Wenger, Extru-Tech jointly unveil extrusion process optimization software

The solution harnesses the power of artificial intelligence to transform extrusion operations by predicting outcomes, optimizing setpoints, and enhancing product quality and operational efficiency.

Credits: Wenger, Extru-Tech

May 23, 2025

Wenger® and Extru-Tech®, both global leaders in extrusion processing technologies, launched EXPRO AI™, an advanced extrusion process optimization software powered by TwinThread. This cutting-edge solution harnesses the power of artificial intelligence to transform extrusion operations by predicting outcomes, optimizing setpoints, and enhancing product quality and operational efficiency.

EXPRO AI™ employs sophisticated AI predictive modeling to analyze historical and real-time process and quality data. By identifying relationships between critical data points, specifications, and operational anomalies, EXPRO AI™ delivers actionable insights that enable manufacturers to predict product quality outcomes and prescribe ideal process setpoints. The result is a significant reduction in process variability and consistently superior product quality.

Key features and benefits are:

Real-Time Digital Twin Dashboard: Offers real-time situational awareness, empowering operators and managers to make informed decisions on the fly.
Data-Driven Process Optimization: Eliminates guesswork by securely utilizing local data from IIoT devices, historians, and MES systems, ensuring process decisions are based on empirical evidence rather than opinion.
Customized Optimization Models: Tailored solutions per recipe and production line that predict production events.
24/7 Intelligent Operations: Operates continuously without interruptions, serving as an electronic subject matter expert (eSME) that prescribes optimum process parameters for peak performance.

EXPRO AI™ is uniquely designed for continuous manufacturing processes and delivers value through improved product yield and quality.

“EXPRO AI™ represents a pivotal advancement in extrusion technology. By leveraging our process expertise and AI-based modeling, our clients are able to achieve unprecedented levels of efficiency and product consistency," said Scott Krebs, president of the Wenger Group. “This technology transforms extrusion processes, making them smarter, more adaptive, and highly efficient.”