Cut Your Cost per m2 with real-time process optimization
Powered by Causal AI
Even in stable, well-managed operations, teams often avoid pushing process limits. Not out of reluctance — but because they lack the visibility and confidence to do so safely.
The result: teams can’t operate close to spec limits with confidence — leaving performance and savings on the table.
When nonwoven lines aren’t run close to spec limits, the result isn’t just caution — it’s cost. Every shift, every roll, the impact adds up.
To stay on the safe side, production operates well above the target basis weight. However, a higher basis weight also means increased polymer consumption — driving up material costs unnecessarily with every square meter.
The result: avoidable costs per line reaching up to €550,000 per year!
Process Booster X (PBX) turns complex process behavior into clear, real-time guidance — helping your team make the right decisions, at the right moment, with confidence.
For nonwoven lines, this means running much closer to target basis weight and reducing energy consumption - while keeping quality and output rock solid.
On a modern spunbond line, PBX uncovered significant untapped potential in process settings.
Within just a few weeks, it enabled a 2.5% reduction in average basis weight, avoiding €500,000 per year in additional polymer costs—while maintaining both quality and output.
How It Was Achieved
PBX optimized stretching, laydown, and bonding—safely pushing the process to its limits. As a result, more square meters were produced per kilogram of polymer, without compromising quality.
PBX brings true intelligence to production — not by adding hardware, but by understanding how your line behaves. It continuously learns, predicts, and acts to keep quality stable and resource use minimal.
PBX learns the real cause–effect relationships of your line directly from raw data — requiring only minimal expert input.
PBX turns live data into real-time actions that increase output and maintain quality while cutting energy and material use.
Start with recommendations for operators; move to automatic execution within guardrails once confidence is built.
PBX directly increases process efficiency and stability—not through new equipment, but by continuously optimizing setpoints in real time. Measurable impact often appears within just a few weeks.
Lower basis weight at the same quality significantly reduces polymer usage per m².
Less material per meter means more product from the same raw material.
Tighter to spec, faster stabilization after changes, fewer deviations, and less scrap.
Through these savings, Process Booster X helps reduce annual production costs by substantial six-figure amounts per line.
We begin with a discovery call to align on goals and available data. Based on that, we conduct a free preliminary analysis to estimate the potential savings for your specific lines — providing a solid foundation for next steps.
We discuss your production setup and challenges and align on where PBX can create the strongest impact.
You share historical production data (under NDA). We evaluate data coverage and quality, and provide first actionable insights - check out our data requirements.
We share the quantified potential and discuss suitable next steps - pilot, scope, and timeline.
Ready to see what’s possible on your lines?
Request a discovery call with our experts to discuss your potential.