Digital Automation and Process Control

Data, algorithms, and Bausano expertise

Predictive Maintenance and Strategic Value for Bausano Plants

Predictive maintenance delivers real value when integrated into the plant design from the outset. For Bausano, intelligent automation and predictive maintenance mean structured knowledge of every stage of the in-house developed extrusion process. Every Bausano extruder, every dosing system, every line accessory generates measurable, traceable data: temperature, pressure, screw speed, torque, and energy consumption are acquired and correlated in real time. This in-depth knowledge of the machine allows Bausano to correctly interpret every deviation from nominal parameters, considering the interaction between mechanical and electrical components and process variables. This makes it possible to identify operational drift before it becomes a production issue: predictive maintenance on Bausano extruders works exactly this way, turning machine data into targeted interventions before a failure occurs. Prevention translates into operational continuity, quality stability, and reduced downtime.
With the Bausano Sphera digital suite, this technical expertise extends to every installed plant. Integrated sensors and Industrial Internet of Things technologies collect information along the entire line, while artificial intelligence algorithms analyze historical and real-time data to identify recurring patterns and anomalies. Intelligent automation thus enables Bausano to supervise customer plants and provide targeted operational guidance based on objective evidence.

Benefits of the Predictive Approach to Extrusion

Continuous monitoring of critical line parameters
Reduced unplanned downtime on Bausano plants
Greater quality stability of the finished product
Dynamic calculation of KPIs and OEE to measure real efficiency
Integration between production, maintenance, and technical support
Optimization of energy consumption and operating costs
Early identification of mechanical and process drift
Decision support based on machine learning algorithms

Bausano Pharos: Digital Control and Line Data Analysis

Bausano Pharos is the Industrial IoT module of the Sphera suite. It digitalizes the entire Bausano extrusion line and connects machines, data, and operators in a single integrated environment. It collects information through industrial protocols such as OPC UA and Modbus TCP. It continuously monitors extruders, feeders, haul-offs, and cutting systems. It displays temperature, pressure, screw speed, energy consumption, and alarm status in real time.
It archives historical data and generates customizable reports by shift, recipe, or line. Through advanced analytical models, it identifies inefficiencies and potential failure risks. Pharos supports targeted interventions and progressively improves analysis accuracy through machine learning.

Bausano Ranger: Digital Assistant for Informed Operational Decisions

Bausano Ranger is the predictive intelligence and digital assistance module integrated into the Sphera ecosystem. It works as a conversational interface between operators and Bausano plants. It integrates historical and real-time data to provide contextual answers on alarms, parameters, and line performance. It suggests corrective actions in the presence of abnormal consumption, pressure drift, or temperature variations.

It is accessible via browser, HMI panel, or tablet. It supports structured event management and facilitates staff training. It helps reduce average response time and increase diagnostic accuracy.

Bausano Scout: Integrated Spare Parts Management in the Plant's Digital Cycle

Bausano Scout is the portal dedicated to original spare parts management, integrated into the Sphera suite. It provides 2D exploded views linked to the serial number of each Bausano line. It allows visual selection of compatible components and direct submission of quote requests. Every activity is tracked and linked to the installed machine. Order history and technical documentation are always available.
Scout reduces identification errors, speeds up procurement times, and makes maintenance an integral part of a structured digital process.

Data Security and Protection as the Foundation of the Digital Suite

The Bausano Sphera suite is designed to ensure industrial data security, confidentiality, and full control over the data generated by the plant's intelligent automation. Each module — Scout, Ranger, and Pharos — operates within a unified architecture based on open industrial protocols, encrypted communications, and certified cloud infrastructure, in compliance with international data protection regulations. Security is built into the digital automation system to ensure operational continuity, traceability of operations, and protection of the customer's know-how.

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Real-Time Monitoring

Bausano digitalizes the extrusion line, making temperature, pressure, screw speed, and energy consumption visible in real time. Data is collected via industrial protocols and organized into intuitive dashboards. Continuous monitoring makes it possible to identify deviations and improve process stability.

Intelligent Digital Assistance

A conversational assistant integrates machine data and technical documentation. Operators can receive support on alarms, parameters, and recipes directly from the HMI, browser, or tablet. Responses are contextual and based on the line's actual conditions.

Integrated Spare Parts Management

The spare parts portal links every component to the plant's serial number. 2D exploded views enable precise identification of compatible parts. Requests are sent directly to Bausano, with full traceability and order history always available.

Performance Optimization

Intelligent automation makes it possible to analyze process parameters, energy consumption, and production output in an integrated way. Data is correlated to identify areas for improvement and stabilize operating conditions. The line runs more efficiently, with greater quality control and optimized use of resources.

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.