European Case Study: Compound Production with Induction Technology and Lower Energy Consumption

Up to 35% reduction in consumption with Bausano's patent.

PlastChem: 7 Induction Lines for Europe's Most Modern PVC Compound Plant

CUSTOMER

PlastChem B.V.

DATE

October 2025

INNOVATIONS

Induction Heating System

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PlastChem: Seven Lines with Induction Heating

PlastChem B.V., a Dutch producer of PVC compounds with more than forty years of experience, is now recognized as one of the most advanced players in Europe in the formulation and production of custom blends. With more than 3,000 formulations developed for technical applications, the company operates on annual volumes of tens of thousands of tons, serving a highly competitive international market.
At the new plant in Hardenberg, designed to be one of the most modern PVC compounding facilities in Europe, PlastChem chose to strengthen its partnership with Bausano by installing six extrusion lines equipped with an induction heating system.
The machine fleet includes two MD 170 twin-screw extruders, three MD 158, one MD 130, and one MD 66, configured to cover different production capacities and ensure flexibility in managing different formulations.

Reducing Specific Consumption by 40% and Ensuring Stability Across 3,000 Formulations

Large-scale PVC compound production requires plasticization stability, rigorous temperature control, and operational continuity over extended cycles. For a producer with thousands of active formulations, process repeatability is a strategic requirement. The new site was designed with a precise objective: to maximize output in kg/h while reducing energy consumption per kg produced, maintaining consistent pellet quality and batch-to-batch consistency.

High-Performance Machines Designed to Measure

All six installed lines are equipped with an electromagnetic induction heating system, chosen as the standard configuration for the entire plant. Induction transfers energy directly to the barrel through an alternating electromagnetic field, eliminating the dispersion typical of traditional resistive systems. Heating is faster, more uniform, and more precise along the entire length of the barrel. This configuration allows a reduction in energy consumption of up to 30–35%, improving overall process efficiency and helping reduce the plant's carbon footprint. The adoption of induction across all lines represents a structural choice consistent with PlastChem's positioning as a technologically advanced, sustainability-oriented producer.

Over 3,000 Formulations

Tom Baveld: COO

“Bausano is an important partner for our company's growth, both because of its high-value-added consulting and its constant support and speed in problem-solving,” Tom Baveld continues. “For this reason, we have embarked on a long-term journey in which the two companies work together toward the best solution, enabling us to adopt virtuous practices and advanced, efficient technologies in order to increase our competitiveness in the market,” and concludes: “A concrete example of this is the expansion of our machine fleet, with two additional compounding lines, on the occasion of the inauguration of our new production site.”

Technical Configuration for Over 3,000 Formulations

The six lines have been configured to ensure operational flexibility in managing thousands of different recipes. The combination of screw geometry, digital parameter control, and the induction system makes it possible to maintain thermal stability even in the presence of rheological variations between one formulation and another. This level of control makes it possible to operate at high throughput while maintaining pellet uniformity, plasticization stability, and process repeatability.

Result: High Productivity with Structured Energy Control

The integration of six lines with induction heating allows PlastChem to operate with high productivity, consistent quality, and optimized energy consumption on an industrial scale.
The technological choice adopted at the Hardenberg site strengthens the company's position as a European benchmark in PVC compound production, with an industrial model that integrates production capacity, energy efficiency, and process sustainability.

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