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Technology, Customisation and AI: Italian Excellence in Extrusion


Bausano designs intelligent extrusion lines for the high-precision production of pipes, profiles and compounds. Advanced systems with integrated sensors, digital interfaces and artificial intelligence, entirely developed in Italy, ensuring extrusion under full control in every detail.

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Bausano Extruder
Engineering

Engineering and Design 

Relying on Bausano means benefiting from design and engineering based on a scientific method: real data, digital simulations and in-house testing are transformed into concrete solutions.
In this way, every plant is optimised according to actual production requirements, ensuring efficiency, reliability and long-term value, even under the most complex conditions and with maximum application flexibility for every sector.

Manufacturing

In-house Production

Every Bausano extrusion line is entirely developed in-house. Screws, barrels and all system components are manufactured in the mechanical workshop.
This production model ensures consistent quality, safety, fast lead times and continuous customisation, while also guaranteeing direct control over resources and more sustainable process management.

 

Services

Services and Support

Choosing Bausano means relying on top-level technical support: a network of specialised teams located in strategic areas worldwide ensures fast and targeted interventions wherever the plant is installed. An in-house spare parts warehouse guarantees immediate component availability, while remote monitoring enables continuous analysis and predictive maintenance, reducing downtime and optimising productivity.

Why choose Bausano technology

Eighty years of industrial history, consolidated expertise and a vision constantly oriented towards the future: it is from this combination that Bausano technology is born, chosen by those seeking reliability and innovation in plastics processing. Each plant is entirely designed and manufactured in the Italian facility through a process that integrates engineering, mechanical machining, assembly and testing.
This vertical management allows Bausano to guarantee quality, reliable lead times and maximum customisation: every screw, barrel and key component is tailor-made, ensuring consistency between design and performance for every application. Bausano technology covers the entire spectrum of extrusion requirements: pipes, profiles, compounds, medical products, recycling and regranulation of post-consumer and post-industrial waste, with customised solutions for both PVC and polyolefins. Each plant can be configured according to the material to be processed, the required output and the operating conditions, thanks to a modular approach that allows every part of the line to be adapted — from the extrusion die to the calibration and cooling table, through to the haul-off unit and dosing systems. The tangible advantages for customers are clear: compatibility with a wide range of thermoplastic polymers — including rigid and plasticised PVC, HDPE, LDPE, PP, WPC, TPE, TPU, PU, ABS and complex blends, including regenerated materials — together with the integration of advanced automation and interconnection systems. All Bausano plants are designed to maximise efficiency and traceability: on-board digital integration leverages artificial intelligence to analyse real-time data, anticipate anomalies and guide targeted interventions, displaying parameters and alarms clearly while providing historical analysis and predictive insights. This results in increased efficiency, reduced downtime and optimised productivity. Choosing Bausano means relying on solid, innovative technology entirely Made in Italy, designed to support every customer in all the challenges of plastics processing, today and tomorrow.

Extrusion lines designed for your factory

Data-driven technical design

 From rheological analysis to flow simulations, every project is developed based on concrete data and validated testing, ensuring functional consistency between material, screw configuration and plant performance.

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Applications

Bausano extrusion lines are designed to meet specific requirements across the main industrial sectors: PVC and polyolefin pipes for drinking water distribution, civil and industrial drainage, wastewater, irrigation and drainage systems; corrugated pipes and conduits for the protection of electrical and telecommunications cables; PVC window and door profiles, technical profiles for construction, automotive and furniture sectors, and WPC profiles for decking and outdoor cladding. The range is completed by compound extrusion lines for moulding and co-extrusion, systems for recycling and regranulation of post-consumer and post-industrial waste destined for new products, and medical extrusion systems for tubing and infusion bags, dialysis devices and disposable products, developed in compliance with sector regulations.Thanks to their flexibility, Bausano lines enable the processing of rigid and plasticised PVC, HDPE, LDPE, PP, TPE, PU, ABS, WPC and other advanced materials, adapting to technical specifications and quality standards across different application fields.

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End-of-line equipment

In every extrusion plant, the final result depends on the perfect integration of all components. Bausano downstream equipment plays a decisive role by optimising productivity, ensuring dimensional stability and determining the quality of the finished product. The proposed downstream solutions are developed to address the most common critical issues during cutting, calibration, handling and cooling, reducing the risk of scrap, downtime and out-of-tolerance production.
Each component is selected and configured according to actual production requirements: type of polymer, profile or pipe geometry, required speed and precision standards.

This ensures operational continuity, long-term reliability, lower operating costs and seamless integration with the rest of the plant, enhancing overall productivity.

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Technology

In extrusion, the choice of technology directly affects efficiency, precision and process sustainability. Traditional solutions often show limitations in terms of stability, control and energy optimisation. Bausano extrusion lines adopt high-performance technologies integrating intelligent systems, advanced components and digital platforms for continuous monitoring. This approach enables real-time response to production variables, optimised energy consumption and waste reduction, always ensuring maximum reliability. The synergy between advanced hardware and software not only guarantees efficient management of all process parameters but also provides a flexible plant, fully integrable into modern industrial environments and aligned with sustainability goals. Choosing Bausano means investing in a solution designed to reduce environmental impact, increase productivity and meet the most advanced requirements in plastics processing.

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Polymers in extrusion

In extrusion, different families of thermoplastic polymers behave in specific ways: PVC ensures dimensional stability and chemical resistance, while polyolefins such as HDPE and PP offer ductility and lightness; TPE provides elasticity, ABS rigidity and impact resistance, and WPC compounds enable eco-sustainable solutions. Each material presents specific variables in terms of melting behaviour, pressure, viscosity and thermal response, making precise control of every parameter essential.
Bausano technology stands out for its ability to design plants optimised for every type of polymer, including filled, modified or high-performance materials, selecting the appropriate screw geometry and the best line configuration to ensure maximum efficiency, operational continuity and consistent finished product quality, enhancing industrial competitiveness.

Bausano solutions for plastics extrusion

Extrusion Lines for Pipes Icon

Extrusion Lines for Pipes

For the production of PVC, PE and PP pipes for water supply networks, sewer systems, agricultural irrigation, gas and compressed air transport, and medical applications.

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Extrusion Lines for Granules

For processing PVC, WPC, recycled materials or compounds into pellets intended for moulding, technical profile extrusion or products for construction and automotive sectors.

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Extrusion Lines for Profiles Icon

Extrusion Lines for Profiles

Ideal for PVC, ABS or WPC profiles used in window and door frames, gaskets, cable ducts, panels and frames for construction, furniture and the electrical sector.

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Extrusion Lines for WPC

For WPC profiles and pellets used in decking, fencing, ventilated façades, outdoor flooring and modular systems for urban furniture.

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Extrusion Lines for Medical Products

Plants for flexible tubing, infusion bags, cannulas, sheaths and sheets in medical-grade PVC, TPE or biocompatible materials, compliant with healthcare regulations.

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Extrusion Lines for Recycling

Solutions for recycling, regeneration and regranulation of industrial plastic waste, post-consumer materials, agricultural films and production scrap.

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Bausano SPHERA: the digital evolution of extrusion

An integrated platform that digitalises and optimises the entire lifecycle of your extrusion plant. With Ranger, Pharos and Scout, you gain full control over performance, predictive maintenance and spare parts management. Modular, scalable and powered by artificial intelligence, SPHERA brings extrusion into the era of Industry 5.0.

Testimonials and Case Histories

Discover how companies around the world have chosen Bausano to achieve tangible production goals through tailor-made extrusion plants. Each case history outlines measurable results achieved thanks to Bausano technology: operational challenges resolved, performance improved, and processes made stable and efficient over time.

PlastChem B.V.
PlastChem B.V.

In the most advanced PVC factory in Europe, the Italian excellence stands out: 
PlastChem chooses Bausano extruders

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News for the plastics industry

The latest updates from the world of extrusion: insights on raw materials, technologies, events and international markets.  An opportunity to explore trends, trade fairs and best practices, with a focus on efficiency, innovation and strategies to optimise processes and reduce plant energy consumption.

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