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sensXPERT enables plastics manufacturers to increase efficiency by up to 30%

30 September 2022

NETZSCH Process Intelligence, a corporate venture of NETZSCH Group, has announced the launch of sensXPERT, a technology business designed to deliver significant productivity and quality benefits to processors in the plastics industry through data-driven manufacturing solutions.

sensXPERT combines real-time material data from the mould with advanced machine learning software to analyse the material behaviour. The smart technology enables continuous process optimisation for up to a 30 percent increase in production efficiency. 

Its technological advanced in-mould sensors provide real-time insights and transparency to react to material deviations and eliminate scrap. While allowing a dynamic and adaptive production, thus maximising throughput, sensXPERT ensures direct in-process quality control of each single moulded part.

“There is a growing need for digital technology solutions in the plastics processing industry to meet the challenges of tighter cost control, total quality assurance and enhanced sustainability,” says Dr Alexander Chaloupka, Managing Director & CTO for sensXPERT. 

“By using the artificial intelligence of our machine learning software to evaluate critical material, machine and process data, we help our customers optimise their manufacturing efficiency in real time, eliminating the need for time and labour-consuming retroactive adjustments.”

At the heart of sensXPERT’s manufacturing solutions, an Edge Device integrates the hardware and software for machine learning models designed to capture even the slightest deviation of material and process parameters. 

Based on measuring data collected from high-precision in-mould sensors, smart machine learning algorithms are applied to simulate, predict and analyse the actual material behaviour on each individual machine. 

The learning models are trained with key parameters, including standard material and experimental data, such as glass transition temperature, pressure and required degree of curing, and are then continuously fine-tuned depending on the in-situ data measured over time. 

“Industry 4.0 stakeholders need real-time answers to what is happening in their manufacturing processes,” adds Cornelia Beyer, Managing Director & CEO of sensXPERT. “Our unique approach unlocks the potential of fully data-driven productivity, delivering immediate quality and efficiency benefits to our customers in the plastics processing industry.”

The sensXPERT technology adapts to any common thermosets, thermoplastics and elastomers processing technique, from injection, compression and transfer moulding to thermoforming, vacuum infusion and autoclave curing. 

It connects with customers’ existing manufacturing and control systems through standard industrial interfaces and is offered as a cloud-based Equipment-as-a-Service (EaaS) solution. An intuitive web app is provided for convenient on-site or remote user access.

Use cases in major industry segments, such as in the manufacturing of automotive composite wheels and aeroplane wing components, have shown significant increases in overall equipment efficiency (OEE), including solid return of investment (ROI). Similar solutions can easily be implemented in other industries.

Visitors of K 2022 from October 19 to 26 in Düsseldorf, Germany, will find sensXPERT at NETZSCH Process Intelligence’s Booth C36 in Hall 12.

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