Bausano @ K2025: The New Face of Extrusion is Digital and Intelligent

At K 2025, the leading trade fair for the plastics and rubber industry, taking place in Düsseldorf from October 8 to 15, Bausano presents itself with a new brand identity and a renewed offering, where digital technologies and artificial intelligence applied to extrusion process control play a starring role (stand B70, hall 16).

“On the eve of the company’s 80th anniversary, Bausano returns to K with a new look that reflects its commitment to scientific rigor and technological excellence” states Clemente Bausano, CEO, who continues: “The new visual identity does not only concern the brand’s aesthetics: it is a concrete and coherent expression of Bausano’s strategic vision, aiming to combine precision engineering and advanced digital technologies to effectively respond to the challenges of modern industry.” He concludes: “This rebranding reflects what Bausano is today: a solid company, future-oriented and capable of anticipating the sector’s needs.”

At the heart of the new positioning lies the concept ‘Extrusion Instinct’, a synthesis of Bausano’s distinctive approach, which combines vertical specialisation, results-oriented culture, and the ability to innovate naturally and continuously. The new logo, composed of two interwoven arrows forming the letter “B”, visually embodies the Company’s dynamism and its commitment to a smarter, more connected and sustainable industrial model.

Advanced control, powered by AI: welcome to Bausano SPHERA

Bausano SPHERA will also make its debut at K 2025: the digital ecosystem that marks the beginning of a new production paradigm, built around real-time control. Its three native modules are designed to transform data into value, anticipating the operational needs of end users.

For the first time, thanks to the Bausano SPHERA software suite, artificial intelligence is integrated directly into the machine, revolutionising traditional extrusion plant control logics. Through an intuitive interface, users can now monitor dynamic KPIs and the plant’s OEE index, receive personalised operational suggestions, and take action to maximise line performance, empowered by predictive diagnostic features.

The Bausano SPHERA suite represents the new frontier of real-time control: a set of advanced and versatile tools, designed to support process managers in making fast, informed decisions aimed at maximum efficiency and enhanced process sustainability.

Innovation takes centre stage with two live demos

Visitors to the booth will have the opportunity to interact directly with the AI-based Bausano RANGER interface, one of the suite’s core modules, installed on two high-performance extruders:

• A counter-rotating twin-screw MD 130/25 for compound production
• A single-screw E-GO 60/37 for multilayer HDPE pipe manufacturing

Both demo systems are concrete expressions of Bausano’s technological expertise, integrating solutions aimed at improving output quality while reducing energy consumption.

Among the most notable features of the twin-screw extruder are:

• Induction heating, a Bausano patent since 2024
• The Multidrive system
• Combined feeding with gravimetric dosing and volumetric conveying

These innovations offer enhanced gelification of PVC. In addition, the PVD treatment applied to the pelletizing head ensures high abrasion resistance and consistent granule quality, even during extended production cycles, while optimising cutting performance.

The E-GO single-screw extruder, on the other hand, features a custom screw with high-dispersion mixer and Maddock element, both developed in-house by Bausano to ensure melt homogeneity even at low fusion temperatures, resulting in lower energy impact. The line is also characterised by its compact design with servo-assisted axial ventilation, designed to reduce footprint and facilitate integration into existing plants.

The solutions showcased at K demonstrate the synergy between advanced technologies and smart control architectures, showing how their integration can significantly boost machine performance. The Bausano booth will thus be the ideal place to explore, alongside Bausano experts, the digital transformation of the extrusion industry.

Read more from Bausano here.

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