Key Takeaways
- Scrap in blown film extrusion causes high costs and negatively impacts the CO₂ footprint.
- Without precise data, the only option is often to scrap the entire batch.
- With real-time data, defective sections can be identified and removed selectively.
Solution with ENLYZE
The specialty plastics manufacturer used the ENLYZE Manufacturing Data Platform to link machine data with precise time stamps, order, and product information. This enabled the team to clearly pinpoint the affected section in the event of a sudden throughput deviation, remove only that portion, and continue processing the remaining batch.
Results
- Significant scrap reduction: Only a few meters discarded instead of hundreds of kilograms of material.
- Immediate savings: Lower material and labor effort, reduced planning pressure.
- Sustainability: Noticeable reduction in the CO₂ footprint.
- Scalability: Any extrusion line can operate with the same solution.
Conclusion
With ENLYZE, the plastics manufacturer demonstrated how digitalization prevents losses and supports sustainability targets. The platform not only provides real-time transparency, but also creates the foundation for continuous optimization—from automated alerts to standardization across all sites. A clear step toward higher efficiency, lower costs, and more sustainable production.
A German specialty plastics manufacturer with more than 10 global production sites is pursuing a clear goal: 50% fewer CO₂ emissions within the next few years. Every unnecessary meter of film makes this goal harder to achieve—because scrap consumes raw materials, time, and money.
What do you do when something goes wrong on the line—and until now the only option was to scrap the entire batch?
Scrap in the production of high-performance and sustainable packaging
Blown film extrusion lines run fast, continuous processes that are absolutely critical to meeting daily production targets.
Normally, any anomaly on the line—especially in throughput—is a warning sign. And without precise data, there is only one safe but costly option: scrap the entire batch to avoid downstream quality issues and customer complaints.
That is exactly what would have happened this time as well at this German specialty plastics manufacturer.
The line speed suddenly dropped to 50% of the target value for about one minute before recovering.
“A short disruption like this? Normally we would have scrapped the entire roll—better safe than sorry. But that would have been hundreds of kilograms of material and many hours of work.”
Targeted scrap reduction with real-time machine data
Thanks to the ENLYZE Manufacturing Data Platform, the team had access to clean, structured machine data—captured directly from the equipment, tagged with precise timestamps, and linked to the product and order number.
During the incident, they were able to:
- Identify the exact start and end time of the throughput drop
- Pinpoint the defective section precisely
- Remove only those meters and continue processing the rest of the batch
The result: immediately measurable savings
Reducing scrap is the key KPI—and the first improvements became visible after just a few weeks:
- Less scrap
- Noticeable savings in material and labor time
- Reduced planning effort
- Lower CO₂ footprint
“No emergency re-order. No tense coordination with planning. Just a clean cut, a few meters scrapped, and the rest of the batch cleared for shipment.”
The solution is scalable: every extrusion line can work with the ENLYZE Manufacturing Data Platform. And the Head of Operational Excellence sees further potential: the machine data can also be used to optimize line speeds in a targeted way.
This is a machine-data-driven digitalization approach that prevents major losses and measurably advances the company toward its ambitious sustainability goals.
What’s next?
- Set up standardized alerts for throughput deviations in Grafana
- Roll out standardization to additional blown film extrusion lines
- Measure and track scrap reduction per line
You don’t need to be IT or data experts
With an end-to-end solution like the ENLYZE Manufacturing Data Platform, based on live production data, you not only reduce scrap—but also complexity.
In many factories, modern machines operate side by side with equipment that has been producing reliably for decades. This is exactly where ENLYZE comes in: the platform collects data from mixed machine fleets—especially custom-built lines—regardless of age or manufacturer, creating a central, complete data foundation across all sites.
One platform, less complexity:
- Pre-configured edge devices precisely tailored to the ENLYZE platform and specifically designed for easy and secure connectivity—without requiring IT expertise
- A comprehensive connector portfolio for OT data sources (such as PLCs and sensors), enabling connectivity beyond just OPC UA or MQTT-compatible equipment
- Data that actually matters, through automated linking of machine data with relevant production information such as orders and products
- Standardized interfaces to ERP, MES, and reporting tools like Grafana and Power BI
- One point of contact for everything—from data acquisition to analysis and integration
ENLYZE reduces the complexity of using production data. We handle the technology so your teams can focus on what matters: operational excellence and continuous improvement.
Text taken over from the original and translated – ENLYZE
