Engineering

A Scientific Approach
to Custom Design

At Bausano, every extrusion system begins with an advanced technical analysis process, involving a specialized design team from the very first stages. 
This scientific design approach starts with a structured and preliminary data collection phase, aimed at fully understanding the production environment, identifying potential critical points, and precisely defining project objectives.

Data-Driven Insights

The data collected is processed using flow simulation software, enabling evaluation of key parameters such as material consistency, homogeneity, viscosity, and thermal response.  

This is followed by a cross-analysis, integrating results from the rheometer, plastograph, and simulation software to identify any thermal, pressure, or flow distribution issues. 
These insights guide the custom design of screw and die geometries, tailored to the specific rheological behavior of the selected polymer.

Test & Simulation Laboratory

Each extrusion line design takes shape through in-depth research, carried out within our in-house Test & Simulation Laboratory. The lab is equipped to reproduce, in a controlled environment, the real behavior of thermoplastic materials, collecting essential data to guide each phase of the design process. Key instruments include:

Capillary Rheometer
Plastograph
Optical Microscope
Precision Scales
Densimeter
Laboratory Extruders

Data-Driven Insights

Test & Simulation Laboratory

Capillary Rheometer
Plastograph
Optical Microscope
Precision Scales
Densimeter
Laboratory Extruders

Tailored Design & Performance Optimization

Combined with the technical team's expertise, this approach allows Bausano to develop customized screws and heads, optimized for the customer’s specific material behavior. 
Geometry adjustments are made to enhance extrusion efficiency by directly acting on output rate, pressure, torque, thermal profile, residence time, degassing efficiency, fill ratio, mechanical shear, and melt stability.
The ultimate goal is to:

Maximize productivity

By optimizing screw and die geometries, the extrusion process reaches higher output rates with greater stability.

Reduce waste

Precise material flow control minimizes defects and off-cuts, ensuring efficient use of raw materials.

Ensure process consistency and control

Advanced monitoring and design adjustments guarantee uniform results, even when operating conditions change.

This integrated approach ensures extrusion lines that deliver superior performance, combining efficiency, sustainability, and long-term reliability.

Extrusion Technologies

Our extrusion engineering combines cutting-edge flow simulation with patented mechanical solutions to deliver systems built around the specific behavior of each polymer.
From screw profile to thermal control, every element is precisely calibrated to maximize throughput and process efficiency.

Test & Analysis

Bausano’s in-house lab enables full-scale simulations to anticipate operational challenges and optimize performance before physical production begins. By integrating data from reometers, plastographs, and flow models, we guarantee solutions that deliver real-world robustness and reliability.

Materials

At Bausano, every material is rigorously characterized through in-depth testing, using precision instruments to define rheological and thermal parameters.
These insights directly influence the design of extrusion geometries, ensuring compatibility and consistent performance across every setting.

Collaborative Engineering

Bausano’s technical consulting guides customers through every stage of plant design, ensuring that each solution is perfectly aligned with real production needs.
Our Technical Department works side by side with the client, focusing on:

Defining production goals with clarity and precision
Evaluating scalability to support future business growth
Analyzing application constraints to anticipate potential challenges

This dialogue, supported by laboratory data and real-world design experience, enables the creation of extrusion lines that are not adapted from standard models but are truly customized.
The real strength of collaboration lies in our ability to listen, analyze, and transform requirements into tailored engineering solutions.

Integrated Engineering

Once the technical analysis is completed, the process evolves into detailed system design.
Our engineering team integrates mechanical, electrical, and software expertise to develop each component in perfect synergy. Key elements include:

Screw and die geometries, optimized for material behavior
Control logic, designed for precision and process stability
User interface, intuitive and reliable for operators

The result is a modular and scalable system, engineered to be seamlessly integrated into digital environments and aligned with the principles of Industry 5.0: efficiency, connectivity, and human-centered design.

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Engineering

A Scientific Approach to Custom Design

Data-Driven Insights

Test & Simulation Laboratory

Data-Driven Insights

Test & Simulation Laboratory

Tailored Design & Performance Optimization

Maximize productivity

Reduce waste

Ensure process consistency and control

Extrusion Technologies

Test & Analysis

Materials

Collaborative Engineering

Integrated Engineering

Didn’t you ﬁnd what you were looking for?

A Scientific Approach
to Custom Design