Innovation according to Bausan

A continuous process driven by experience and industry

Innovating means understanding the process, recognizing critical issues and designing solutions that last

Bausano interprets innovation as an integrated engineering process, in which knowledge of extrusion technologies is continuously tested against the real needs of industrial applications. Innovation is not an abstract concept, but a structured method that combines analysis of production requirements, selective adoption of emerging technologies, and verification of results through testing under real operating conditions. This approach makes it possible to introduce effective, measurable technical solutions in plants that handle different materials, complex geometries and strict process specifications.
Attention to client needs is central to the innovation process: every development originates from identifying critical issues such as process instability, high energy consumption, component wear or difficulties in digital integration. Technologies are then designed to address these points, for example by integrating advanced monitoring and control platforms with data analysis capabilities, adopting transmission systems such as Multidrive that distribute torque and reduce mechanical stress, or applying more efficient induction heating methods to contain consumption.
At Bausano, innovation is a path of continuous improvement based on engineering criteria: the adoption of technologies such as Industrial IoT, artificial intelligence for process control and advanced heating systems is preceded by a technical analysis of expected performance and experimental validation of the solutions. The result is a portfolio of technologies that address specific extrusion needs — from process stability to reduced consumption, from managing recycled materials to optimal power distribution — and that can be integrated into lines with a vision of performance, control and sustainability.

IoT solutions and artificial intelligence applied to extrusion plants

Artificial intelligence applied to extrusion marks a paradigm shift: it analyzes process parameters in real time — temperature, pressure, torque, flow rate — and correlates them to prevent anomalies before they turn into scrap or machine downtime. Bausano is the first manufacturer to have natively integrated it into the Sphera platform, to support production and improve the quality of the finished product. Thanks to Industrial IoT, each line becomes a connected system capable of collecting and transmitting process data in real time, enabling predictive maintenance and complete traceability of production parameters. The result is deeper process control, greater production stability and concrete support for operational decisions, with reduced scrap and line downtime

KEEP READING

Patented Induction Heating

Bausano's patented induction heating system uses electromagnetic induction to heat the barrel without direct contact between the heating element and the metal surface. Compared to traditional resistive systems, this technology reduces energy consumption by up to 35%, improves thermal stability along the entire barrel, and extends component life, reducing maintenance frequency and related line downtime.

Energy Efficiency in Extrusion Lines

Extrusion is among the most energy-intensive industrial processes: this is why Bausano designs its lines to optimize energy efficiency throughout the entire production process. Measuring, reducing and predicting energy costs is not just a technical choice, but a strategic economic factor that directly impacts the client's competitiveness, thanks to solutions such as induction heating, digital control via Sphera, and optimized screw configurations to reduce energy waste.

Patented Multidrive System

Multidrive is Bausano's patented transmission system that significantly affects the line's overall energy balance, distributing torque across multiple motors instead of relying on a single central gearbox. Every Bausano line is designed to optimize process parameters and reduce consumption, thanks to technical solutions aimed at containing energy costs, reducing mechanical stress on components and ensuring the plant's long-term sustainability.

Polywood Technology

Polywood technology makes it possible to process mixed, recycled or natural raw materials, such as wood fibers in WPC (Wood Plastic Composite) compounds, with high formulation flexibility. It is ideal for extruding WPC profiles, such as outdoor decking and cladding, with advantages in terms of environmental sustainability, valorization of waste materials and production continuity even with variable formulations.