Bausano introduces new analysis tools and doubles test space

Bausano is strengthening its R&D department and reinventing the concept of innovation with the introduction of new analysis tools and doubling the space dedicated to testing. To this scope, the company provides a wide range of services through which customers can experience the company's quality in the design of their systems.

Thanks to the laboratory dedicated to test and experimentation, Bausano offers an exclusive working method, which starts from the customer's specific formulation to elaborate structured analyses, aimed at making each extrusion line completely tailor-made. Indeed, before designing a system, analyses are carried out at Bausano using the capillary rheometer, which studies the behaviour of the material when it flows and deforms, to understand its viscosity as a function of the shear rate gradient. With rheological material characterisation, Bausano is able to define the type of materials that can be extruded on an existing plant, optimise head design, and fine-tuning the design of the screws.

At the same time, the information collected is processed using a plastograph. Here, the customer starting materials are fed into the chamber, where they are heated and undergo shear stresses between two counter-rotating rotors. During machining, the torque applied to the rotating screws is measured, which provides information on the viscosity of the molten material and thus on any changes produced by machining on the system (gelation, branching, degradation).

The result of these analyses, a fundamental and distinctive preliminary step in Bausano know-how, is compared with data processed by software dedicated to fluid-dynamic analysis. This pre-design phase allows the development of new extrusion heads, dies and screws to be optimised by predicting exactly how the material will behave during the machining process.

Bausano's work process also differs in that the data returned by the laboratory instrumentation can be tested in advance at its factory. As a matter of fact, the company is expanding its premises and doubling the space dedicated to the test room for its customers. Specifically, Bausano has two counter-rotating twin-screw extruders MD30 and MD75. The first, for small production trials, allows the customer's formulation to be introduced into the machine and the extruded output to be observed before the line is scaled up to industrial level. The second, dedicated to trials on medium-sized plants, is aimed at guaranteeing the productivity targets required by the customer and providing the latter with a sample of material so that it can also be subjected to internal quality controls. Further enhancing the test are two more complete systems, available to Bausano customers. The first, based on an E-GO single-screw extruder for testing PP/PE base blends for the production of single and multilayer pipes, and the second, based on a single-screw extruder from the E-GO R range to test the possibility of regenerating waste materials.

The uniqueness of Bausano's services therefore lies in being able to test the customer's system twice, firstly at its own site. Prior to setup at the customer's production site, Bausano starts up the line in its own factory, either in the presence of the customer or virtually, to validate the design assumptions and test its performance, operation and noise levels. Bausano technicians are thus able to intervene promptly even before the factory acceptance test (FAT), guaranteeing maximum flexibility for the customer. In this way, Bausano offers a space where customers can refine their R&D, for a concept of innovation that goes beyond technological progress and also embraces the value-added services sector.

"The priority for Bausano is customer satisfaction. This is why our distinctive feature lies both in the exclusive range of pre-design services which, starting from the customer's formulation, allows us to tailor-make the best extrusion line, and in the possibility of verifying the design itself with double testing", said Giovanni Bausano, R&D Manager. "In addition to this, there are the after-sales services, which include an extremely well-stocked warehouse of accessories and original spare parts, and a specialised, timely assistance, both onsite and remote, for an all-round support capable of reducing machine downtime and guaranteeing continuity in the production department. A combination that positions us as a reliable partner along the entire value chain”.