Cut Your Cost per m2 in spunbond with real-time process optimization
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To compensate for limited real-time visibility, many spunbond lines run significantly above the target basis weight to build in safety margins - burning cash every shift.
Running above the target basis weight quickly accumulates into significant avoidable costs of up to €500k per year!
The good news: smarter guidance and control can cut variable cost per m² significantly.
Even with modern systems and experienced teams, achieving the perfect balance between quality and safety remains difficult. Three root causes keep most nonwoven lines from operating at their true potential:
Without better visibility and guidance, even skilled teams can’t close the control gap that drives higher variable costs shift after shift.
PBX brings intelligence directly to the line — continuously analyzing live data, predicting outcomes, and guiding operators in real time. The result: stable quality, lower resource use, and more confident decision-making.
PBX transforms everyday control decisions into measurable savings — turning hidden inefficiencies into a clear competitive advantage.
On a modern line in Western Europe, PBX uncovered significant untapped potential in process settings.
Within just a few weeks, PBX achieved a 2,5% reduction in polymer consumption, equivalent to €500k per year in savings.
How It Was Achieved
PBX optimized the collection/line speed, web handling and thermal calendering, so the spunlaid web yields more m² after laydown - at the same polymer throughput rate with quality remaining in spec.
Why It Matters
Even well-optimized mills still lose significant money due to conservative settings and changing process conditions. PBX closes this gap automatically — making visible savings possible on lines that already run “efficiently on paper.”
PBX brings true intelligence to nonwovens production — not by adding hardware, but by understanding how each 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 maintain output and quality while while cutting energy and resources use.
Start with recommendations for operators; move to automatic execution within guardrails once confidence is built.
PBX directly improves process efficiency and stability — not through new equipment, but by optimizing how existing systems are controlled. The impact becomes visible within weeks of operation.
Lowerbasis weight with the same quality substantially lowers the required granulateper m2.
Withless material per meter, the same raw material yields more product.
Tighter to spec, faster stabilization after changes, fewer excursions and less broke.
We offer a free preliminary analysis to quantify potential savings for your specific lines. Before that, we’ll start with a short discovery call — to align on goals, data availability, and what matters most for your lines.
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.
