In modern extrusion environments, efficient production planning, accurate process simulation, and stable control are essential to stay competitive. Cable and rubber manufacturers face growing pressure to deliver customised products quickly and consistently—while maintaining high quality and energy efficiency. boTec’s Smart Manufacturing Solution is designed to meet these challenges. It combines production planning software, manufacturing simulation software, and advanced control tools into one integrated system for extrusion lines—fully aligned with Industry 4.0 strategies.
By combining digital simulation, process control, and data integration, boTec enables a continuous, intelligent production chain. The digital twin of the extrusion line maps all plant parameters in real time, optimizes production processes, and reduces waste and energy consumption. This not only makes planning and control processes more efficient, but also more flexible—laying the foundation for sustainable, future-proof manufacturing in line with smart manufacturing principles.
Challenges in Production Planning and Control
- Disconnected Planning and Operations
Many extrusion lines lack a digital link between engineering and production. Manual setups lead to delays, inefficiencies, and missed quality targets. - Time-Intensive Commissioning and Changeovers
Without virtual testing, adapting lines for new products consumes resources and requires physical trial runs. - Limited Process Transparency
When production data isn’t digitally recorded, it’s difficult to trace root causes, ensure compliance, or make confident planning decisions. - Pressure to Deliver Custom Products Faster
Short lead times and varying customer requirements demand faster, more adaptable production control systems.
boTec Smart Extrusion Solution
boTec’s solution creates a digital twin of the extrusion line, providing a central tool for production planning, simulation, and live control. It’s specifically built for the complex environments of cable and rubber manufacturing.
- Virtual Line Configuration
Use advanced manufacturing simulation software to model full production lines—including extruders, curing tunnels, nitrogen or steam processes, and thermal zones. - Validated Recipe Planning
Engineers define material parameters, line speeds, and thermal profiles digitally and run simulations to validate performance before physical setup—supporting virtual commissioning. - Integrated Production Control
Once planning is complete, the system transitions to execution mode, using validated recipes to run real-time production control. All process parameters are centrally monitored and adjusted as needed. - Smart Interfaces and System Integration
The solution supports OPC UA, MQTT, and other open protocols for seamless communication with MES, SCADA, and automation systems. - Complete Traceability
Every parameter, batch, and process step is recorded in a digital production file—ensuring end-to-end transparency.
Supported Extrusion Scenarios
boTec’s solution supports a wide range of use cases in rubber and plastics extrusion:
- Vulcanisation – Combine extrusion and curing for hose, cable, or seal production
- Compounding / Mixing – Model batch or continuous mixing processes for rubber and thermoplastics
- Profiling & Co-Extrusion – Configure complex multi-layer or multi-material processes
- Automated System Interlinking – Coordinate full production chains, from mixing to extrusion, curing, and cutting
Business Outcomes
Real-time control, predictive simulation and scalable system management reduce costs, increase safety and improve efficiency.
- Faster Time-to-Production
Digital recipe validation and virtual commissioning shorten setup time, reduce startup waste, and speed up delivery. - Reliable, Repeatable Quality
Stable production control ensures consistent curing and extrusion—even under changing product conditions. - Smarter Production Planning
Integrated production planning software enables faster configuration, better coordination, and fewer production delays. - Compliance and Risk Reduction
Detailed logging and traceability support quality assurance and audit readiness.
Our Differentiators
boTec’s solution unifies advanced simulation and control in a single system, purpose-built for the specific demands of rubber and cable manufacturing.