The IIoT startup iDOO uses Hilscher's netFIELD edge management platform to digitally network machines of extrusion specialist iBA. This makes production data available in real time, allowing processes to be analyzed and optimized in a traceable manner. The result is greater transparency, reduced effort, and stable system operation. Read more in our success story.
Success Story: Data-driven Process Optimization in Plastic Extrusion
Data-driven process optimization plays a key role in modern plastic extrusion. Together with the IIoT experst from iDOO, Hilscher enabled transparent access to production data of plastic extrusion specialist iBA GmbH. This laid the foundation for continuous process improvement. The result: measurable gains in efficiency, quality, and decision-making.
Key highlights of this success story:
- Real-time production data from extrusion lines
- Data-driven optimization instead of manual trial and error
- Improved process stability and product quality
- Scalable IIoT architecture for future use cases
Get first-hand insights from our interview with Martin Deters, Managing Director of iBA, and learn how data helps transform plastic extrusion processes today.
Watch the video for more details!
The Challenge
Plastic extrusion is a complex process. Numerous parameters such as temperature, pressure, and material flow must be precisely coordinated. For a long time, this expertise existed mainly in the minds of experienced specialists. However, such experts are becoming increasingly scarce.
Additional challenges include:
- Recording production parameters required significant manual effort
- Long-term data analysis was error-prone and often incomplete
- Customers demanded full traceability and quality documentation
- External requirements, such as higher cybersecurity standards under the Cyber Resilience Act (CRA), increased pressure
The result: Without digital support, companies risked a lack of transparency, higher scrap rates, and growing competitive disadvantages.
Digitalization doesn’t have to hurt. With netFIELD and iDOO, we were able to start immediately, create value right away, and ensure that we are ready for the future. We have never experienced a faster IT integration. There were no high initial costs, no lengthy pilot projects, and no risk of failure due to complexity. My advice to others: Just do it. Those who spend too long planning digitalization without acting miss valuable competitive opportunities.
Martin Deters
Managing Director
iBA GmbH
Technical Implementation
The solution: iBA relies on the netFIELD ecosystem from Hilscher, together with iDOO. Every new extrusion system now comes standard with a Hilscher Edge Gateway. This gateway collects production data directly at the machine through containerized software applications and makes it reliably available via the iDOO platform.
The software applications responsible for data acquisition are managed centrally via the netFIELD edge management, which also supports fleet and patch management – reducing administrative effort and cutting costs.
The collaboration for iBA’s extrusion systems can be summarized as follows:
- netFIELD ensures stable data collection at the shop floor. Thanks to buffer mechanisms, no data is lost, even during network outages.
- iDOO analyzes and visualizes the data, providing dashboards, alarms, and reports in real time.
Integration was remarkably simple: all that was needed was a connection to the production network and the Internet – the entire data pipeline was up and running within a few hours. There was no need for lengthy implementation projects or expensive pilot phases. In most cases, a machine can be fully connected to the cloud within 2–3 hours, including installation of the edge gateway and configuration of the data connection. This enables a quick start without interrupting production. This “out-of-the-box” solution based on netFIELD and iDOO proved to be a decisive advantage for iBA.
For iBA, the decision was quickly made. Other key benefits of netFIELD that convinced iBA included:
- Stability and security in continuous operation
- Flexibility through Docker container technology, enabling easy rollout of new functions
- Everything from a single source: hardware, platform, and device management from Hilscher – complemented by iDOO’s IoT expertise
Especially favorable was the largely autonomous operation of the solution. Expansions or new component integrations can be implemented with minimal effort. For iBA, this means: less complexity, lower risk, and faster project delivery.
Benefits
Since introducing netFIELD, iBA has gained multiple advantages:
- Greater transparency: All production parameters are available globally, seamlessly, and in real time.
- Improved quality assurance: Complete documentation provides evidence for customers and reduces complaints. End users and customers can check production parameters accurately, regardless of whether the production date was days or even years ago.
- Higher process efficiency: Deviations are detected and corrected immediately, reducing scrap and optimizing energy consumption of extrusion plants.
- Competitive edge: iBA delivers not just machines but complete solutions – data-driven from day one.
- New services: Remote support and predictive maintenance are possible without additional hardware or retrofitting.
The iDOO services and dashboards are designed to provide a comprehensive and transparent overview of production processes. This allows process experts to monitor significantly more systems simultaneously, as all relevant process data is available in real time and optimization potential can be identified immediately. Operators receive immediate notifications, production managers identify trends, and quality assurance has reliable evidence at its disposal. Users thus benefit from over 40 years of expertise in plastics extrusion from iBA and iDO.
Outlook
iBA and iDOO plan to continue their collaboration with Hilscher. The next step is to expand data-driven services – such as AI-based anomaly detection and digital assistants. The goal is to not only monitor production but to control and optimize it proactively.
A key success factor: openness and standardization. Only when machines from a wide range of manufacturers can be efficiently connected will a solution offer added value in practice. With netFIELD and its centralized device management, Hilscher provides the ideal foundation for a future-proof extrusion process.
iBA GmbH
iBA GmbH is an internationally operating company specializing in the development and production of innovative systems for plastic extrusion. For many years, iBA has been delivering high-quality PE-Xa extrusion systems that are used worldwide.
The company’s deep technological expertise, precise plant engineering, and flexibility in adapting to customer requirements are what make iBA stand out.
iDOO GmbH
With iDOO, iBA has a strong partner in the field of Industrial IoT (IIoT) and digitalization. iDOO combines over 40 years of extrusion expertise with innovative, data-driven services, turning industrial data into valuable insights. The company develops solutions for Industrial Data Management and Edge Services, enabling real-time collection, analysis, and targeted use of production data for process optimization.
The foundation for this is Hilscher’s netFIELD technology, which ensures reliable and secure connectivity of diverse machine components.
Hilscher Gesellschaft für Systemautomation mbH
For almost 40 years, Hilscher has been a leading provider of solutions for industrial communication. With netFIELD, the communication specialist offers a comprehensive IIoT platform for the secure networking of machines—from the shop floor to the cloud. At its core is a centralized device management that allows users to manage Edge Gateways and containerized applications. This enables secure software updates, large-scale device fleet management, and efficient IT/OT integration—supporting new data-driven business models and ensuring future-proof production.
Want to try out netFIELD firsthand? Sign up for our free netFIELD Cloud Free account and evaluate the full range of our platform features with no cost or contractual obligations. The free account is able to manage up to two devices at a time and can be upgraded at any time.
With netFIELD, you benefit from Hilscher’s deep expertise in industrial communication—empowering reliable IT-OT convergence and Industry 4.0 implementations. The platform enables you to efficiently operate, manage, and scale edge gateways and IIoT applications—whether cloud-connected, hybrid, or fully on-premise.
An overview of our Managed Industrial IoT platform: netFIELD is your IIoT edge infrastructure for implementing Industry 4.0 solutions. It enables you to make your machine data accessible and the necessary software and hardware centrally manageable.
