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    Automatic Air Ring

    Control film thickness and achieve constant film gauge automatically

    Offline Film Gauging

    Measure plastic film thickness in lab and guarantee quality expectations

    Film Thickness Measurement

    Inline and real-time gauging data to automate film production adjustments

    Film Width Control

    Measure and automatically control the width of your plastic film extrusion line

    Gravimetric Dosing SmartGDS

    Real-time control of component ratios directly at the extruder screw

    Batch Blender SmartBDS

    Batch dosing system directly at the extruder inlet

    Bubble Stabilization Control (Calibration Basket)

    Bubble control and stabilization for dimensional uniformity and superior film quality

    Internal Bubble Cooling (IBC)

    Internal bubble cooling with high-precision dynamic control technology

    Raw Material Feeding

    Intelligent vacuum-based raw material feeding system with full automated operation

    Film Extruder Upgrade

    Custom projects and retrofitting of legacy and outdated extrusion lines

    Film Production Management

    Systems and software to automate quality control for film extrusion

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SmartBDS

Gravimetric Batch Blender for full control of film composition

With a precision up to ±0.5% of the nominal value, the SmartBDS accurately measures, doses and blends each component ensuring reliable, consistent formulations for every reel.

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Application

What is the SmartBDS?

Combined with Octagon’s extrusion control system, the gravimetric batch blender SmartBDS ensures the highest performance available.

The BDS module precisely measures the consumption of each material with an integrated load cell using the loss-in-weight principle. The correct film composition is achieved by the batch method where the necessary additives are blended.

The screw speed on single-layer extruders is automatically calculated and adjusted by the Octagon ScenEx Pro. On co-extruders the screw speed of each layer is controlled independently, enabling precise output and average gauge control per layer. At the same time the weight per meter of the film is maintained through automatic synchronization of haul-off speed, ensuring consistent gauge throughout the entire process.

The SmartBDS line is part of Octagon’s latest generation of dosing technology, combining  robust and precise dosing chambers with a patented mixing system.

How it works

Dosing, blending and control in a single system

Single-layer extruders

Single extruder screw control: ScenEx calculates and adjusts screw speed automatically based on BDS throughput values, keeping film weight per meter within specifications.

Co-extruders

Layer-by-layer control: On co-extrusion lines each extruder is controlled independently. Individual layer gauge can be adjusted without stopping production.

Precision up to 0.01%
of batch volume

±0,5%
of nominal value

Immediate response
to process disturbances

Patented
mixing technology

System Integration

Part of an integrated system

The SmartBDS connects to ScenEx Pro and exchanges data in real time with the thickness sensors (PMS), the automatic air ring (SmartLip) and the width control system (GMS/LMS). The software compares dosing readings with the measured thickness profile and automatically adjusts process parameters to keep the film within defined tolerances.

For lines with existing Octagon equipment, the integration of SmartBDS by retrofit is possible in most cases. Each situation is assessed individually by our technical team.

Which solution is the correct one for my line?

SmartBDS or SmartGDS?

Both systems use the loss-in-weight principle, but they stand for different needs. The right choice depends on the type of blend you produce and the required precision of your blend. Octagon’s technical team can help to determine which is most suitable for you.

SmartBDS - Batch dosing

Smart BDS doses, weighs and blends in distinct cycles. It is ideal for formulations with multiple additives and frequent recipe changes and controls up to 8 components per module.

SmartGDS - Continuous dosing

Smart GDS stands for continuous real-time control of component ratios. It is best suited for lines with less frequent production changes and a focus on output consistency.

What improvements are gained in production?

What does the SmartBDS solve in practice?

Without a precise dosing control, the tendency is to compensate with a safety margin leading to more additives than needed, inconsistent film composition from batch to batch and an actual resin consumption that does not match nominal values. The SmartBDS eliminates this cycle.

Component ratios are controlled batch by batch. Material consumption per component becomes traceable. For operations with frequent recipe changes, the formula management integrated into ScenEx Pro speeds up setup times and eliminates errors by manual data input.

Specially in co-extrusion individual layer control opens up the possibility of working with technical and high-barrier films more consistently without relying on manual adjustments between shifts.

Is there a need to improve your production performance?

Contact our sales team!

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Software

Smart HMI Interface

The new generation panel combines Octagon’s control system with web-based visualization. The operator gains access to the same data from the fixed panel, tablet or smartphone without installing anything.

Resources

Complete graphical overview of process data

Recipe and alarm management

Comprehensive production reports

Integrated raw material conveying

Integration with Siemens S7

Ready for Industry 4.0

Performance Guaranteed by Contract

We are the only company in the sector that guarantees by contract clear productivity and quality improvement targets for our clients.

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Competitive Advantage

Patented blending with accurate dosage per-component

The SmartBDS combines a precision dosing valve with a patented mixing system and an individual load cell per component. The result is a homogeneous and reproducible blend with every batch, without relying on estimates or aggregated averages. This is achieved by:

Individual load cell

Each component is weighed independently ensuring real accuracy per material.

Independently suspended chamber

It is isolated from external vibrations to protect the LIW load cell signals

Patented blending system

This guarantees a blend homogeneity before the material reaches the extruder.

Integrated production control

ScenEx Pro closes the loop. It compares dosing data with screw and haul-off speeds to maintain consistent weight per meter across the entire reel.

Product Engineering

Operational simplicity without compromising precision

The SmartBDS was not designed only for precise dosing. Every structural detail was well thought-out to reduce downtime, simplify material changeovers and protect critical system components over time.

Sliding plate for quick emptying of material

Sliding plate for complete emptying of chambers at material changeovers, no tools required, available for each chamber

Stainless steel mixing chamber

Independently suspended on an articulated base, creating a mechanical barrier against accidental impacts on the load cell.

Removable access panels

Protection of critical wiring without impairing maintenance access

Wide door with inspection window

Direct access to the blender for visual inspection and cleaning without disassembly.

Optional level sensor

Individually adjustable on any chamber, no equipment modifications required

Heavy-duty extruder adapter

Optional, with integrated sliding plate for emptying on high-output lines

Smart Investment

Choosing the SmartBDS means having real control over the components of each reel. Accurate formulation, traceable material consumption and less raw material waste: The ROI is achieved sooner than expected.

Advanced Technical Specifications

Performance

Dosing precision

Up to 0.01% of batch volume

Nominal value tolerance

±0,5%

Standard components per module

6 (up to 8 with expansion)

Mixing chamber

Stainless steel, patented technology

Measurement system

Integrated loss-in-weight

Integration

Siemens S7, ScenEx Pro

Available models

Specifications

BDS 100

BDS 200

BDS 400

BDS 800

Hopper volume (L/compartment)

15

15

23

32

Standard number of components

6

6

6

6

Option of additional components

0

2

2

2

Standard batch weight (kg)

1

3

5

9

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