Plastics extrusion
Give your extrusion floor a voice — output, energy and true cost per unit.
Turn your extrusion floor into an agent: live output, the energy each line draws, and true cost per kg — automatically, on any extruder. No log sheets, no shift-end guesswork.
The problem
Energy is a big share of your cost — and it's invisible per line.
Power is one of your largest costs, yet nobody can say what each line draws — or what it adds to a kilogram. Output is whatever the operator notes at shift end. You're pricing on a feeling.
What did Extruder 2 actually produce on the night shift?
How many kWh — and how many rupees — did each line burn today?
What does one kg of this profile truly cost — resin, energy, labour and overhead?
Which line — and which product — is actually making me money?
How it works on extruders
Every extruder reports itself.
A small sensor on each extruder senses running versus idle. Blitz turns that into live output, downtime, energy and true cost per unit — per shift, per line, on one dashboard. Plan each line to its order and target, and watch plan versus actual as it runs.
Nothing stops, nothing gets rewired, the operator writes nothing down. Pipe, profile and film all track the same way — your whole floor in one picture.
The number that decides your profit
True cost per unit — by product, by line.
Resin, energy, labour and overhead — added up automatically for every kilogram. Quote from your real number and see which lines actually make money. Energy, the share most owners under-count, is right there in it.
How true cost per unit worksFigures shown for illustration — Blitz builds yours from your own runs. Output is measured gross at the line and reconciled at your weighbridge — quality stays your call.
One suite for the whole plant
From the resin gate to your books — and an AI that tells you what needs you.
Blitz on the floor is one of three. Together they give your factory a voice — the numbers come to you.
Every extruder reporting its own output, energy and true cost per kg — on one live dashboard.
See the platform →Snap the resin bill at the gate, check-and-approve, hand clean entries to your accounts. Gate to books.
Material intake →Emails you the moment a line goes down or resin runs low, answers anything, briefs you on the plant. Comes with Blitz Plus.
Meet Jarvis →Plastics extrusion questions.
How do I track extruder output without manual logging?
A small sensor on each extruder tells Blitz when the line is genuinely running versus idle, and Blitz turns that into live output for the day — automatically, with nobody writing kilograms or run-length into a register. Your operators carry on exactly as they do today.
Does it work on pipe, profile and film lines?
Yes. Whether the line makes pipe, profile, sheet, or blown and cast film, Blitz tracks each extruder's running time, output and cost the same way — so a mixed plant runs on one dashboard, side by side.
How is energy cost per line worked out?
Energy is one of the biggest shares of extrusion cost, and on most floors it's invisible per line. Blitz measures how long each extruder genuinely runs and applies your energy rate to its draw, giving a live energy cost per line and per unit — finally visible, so you know exactly what each line adds to a kilogram. See how true cost per unit works.
Will it work on my old extruders?
Yes. The sensor is non-invasive and is fitted in minutes with no rewiring or modification — so it works on any extruder, however old, and on lines of any make running side by side. If a machine runs, Blitz can track it.
See your extrusion lines clearly.
Book a 20-minute demo. We set it up on a few extruders — watch real output, energy and cost per kg, live on your own floor.