South America: 120% Increase in Compound Production Capacity

Bausano line configured to double output and ensure process stability.

Millpolimeros: +120% Hourly Output in Compounding

CUSTOMER

Millpolimeros

DATE

February 2025

INNOVATIONS

High productivity

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Millpolimeros: +120% Hourly Output

Millpolimeros, an industrial producer of compounds for various applications, had a clear goal: significantly increase the hourly output of its compounding lines, while maintaining consistent pellet quality and process stability.
The required increase did not concern only machine capacity, but the entire balance between formulation, plasticization, and downstream management.

Formulation Fine-Tuning for Stability and Higher Output

The project started with a technical analysis of the formulation used by the customer. At the Bausano plant, tests were carried out on internal pilot systems, available to preliminarily validate material behavior under real extrusion conditions. The tests made it possible to analyze torque, thermal stability, plasticization yield, and the mixture's response to flow rate variations. Based on the data collected, improvements to the formulation were suggested, optimizing additive balance and load management to improve workability and process stability at high outputs.

Balancing Plasticization and the Air Cutting System

Alongside the formulation review, the line was configured with a calibrated dosing system to ensure constant feeding and flow rate stability, reducing pressure fluctuations along the barrel.
The screw geometry, designed and built in-house, was optimized to work at high throughput, with conveying and compression profiles designed to improve plasticization efficiency and maintain melt uniformity even at high speeds.
A key role in the production increase was played by the three-blade air cutting system, designed to operate under high-throughput conditions without compromising pellet regularity. The system uses a controlled air flow to cool and stabilize the material immediately after cutting, reducing deformation and adhesion between pellets.
The three-blade configuration allows uniform, continuous cutting even at high rotation speeds, minimizing vibration and ensuring consistent pellet length. The balance between rotation speed, air pressure, and material temperature was calibrated to sustain higher output than the previous configuration, avoiding buildup and irregularities downstream.
This integration of stable feeding, optimized plasticization, and a high-efficiency air cutting system directly contributed to achieving the 120% increase in hourly output.

A Customized Solution

María Victoria Navas: President

“From the very first extrusion line, we built an excellent relationship of trust with Bausano. It was a great pleasure for us to share this challenge, born under the sign of innovation. Relying on solutions designed specifically around the blend to be pelletized has allowed us to promptly meet our customers' needs. A success also made possible by Bausano's first-class customer service.

The Result: A 120% Increase in Production

The integration of formulation review, dosing system, screw design, and cutting optimization made it possible to achieve an increase of up to 120% in hourly output on some processes.
The increase in output in kg/h was achieved while maintaining consistent pellet quality, thermal stability, and operational continuity. The improvement is the result of an integrated approach that considers machine, material, and process as a single system.

Bausano Technology: Testing, In-House Design, and Process Control

The project demonstrates how Bausano's technology is not limited to supplying the plant, but includes preliminary analysis, validation on pilot lines, and in-house mechanical design.
The integration of material study, component optimization, and process control makes it possible to achieve measurable production increases, improving competitiveness and industrial capacity over the long term.

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