Australia Case Study: Increased Production Capacity for Profiles

Over 100 tons per day with process stability.

24/7 Production and Integrated Data Management: The Australian Plastic Profiles Case

CUSTOMER

Australian Plastic Profiles

DATE

April 2025

INNOVATIONS

IoT Technologies

ARE YOU INTERESTED?

APP: Connected Extrusion for Continuous Production

Australian Plastic Profiles (A.P.P.), an Australian company based in Sydney, produces PVC pipes and profiles for hydraulic, electrical, and civil applications. With a capacity of more than 100 tons per day and continuous 24-hour operation for 50 weeks a year, the company operates in a high-intensity production environment.
In this scenario, the priority is to ensure operational continuity, control of process parameters, and structured management of energy consumption, reducing the risk of unplanned interruptions

The Need: Greater Visibility into Extrusion Data and Anomaly Prevention

Managing lines that run 24/7 requires tools capable of providing reliable, immediately interpretable data. Australian Plastic Profiles needed a system able to continuously monitor temperature, pressure, torque, and energy consumption, turning process information into measurable indicators. The goal was to achieve greater production predictability, improve maintenance planning, and intervene promptly in the presence of deviations from set parameters.

Industrial IoT Integration and Real-Time Monitoring

The Bausano lines installed at A.P.P. are integrated into an Industrial IoT ecosystem that enables the continuous collection of process data and its use for performance analysis. Extrusion parameters are monitored in real time and archived for historical and comparative analysis. This approach makes it possible to assess production trends, analyze consumption in kWh/kg produced, and verify process stability over continuous cycles. The interconnection between the machine, operators, and company management makes it possible to structure data into technical reports, supporting decisions based on objective, measurable indicators.

Challenges Solved Together

Peter Chivers: Production Manager

“We are proud of our quality products, achieved thanks to a specialized staff and the excellence of Bausano-branded extruders, a company with which we have developed a first-class partnership, cultivated over years of collaboration and challenges solved together, as a team, creating unprecedented solutions,” he continues. “The new extrusion lines fully meet our needs, thanks in part to the innovative systems at the heart of Bausano's high-tech solutions.”

Results Achieved: A More Controllable Process and Fewer Unexpected Events

The integration of IoT technologies has allowed Australian Plastic Profiles to operate with greater control over production parameters and energy consumption.
Continuous monitoring has improved the ability to detect anomalies before they cause machine downtime. The availability of structured data has made the process more predictable, facilitating scheduled maintenance and resource optimization.
Continuous 24/7 production is now supported by a digital system that enables constant performance analysis, reduced process variability, and more efficient management of operating costs.

A Partnership Focused on Digital Extrusion Management

The partnership between Australian Plastic Profiles and Bausano demonstrates how the integration of Industrial IoT technologies can strengthen the reliability of extrusion lines in high-intensity production environments.
Extrusion is managed as an interconnected process, based on continuous monitoring, structured data collection, and performance analysis over time, with concrete benefits in terms of operational stability and long-term planning.

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