Success Story: Data-driven process optimization in plastics extrusion

Data-driven process optimization plays a key role in modern plastic extrusion. Together with the IIoT experst from iDOO, Hilscher enabled transparent access to production data of plastic extrusion specialist iBA GmbH. This laid the foundation for continuous process improvement. The result: measurable gains in efficiency, quality, and decision-making.

Key highlights of this success story:

Real-time production data from extrusion lines
Data-driven optimization instead of manual trial and error
Improved process stability and product quality
Scalable IIoT architecture for future use cases
Get first-hand insights from our interview with Martin Deters, Managing Director of iBA, and learn how data helps transform plastic extrusion processes today.

The Challenge
Plastic extrusion is a complex process. Numerous parameters such as temperature, pressure, and material flow must be precisely coordinated. For a long time, this expertise existed mainly in the minds of experienced specialists. However, such experts are becoming increasingly scarce.

Additional challenges include:

Recording production parameters required significant manual effort

Long-term data analysis was error-prone and often incomplete

Customers demanded full traceability and quality documentation

External requirements, such as higher cybersecurity standards under the Cyber Resilience Act (CRA), increased pressure
The result: Without digital support, companies risked a lack of transparency, higher scrap rates, and growing competitive disadvantages.