Gefran’s advanced automation redefines Bausano’s AI-driven extrusion

The ability to collect, analyse, and interpret data in real time—through intelligence distributed throughout the entire process—enables the transformation of plant-generated data into immediately actionable insights that can tangibly support operators in their daily decision-making. The result is more stable, efficient, and responsive production, in which data becomes an active element for enhancing performance: AI transforms process KPIs into concrete and timely actions, helping to prevent anomalies and ensure a continuous and efficient production flow.

To address these challenges, Gefran introduces G-Mation, an open, modular, and scalable automation platform that integrates process control, Industrial IoT, and generative artificial intelligence. A key component is the G-Mation P6 PLC, a panel-mounted device that combines the functionality of a process controller with that of an edge device. The PLC guarantees cycle times of up to 250 µs, supports multiple EtherCAT network topologies, and integrates a webserver that offers multiple visualization options. It also implements the MQTT, OPC UA, and Euromap communication standards and supports the installation of a VPN agent to ensure secure network connections without the need for external gateways. Furthermore, the Docker architecture allows new applications to be added as apps without affecting the machine’s control performance. The architecture of the G-Mation P6 PLC has been designed to comply with the requirements of new cybersecurity regulations by integrating control, visualization management, apps, and cloud connectivity within a single device. This reduces the number of interfaces exposed to cyberattacks and significantly reduces the effort required for machine certification.

It is precisely on this innovative Gefran architecture that Bausano has built a new paradigm for AI-driven plastic extrusion. In a market where skilled operators are increasingly hard to find, the challenge—beyond automation—lies in transferring expertise and decision-making capabilities directly into the process control system. The integration of machine learning algorithms into the production line enables real-time analysis of operational data, prevents anomalies, and dynamically optimizes process parameters. In fact, every second, an extrusion line generates thousands of data points that AI converts into measurable value, facilitating operator onboarding, structurally reducing downtime, and ensuring greater stability, safety, and overall line performance.

It is in this context that SPHERA takes shape—an AI ecosystem directly integrated into the extrusion line and designed to operate in a coordinated manner within a single suite. At the heart of the platform is PHAROS, an analytics engine that enables real-time monitoring of dynamic KPIs and OEE, predictive diagnostics, and historical data analysis to prevent anomalies and keep the extruder in optimal operating condition. Working alongside PHAROS is RANGER, the result of combining Generative and Agentic AI models; it is now capable of autonomously reading the data generated by PHAROS and intervening proactively to prevent deviations and optimize performance. Trained and customized specifically to meet the customer’s unique needs, it directly supports the operator in making critical adjustments by providing contextual, data-driven suggestions.

 

“The adoption of artificial intelligence in companies is now an increasingly strategic competitive factor. According to Eurostat, by 2025 nearly 20% of European companies with at least 10 employees will be using AI-based technologies, a figure that exceeds 55% among large companies.” comments Renzo Privitera, Sales Director at Gefran, who concludes, “True progress in extrusion stems from the integration of mechanics, data, and digital intelligence, and it is precisely by a company’s ability to manage complexity—by simplifying it—that we measure how well it will be able to compete in the market.”

 

Massimiliano Fenili, Technical Manager at Bausano, states: “When technological infrastructure and process expertise converge, extrusion evolves into a truly intelligent system capable of dynamically adapting to production variables,” he concludes. “Once again, this is the value of the collaboration between Bausano and Gefran: jointly developing a cutting-edge solution specifically designed for extrusion, already in operation in the field with concrete and measurable results.”