Reducing energy consumption in extrusion processes

Energy efficiency for greater competitiveness

Energy and competitiveness: reducing consumption to improve plant performance

According to a study conducted at a European level in the manufacturing sector, energy is now the main variable cost item. In industrial processes, the energy consumption associated with machinery, lighting, heating and cooling has a direct impact on the economic balance of every plant. In particular, in the plastics processing sector, energy consistently ranks among the top three expense items.
In this scenario, adopting more efficient technologies is not just a technical choice, but a strategic lever for optimizing available resources, containing consumption and improving operational management. The goal is twofold: increasing the company's competitiveness by improving economic performance and, at the same time, reducing environmental impact through more rational use of energy.
Bausano offers various solutions to reduce energy consumption, improving the plant's overall efficiency without compromising productivity.

Sewage

Fresh Water

Heating

10%

Electricity

88%

Comparative technical data to assess plant efficiency

The results of internal tests conducted on Bausano extruders were analyzed and collected, with the aim of comparing mechanical and electrical configurations in terms of installed power, motor type and energy efficiency. The technical data sheet provides a clear, measurable picture of performance, useful for assessing the real impact of different systems on specific consumption and productivity. Download the document to review the data and explore the technical parameters recorded under standard operating conditions.

01. THE CHOISE OF THE EXTRUDER
02. THE MOTORS
03. THE BARREL HEATING SYSTEM
04. MONITORING OF CONSUMPTION

HOW TO REDUCE ENERGY CONSUMPTION

Choosing the extruder

Choosing the most suitable configuration is the first step in optimizing the production process and containing energy costs. Using a large extruder to produce small cross-section profiles results in an unnecessary expenditure of energy and resources. Each polymer and each formulation requires dedicated technical testing to identify the most efficient solution, depending on the material's characteristics and screw geometry. Operating speed is also a decisive parameter: an extruder reaches minimum energy consumption when operating at the maximum speed for which it was designed, corresponding to the point of maximum mechanical efficiency. Consumption is also affected by the plant's mechanical condition: wear, coupling clearances and outdated components can cause energy dispersion and significantly increase energy requirements. However, even among new machines there are significant design differences. The Multidrive system, developed and patented by Bausano, makes it possible to reduce consumption at equal performance levels, by splitting torque across multiple drive shafts. It is a technology underlying Bausano's twin-screw extruders, designed to improve transmission reliability and contain the energy absorbed by the plant.

HOW TO REDUCE ENERGY CONSUMPTION

The Motors

The energy efficiency of electric motors has a direct impact on the plant's consumption. Motors are classified into efficiency classes IE1, IE2, IE3 and IE4, where each higher level corresponds to lower energy loss. Moving from IE3 to IE4 results in an increase in nominal efficiency and a reduction in losses, with measurable effects on operating costs. Bausano lines can be configured with IE3 asynchronous motors or, depending on production needs, with IE4 synchronous motors, which are more compact and efficient. Management via inverter ensures consistent performance even under variable load conditions. This architecture enables consumption reductions of up to 35%, helping to improve the plant's overall efficiency, with benefits in terms of production continuity, sustainability and energy cost containment.

HOW TO REDUCE ENERGY CONSUMPTION

The barrel heating system

In traditional extrusion lines, barrel heating occurs through direct contact via ceramic resistances, a system that involves high heat loss, significant thermal inertia and low uniformity in heat distribution. With this method, the material's actual temperature tends to remain about 20°C lower than that of the barrel, with energy efficiency rarely exceeding 70%. To overcome these limitations, Bausano has developed a patented induction heating system, based on the application of an alternating electromagnetic field generated by coils wound around the barrel. The action of eddy currents induced directly in the metal enables fast, uniform heating, keeping the outer surface cool and reducing radiation losses. The result is more efficient heat transfer, bringing the material to the desired temperature in less time and with greater thermal precision. The system achieves efficiency of up to 95%, with an estimated energy saving of 35% compared to traditional resistance systems.

WHICH PARAMETERS TO ANALYZE TO IMPROVE PLANT EFFICIENCY

Consumption monitoring

To reduce consumption and optimize plant performance, it is essential to have reliable data on energy absorption at the various stages of the production process. Detailed consumption analysis makes it possible to identify any inefficiencies, schedule targeted interventions and prevent waste. This is a complex activity, especially on articulated lines, where stopping production for manual checks can result in downtime and additional costs. For this reason, Bausano has integrated a suite of IoT solutions into its lines, allowing real-time monitoring of the plant's energy performance, remote data visualization and direct intervention on key process parameters: motor absorption, temperature control, alarm thresholds and operational priority management. Through the SPHERA platform, it is also possible to access technical analysis and energy consultancy services provided by Bausano, with the aim of identifying areas for improvement and defining optimization strategies that are sustainable over time. An integrated approach to consumption management, which turns data into decision-making tools and supports the company in cost containment and long-term efficiency

Bausano extruders guarantee the lowest consumption in their category

Bausano is committed to developing extrusion lines that integrate patented technologies, capable of concretely reducing operating costs and the environmental impact of the production process. One application example demonstrates this: on a twin-screw extruder from the MD 130 series, the adoption of the induction heating system enables an energy saving of 13.8%, bringing actual consumption to 112 kWh/h compared to a reference value of 130 kWh/h. In a context with an average energy cost of €0.20/kWh, the cost per kilogram produced drops to just €0.0224/kg.
Measurable figures that confirm the efficiency of Bausano's solutions. In addition to the induction heating system, the Multidrive 4×2 mechanical transmission also helps improve overall yield, optimally distributing torque and reducing mechanical losses. Bausano's design approach combines energy efficiency, reliability and process data control, with the aim of providing machines designed to last, consume less and be economically sustainable. Through engineering innovation, consultancy services and integrated monitoring tools, Bausano extrusion lines rank among the most efficient solutions on the market in terms of energy-to-product ratio.

A starting point to define the right solution together

By filling in the form below, it is possible to describe specific technical or production requirements. The technical team will carefully evaluate the request in order to propose the most suitable extrusion line or extruder.

Reducing energy consumption in extrusion processes

Energy and competitiveness: reducing consumption to improve plant performance

Sewage

Fresh Water

Heating

Electricity

Comparative technical data to assess plant efficiency

01. THE CHOISE OF THE EXTRUDER

02. THE MOTORS

03. THE BARREL HEATING SYSTEM

04. MONITORING OF CONSUMPTION

Choosing the extruder

The Motors

The barrel heating system

Consumption monitoring

Bausano extruders guarantee the lowest consumption in their category

A starting point to define the right solution together