Induction system: energy efficiency

35% less than traditional systems

Bausano induction system: lower consumption, higher efficiency

In 2024, Bausano patented an innovative induction heating system, the first in the plastics extrusion sector to be applied on an industrial scale. The system replaces traditional ceramic resistance heaters with an electromagnetic field that generates heat directly on the barrel surface. This allows for more efficient heat transfer, a significant reduction in heat loss, and more stable temperature control throughout the entire production cycle.
Compared to traditional heating systems with ceramic resistances, the induction technology developed by Bausano ensures energy savings of up to 35%, reducing operating costs and improving the plant's overall performance. This is combined with faster start-up times, more uniform heating, and a significant reduction in component wear.
The system's energy efficiency also contributes to the environmental sustainability of the entire process, with lower consumption and reduced indirect emissions. A concrete advantage for plants serving high-volume sectors such as construction, packaging, medical and automotive, where operational continuity and cost optimization are decisive factors.

The advantages of the Induction System: more efficiency, less waste

Energy savings of up to 35% compared to traditional heating systems with ceramic resistances
Faster line start-up thanks to direct heating on the barrel
Stable temperature during the process: less scrap and higher product quality
No thermal dispersion to the outside: greater safety for operators

Simplified installation with an openable coil
Ventilation costs reduced by up to 50% thanks to lower heat dispersion into the environment

Features of the Patented Induction Heating System

Energy efficiency of up to 95% during the heating phase
Direct heat transfer to the barrel through electromagnetic induction
Uniform temperature distribution across the entire heated surface
No thermal inertia: immediate response to setpoint changes
Heaters designed for an unlimited operating service life
Minimal temperature difference between the material and the barrel

HOW TO REDUCE ENERGY CONSUMPTION

Features of Traditional Ceramic Heaters

Average energy efficiency of approximately 70%
Heat transfer through direct contact with the heating elements
Non-uniform temperature distribution across the barrel
High thermal inertia, resulting in longer response times
Heaters subject to wear, with a limited service life
Average temperature difference of 20°C between the material and the barrel surface

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System comparison

Resistance system MD 130							Induction system MD 130
Rated Power
No. of heating intervals	Power intervals in Watts	Total area power in Watts	Interval control (sec)	Time on (sec)	% time on (sec)	Absorbed power (kWh)	Power reduction (%)	Absorbed power (kWh)	Energy saving kWh	Energy saving %
1	10.000	10.000	60	36	60	6	30	4.2	1.8	30
3	5.000	15.000		30	50	7.5		5.25	2.25
3	5.000	15.000		30	50	7.5		5.25	2.25
1	7.500	7.500		12	20	1.5		1.05	0.45
1	7.500	7.500		12	20	1.5		1.05	0.45
1	6.000	6.000		12	20	1.2		0.84	0.36
1	6.000	6.000		12	20	1.2		0.84	0.36
1	7.500	7.500		12	20	1.5		1.05	0.45
1	7.500	7.500		12	20	1.5		1.05	0.45
Total areas		82,000				29.4		20.58	8.82

Energy saving forecasts - Depreciation calculation
Cylinder power consumption reduction	kW	A	8.82
System operating hours	h/year	B	6.000
Energy cost	€/kWh	C	0.14
Energy saving	€/year	D = ABC	7.409

Estimate calculated over an active production cycle, based on the estimated consumption of each individual zone, considering 4 to 9 active zones for 20% of the time.

Induction technology: the advantage is operational

Bausano's patented induction heating system generates heat directly in the barrel through eddy currents, ensuring fast, uniform and precise heat transfer. With efficiency of up to 95%, it enables energy consumption savings of up to 35% compared to traditional systems with ceramic resistances, optimizing start-up times and temperature control.
The technology can be integrated across the entire range of Bausano extruders – MD, E-ON, E-GO and E-GO R – and is applied to the production of pipes, profiles, pellets and medical components. The absence of thermal dispersion to the outside also reduces ventilation requirements, improving the efficiency of the production environment. For the client, this means cutting energy costs and having a concrete impact on the cost per kilogram of processed material, with measurable and consistent benefits over time.

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.