Case Studies

Our technology is well suited for almost any continuous manufacturing process, such as fiber optic cable drawing, thin film manufacturing, chemical processing, and food & beverage production.

Here are a few of our success stories:

reactive extrusion

The production lines each utilized four large extruders with flows that combined into a single continuous profile. Each extruder produced a different polymeric material, and all of them utilized reactive extrusion (polymerization initiated by injecting chemicals into the extruders). The customer suffered from unstable output due to natural variations in raw materials and plant conditions.

We deployed on three production lines in this facility and achieved:

• 39% reduction in scrap and waste

• 82% reduction in unplanned line stops

• Payback < 3 months

rubber extrusion

The production lines utilized multiple large extruders feeding a complex die that combined the material flows around a metallic backbone. Extruders utilized various synthetic rubber compounds, and polymerization was performed by a series of gas-fired ovens downstream. The customer wanted to improve dimensional stability of the final parts and reduce the hourly interactions required by a line operator.

We deployed on two production lines in this facility and achieved:

• 47% reduction in dimensional variation

• 21% to 55% reduction in line scrap

• Runs exceeding 12 hours with no operator interventions

• Payback < 6 months

thermoplastic extrusion

The production lines utilized multiple large extruders that combined material flows into a complex profile produced at high speed. Materials were thermoplastic polymers, and the profile geometry was stabilized by a cold-water bath downstream of the extruders. The customer wanted to improve dimensional stability of the final parts and reduce the hourly interactions required by a line operator.

We deployed on two production lines in this facility and achieved:

• 54% reduction in dimensional variation

• Runs exceeding 12 hours with no operator interventions

• Payback < 6 months