The digital ecosystem for extrusion control

Digital suite based on IIoT, AI and data analysis

Introducing SPHERA: industrial IoT and artificial intelligence for smart line management

In modern extrusion lines, continuous process parameter control, reduced plant downtime and rapid access to operational information are essential requirements. The availability of reliable real-time data makes it possible to intervene with greater precision, reduce scrap and maintain stable, repeatable production conditions.
Industrial IoT technologies integrated with Bausano's proprietary artificial intelligence make it possible to acquire, store and analyze the data generated by plants, turning it into useful operational information. Advanced data analysis supports performance monitoring, detection of process drift and anomaly prevention. Digital assistance facilitates interaction between operators, machines and technical support, simplifying day-to-day line management.
This is the context in which Bausano Sphera was created, the AI-based digital suite developed for extrusion control. An integrated ecosystem that combines IIoT supervision, AI, structured spare parts management and digital operational support in a single platform. Sphera is organized into three interconnected modules: Pharos for monitoring and analyzing production data, Scout for autonomous management of spare parts and technical documentation, and Ranger for operational assistance based on the line's real-time data.
For the client, Sphera means greater process visibility, data-driven operational decisions, more efficient plant management and constant, real-time assistance thanks to generative artificial intelligence. The result is reduced downtime, better consumption control and continuous support throughout the entire lifecycle of the extrusion line.

The SPHERA ecosystem is organized into three fully integrated modules:

PHAROS

Pharos is the Industrial IoT module of Bausano Sphera dedicated to monitoring and analyzing production data. It acquires the line's key parameters in real time, stores them, and makes them available for operational and comparative analysis. Pharos supports performance control, detection of process drift and downtime prevention, improving stability and production continuity

SCOUT

Scout is the Bausano Sphera module designed to simplify spare parts and technical documentation management. Through interactive exploded views and personalized access, it enables correct component identification, sending requests and consulting order history. Scout reduces errors, downtime and unplanned activities, making maintenance more efficient and traceable.

RANGER

Ranger is the Bausano Sphera artificial intelligence assistant that supports operators and technicians in their daily activities. It interprets the line's real-time data and provides contextual operational guidance through natural language. Ranger speeds up anomaly diagnosis, facilitates onboarding of new operators and improves interaction between the plant and Bausano's technical support.

BAUSANO SPHERA connects machines, data, and people, transforming extrusion into a smart, efficient process ready to meet the challenges of future industry.

Bausano SPHERA
Welcome to the new era of extrusion

Bausano Sphera is a suite of digital services that allows Bausano to continuously support the client in managing and evolving the extrusion line.

Through Pharos, Scout and Ranger, Bausano collects and interprets process data, operational information and maintenance history, maintaining an up-to-date, structured view of each plant's status. This constant connection between machine, data and expertise makes it possible to offer ongoing monitoring, performance analysis and targeted technical consultancy, based on real operating conditions. The result is concrete support for improving production efficiency, preventing critical issues and planning interventions, accompanying the client throughout the entire lifecycle of the line.

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Bausano Sphera 5.0: digital artificial intelligence ecosystem

Structured analysis of production data makes it possible to optimize resource use throughout the entire extrusion process. Continuous monitoring makes it possible to detect deviations and abnormal conditions in advance, reducing waste, unexpected downtime and corrective actions. Intelligent diagnostics and predictive maintenance support the line's operational stability and production continuity.

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PHAROS: the data analysis software

Pharos is the digital core of the production line: a modular, scalable IIoT platform designed to transform extrusion systems into connected, traceable and intelligent environments. Provided as Software-as-a-Service, it enables advanced production management, supporting data-driven operational decisions and improving performance at every stage of the process.
Its goal is to bridge the information gap between Bausano and the plant's end user, offering continuous, real-time and historical visibility of machine performance and process parameters.
Pharos supports manufacturers in the transition toward smart, data-driven production, providing a structured, shared view of line information. Through continuous acquisition of machine data via standard industrial protocols and integrated sensors (OPC-UA, Modbus TCP, SQL), Pharos interprets process parameters and turns them into reliable operational information. This approach allows everyone involved in production to work with consistent, up-to-date data, improving process control and the quality of operational decisions.

SCOUT: structured spare parts management

SCOUT is Bausano's intelligent portal for spare parts management, fully integrated into the Bausano SPHERA digital ecosystem. It is designed to concretely support maintenance and technical support activities, offering the client a structured tool to manage spare parts precisely and consistently throughout the entire lifecycle of the plant.
Through interactive exploded views linked to the line's serial number, SCOUT makes it possible to correctly identify compatible components, reducing the risk of errors and downtime. The order history, request traceability and direct access to technical documentation enable more efficient and informed maintenance management.
Accessible from any browser, with no local installations, SCOUT is available anytime, anywhere. This operational continuity ensures the client a timely and secure spare parts management experience, simplifying the relationship with Bausano's after-sales service and improving the overall reliability of the extrusion line.

RANGER: the integrated digital assistant

Ranger is the artificial intelligence assistant integrated into the Bausano Sphera ecosystem that acts as an operational interface between people and the extrusion line. It doesn't just display data — it uses it to answer questions, guide operational activities and support problem diagnosis, based on the plant's actual status.
Ranger accesses process data, alarms, machine events and technical documentation associated with the specific line. Through natural language interaction, it allows operators and technicians to obtain contextual information, operational guidance and step-by-step support, without having to consult manuals or separate systems.
For the client, Ranger means reducing intervention times, supporting less experienced operators, standardizing operational procedures and improving the connection between the plant and Bausano's technical support. The result is faster, more consistent assistance based on the line's actual data.

Data security and protection as the foundation of the digital suite

The Bausano Sphera suite is designed to ensure security, confidentiality and full control of industrial data. Each module operates within a unified architecture based on open industrial protocols, encrypted communications and certified cloud infrastructures, in compliance with international data protection regulations. Security is built into the system to ensure operational continuity, traceability of operations and protection of the client's know-how.

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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.