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AI and Industry 4.0: Transforming the Future of Extrusion Manufacturing

In the long journey, the Industrial Revolutions, have served as the ultimate milestones of our advancement. From the 18th century’s Industry 1.0 to the digital frontier we occupy today, each era has redefined what is possible. At Rajoo Bausano Extrusion Pvt. Ltd., we believe the current shift toward Industry 4.0 isn’t just about making machines faster—it is about making them more human-centric, sustainable, and intelligent.

From Steam to Smart: A Journey Through the Revolutions

The history of industrial revolutions showcases humanity's progress toward greater efficiency and innovation:

  • Industry 1.0: Mechanization with steam and water power replaced manual labor.
  • Industry 2.0: Electricity enabled mass production and assembly lines.
  • Industry 3.0: Electronics, IT, and automation introduced computers for enhanced precision.
  • Industry 4.0: Today, AI, IoT, and cyber-physical systems create connected, intelligent factories.

In plastic extrusion manufacturing, Industry 4.0 means extrusion lines that not only produce faster but also predict issues, optimize energy use, and ensure consistent quality—making operations more human-centric and environmentally responsible.

AI in Extrusion: Beyond Smart, Towards Intelligent

Based in Rajkot, we at Rajoo Bausano Extrusion Pvt. Ltd. manufacture pipe and profile extrusion lines, and we have been actively integrating AI into our machinery. Formed as a joint venture between Italy’s Bausano & Figli and India’s Rajoo Engineers Ltd., we are now incorporating an advanced AI-powered system, Sphera, into our extrusion lines to enhance performance, intelligence, and operational excellence.

Mr. Sandip Bhuva, CEO- Rajoo Bausano, emphasizes that the AI-powered digital ecosystem Sphera is nothing short of a revolution in pipe, pellet, and profile extrusion technology. With its integration, we are setting a new benchmark for the industry. This technology not only makes our machines smart but also empowers them with intelligent decision-making, predictive diagnostics, and real-time optimization. As a result, our customers experience an entirely new level of efficiency, quality, and reliability.

Approaching its 80th anniversary, Bausano participated in K 2025 in Düsseldorf, Germany, where it showcased its new AI-powered digital ecosystem Sphera, integrated into a counter-rotating twin-screw extruder for compound production and a single-screw extruder for multilayer HDPE pipe manufacturing.

One of the key strengths of this ecosystem is how it enhances machine intelligence:

  • Predictive Maintenance: The system identifies warning signs in components before failures occur, reducing unscheduled downtime.
  • Real-Time Monitoring: Critical extrusion parameters such as temperature, torque, and pressure are monitored continuously to maintain stability.
  • Dynamic KPI Tracking & OEE: The system keeps track of essential performance metrics, including Overall Equipment Effectiveness, as processes run.
  • Personalized Suggestions: Based on machine data, AI algorithms provide actionable operational advice tailored to each line.
  • Learning Optimization: Over time, the system learns from historical runs to improve performance and reduce operator adjustments.

Ensuring Measurable Quality in Extrusion Processes

Advanced monitoring systems in extrusion lines ensure that every product meets the highest quality standards. These lines are engineered to provide precise and consistent control over all critical process parameters, from raw material to the finished product. With extensive expertise, tailored solutions are delivered to guarantee quality, reliability, and efficiency at every stage of production.

Powering Smarter Efficiency

AI-powered digital ecosystems in extrusion lines are designed to deliver significant energy savings. By intelligently optimizing heating and cooling cycles, the system minimizes unnecessary power consumption while maintaining precise process stability. With the Smart Energy System, energy consumption is reduced by up to 35% compared to traditional systems. This not only lowers operational costs but also supports sustainability goals, enabling manufacturers to achieve higher productivity with a reduced environmental footprint.

The Future of Extrusion in Industry 4.0 and Beyond

The journey of industrial progress shows us that every revolution has brought a new wave of possibilities, reshaping how businesses operate and how products are created. Today, as we stand in the era of Industry 4.0, the fusion of artificial intelligence, digital ecosystems, and smart manufacturing is driving a shift that goes far beyond productivity. It is about creating systems that are more intelligent, more sustainable, and more responsive to the needs of both manufacturers and consumers. From predictive maintenance to energy efficiency, and from real-time monitoring to quality assurance, these advancements reflect a broader vision—one where technology not only supports operations but also redefines them. As industries continue to innovate, this transformation is laying the foundation for a smarter and more sustainable future for global manufacturing.