IoT · MES · OEE · Energy

Finally: OEE and Energy Intelligence Built for Extrusion

ExtrudIQ connects to your lines in hours — not months — and turns raw sensor data into OEE scores, energy KPIs, and AI alerts that stop downtime before it starts.

Request a Line Demo See how it works

No integration consultants. No 6-month rollout. Deployed in one shift.

Line 3 — Live Dashboard

Updated 2s ago

OEE

87.4%

+3.2% vs yesterday

Availability

93.1%

↑ from 88.4%

Energy

0.38 kWh/kg

Target: 0.35

Scrap Rate

1.8%

AI Alert

Die pressure rising 12% above baseline. Inspect head at next break.

Melt Temp — Past 8h

221°C avg

Live in 4 hours

Average deployment time

4 hrs

Average line connection time

+14%

Average OEE improvement in 90 days

23%

Avg energy cost reduction first year

< 1 day

Time to first actionable insight

Your lines are running. You just don't know how well.

Most extrusion plants track production with shift sheets, gut feel, and Excel. You know something is off when scrap spikes or a line goes down — not before. Energy waste is invisible until the utility bill arrives. And when an auditor asks for OEE history, someone spends a week in spreadsheets.

Downtime you didn't see coming

Die pressure, melt temperature, and motor load all signal failure hours before it happens — if you're watching.

Energy costs you can't explain

kWh per kg varies by 30% across shifts and nobody knows why. That gap is margin you're leaving on the floor.

OEE reports that arrive too late

Weekly reports tell you what went wrong. You need to know what's going wrong right now — so you can fix it.

OEE Tracking

Real OEE — not estimated. Not manual. Automatic.

ExtrudIQ pulls encoder pulses, cycle counts, and downtime events directly from your line PLCs and IoT sensors. Availability, Performance, and Quality scores update every 30 seconds — no operator input required.

Automatic downtime classification — planned vs unplanned
Shift-by-shift comparison across multiple lines
Quality rate from inline thickness or vision checks
Export to PDF for customer audits in one click

OEE Breakdown — Line 2 / Shift A

Availability 93.1%

Performance 95.7%

Quality 98.2%

Overall OEE 87.4%

Energy KPIs — 7-day view

kWh/kg kWh total

Avg kWh/kg

0.389

Best shift

0.354

Savings potential

$2,840

/month

Energy Intelligence

See exactly where your kWh goes — and what's wasting it.

ExtrudIQ measures energy consumption at the machine level and correlates it to output in real time. You get kWh per kg by line, by shift, by operator — so you can find the inefficiencies that add up to tens of thousands of dollars a year.

Direct meter integration — no estimating from utility bills
Energy efficiency benchmarks by material type
Idle power monitoring — catch phantom loads between runs
CO₂ emissions reporting for customer sustainability audits

AI Alerts

Know a breakdown is coming. Hours before it happens.

ExtrudIQ watches die pressure, melt temperature, motor current, and 40+ other parameters against your baseline. When patterns signal trouble, you get a plain-English alert — not a raw sensor number — with exactly what to check and when.

Baseline auto-learned from your first 30 days of data
Alerts via SMS, email, or in-app — no IT setup needed
Root cause suggestions based on extrusion process knowledge
Alert history tied to actual downtime events for validation

AI Alert Feed — Today

WARNING Line 3 · 09:14

Die pressure trending 11% above baseline. Inspect screen pack within 2 hours.

RESOLVED Line 1 · 07:52

Melt temp stabilized after startup. OEE recovery: +6.2% vs previous shift.

DOWNTIME Line 3 · 06:31

Motor current spike detected. Unplanned stop logged. Duration: 18 min.

ENERGY Line 2 · 04:05

Energy usage 22% above target for material PE-100. Check screw wear.

Built for extrusion. Not adapted from something else.

Generic factory tools give you data. ExtrudIQ gives you extrusion intelligence — pre-configured for pipe, profile, film, sheet, and compounding lines, with KPIs that actually match how your plant operates.

Capability	Generic MES	Spreadsheets
Extrusion-specific KPIs (kWh/kg, die pressure, melt temp)
Live OEE — no operator input	partial
Deploy in one shift		n/a
AI-powered downtime prediction
Scrap & quality rate tracking	partial	manual
Energy cost analysis by line
Works with existing PLCs & sensors	partial
Pricing built for SME manufacturers

Up and running before your next shift ends.

We designed ExtrudIQ for plant managers who don't have time for an IT project — so we made it not be one.

Connect your sensors

Clip our IoT gateways onto existing signal wires or tap into PLC outputs. No rewiring, no downtime. Our team walks you through it remotely in under 2 hours.

ExtrudIQ learns your baseline

Over the first 24 hours, the platform maps your normal operating parameters — OEE, energy draw, temperatures, pressures — by line and by material.

Act on real intelligence

Your dashboard goes live. AI alerts start firing. Your plant team opens ExtrudIQ on tablets on the floor — and starts making decisions based on data, not instinct.

Pricing built for real manufacturing budgets.

No per-seat licensing. No integration fees. Pay per production line — and the ROI calculation is simple.

Starter

$299 /line/mo

Single line, single site. Perfect for your first pilot.

1 extrusion line
OEE + energy KPIs
AI alerts (email + SMS)
30-day data history
Remote onboarding included

Start my pilot

Know your line.
Run it better.

Book a 30-minute demo with our extrusion team. We will connect to one of your lines live, show you what ExtrudIQ sees, and give you a realistic ROI estimate for your plant — no sales theater.