further material loss and saving the company €8000. The global market for extrusion machinery is projected to grow at a CAGR of 4.5% from 2021 to 2026, highlighting the increasing demand for efficient process control solutions [source].

Improved Traceability and Quality Control

Enhanced traceability reduces defects and recall costs, ensuring high-quality output. Better data management and real-time analytics allow immediate identification of deviations from production specifications. This improvement in traceability ensures that extrusion processes meet high standards consistently. Implementing real-time monitoring can reduce material waste by up to 15% [source].

Addressing Key Challenges in Extrusion

Extrusion processes face several challenges, including:

  1. High Scrap Rates: Poorly calibrated machinery and inadequate process control lead to significant material waste.

  2. Excess Material Usage: Without precise control, there is a tendency to use more material than necessary, increasing production costs.

  3. Energy Inefficiency: Non-optimal machine settings result in higher energy consumption and operational costs.

  4. Inconsistent Product Quality: Variability in process parameters causes rework and increased scrap rates.

  5. Maintenance and Downtime: Frequent breakdowns due to inadequate maintenance result in unexpected downtime and repair costs.

Why Choose RE: GmbH as Digitalization Partner?

With c.Hub, RE GmbH offers a unified platform for interconnecting machinery from different vendors, making it easier for extrusion companies to leverage their data. The intuitive user interface and real-time reporting features of ExtrusionOS enhance process control and efficiency in plastics extrusion production.

The Value of Data-Driven Decision Making

Data-driven decision making is recognized for its potential to significantly enhance business performance. According to the BARC Data, BI and Analytics Trend Monitor 2024, data security and privacy have become top priorities, reflecting the importance of safeguarding sensitive information in the digital age [sources: 1, 2]. The report also emphasizes the need for data quality management, highlighting that high data quality standards enable organizations to make informed decisions and maintain regulatory compliance.

Conclusion: Data-driven Process Control with RE: in Plastics Extrusion

Data-driven process control transforms the extrusion industry by optimizing operations, reducing costs, and improving product quality. Embracing these technologies is crucial for staying competitive and achieving long-term success. Improved traceability can decrease defect rates by 20%, significantly lowering recall costs [source].



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