Changeovers
Every product swap burns purge material and minutes. Few plants know what their changeovers really cost.
Melt measures minutes and scrap kilos for every changeover.
Owl Melt for film and pipe extrusion
Your line already knows where the scrap comes from.
Owl Melt reads the extruder, gauges, dosing and winder you already have. It shows in euros what every changeover, every bad lot and every extra micron costs you, then helps your operators stop paying for them.
- Typically connected in two working days per line
- Connects over OPC UA, Modbus, S7 and other common interfaces
- On-prem installs keep running without internet
- On the floor in Finnish, Swedish or English
Where the money leaks out of an extrusion line.
Raw material is the biggest part of what film or pipe production costs. A handful of problems cause most of the waste. Melt puts a price on each one.
Excess thickness
Running a few microns over spec to be safe is material you give away on every metre, every shift.
The downgauging assistant finds the thinnest safe target and proves the saving from weighed rolls.
Bad lots
A recyclate lot that melts differently turns up an hour later as gels, breaks and a scrap roll.
Melt-state watch names the lot while it is in the barrel, before the first bad roll.
Idle heat
Barrels and dryers held at temperature with nothing running, on a weekend or between orders.
The idle-energy alarm says which line is wasting heat and how many kilowatt-hours it has cost so far.
Follow the melt, from silo to roll.
Melt reads the extruder, gauges, dosing, dryers and winder you already have, and maps each signal to its place on the line.
The screenshots show the Finnish interface. Each user can switch to Swedish or English.
- Monitor
- Optimize
- Trace · coming soon
1 Silo and dosing
Know what actually went into the hopper.
Melt stores the supplier's product data, measures the lot when it arrives and shows the difference, so a slipping supplier shows up in your scorecard before it shows up in your film.
- Trace · coming soon Incoming lots registered from a scan and the supplier's certificate, read automatically
- Trace · coming soon Supplier claim against measured value, with a twelve-month supplier scorecard
- Trace · coming soon Silo contents by lot and fill order. A held lot is flagged in every vessel it is in
- Trace · coming soon Your own regrind traced back to the rolls it came from
- Trace · coming soon Pellet loss log, rolled into the EU 2025/2365 report
2 Extruder
Catch a bad lot before it shows up in the product.
Melt pressure, temperature, torque and screw speed tell you how the material is melting. Melt compares them with your golden run for this product, and when they start to change during steady running, it names the indicator and the lot.
- Monitor Startups, changeovers and steady running detected automatically
- Monitor The recipe that actually ran, next to the one on paper
- Monitor Energy per kilo by line, product and shift, plus an idle-energy alarm
- Monitor Screw, barrel and screen wear, with a forecast of when service is due
- Optimize Golden run: live deviation from your best run, likely causes ranked
- Optimize Melt-state watch that catches a bad lot before it becomes scrap
- Optimize Setpoint advice within limits you set, confirmed by the operator and logged
- Optimize Every setting change gets a reason. Good tweaks become recipe versions
3 Die and gauge
Every micron, at every metre.
The thickness profile from your gauge is stored at full resolution. Look at any metre of any roll you have ever made, see how the profile behaves, and find out how thin you can safely go.
- Monitor Thickness or wall profile at any metre of any roll or pipe
- Monitor Profile drift heatmap across the web
- Optimize Downgauging assistant: the thinnest safe target and the euros it saves
- Optimize Quality-risk events linked to the lot and the rolls they hit
- Optimize SPC, lab results and a certificate of analysis built from measured values
- Optimize Pipe marking checked field by field against the order
4 Winder and roll
Every roll knows where it came from.
Rolls are created by the line itself, from the cut pulse and the scale. Each one carries its lots, blend, process conditions and quality events, down to the metre. A complaint becomes a five-minute lookup instead of a two-day hunt.
- Monitor Rolls created from the winder cut with length, weight, lot and blend
- Trace · coming soon Complaint root cause: enter a roll and a metre, get the lot, conditions and every sibling roll at risk
- Trace · coming soon Genealogy with mass balance, plus a daily mass balance per line
- Trace · coming soon Recycled content calculated under each certification scheme, side by side
- Trace · coming soon One-click packs: PPWR, ISCC PLUS, RecyClass, EN 15343, DPP, EPR, CSRD
- Trace · coming soon A QR code on the delivery note opens a trace page for your customer
- Trace · coming soon Time-limited auditor access and an EPCIS 2.0 feed
5 Shift and plant
Everyone around the line sees the same numbers.
Operators get a tablet with six controls at most. Shift leads get a handover that writes itself. The plant manager gets one morning view per line, and every number on it links to the screen that explains it.
- Monitor Operator tablet with reject and stoppage reasons in two taps
- Monitor Automatic shift handover and a morning view for the plant manager
- Monitor What every changeover costs, in scrap kilos and minutes
- Monitor Sensor health, so you know which numbers you can trust
- Optimize Schedule board that prices each changeover as you move jobs
- Optimize Recipe management with approval and rollout to lines
- Optimize Orders in from your ERP, produced quantities back
- Optimize Search past runs: how did we run this lot class last winter?
What does scrap cost you?
Put in your own numbers. The arithmetic runs in your browser and nothing is sent anywhere.
Scrap costs you €216,000 a year, 180,000 kg of material.
Melt Optimize for 3 lines costs €42,080 a year.
It pays for itself if your scrap rate drops from 4.0% to 3.2%.
Annual cost includes the Owl platform and the onboarding fee spread over the first year. It leaves out energy, capacity and downgauging savings.
Priced per line, in public.
Start with Monitor and see your own numbers. Move to Optimize on the lines where they show money. Trace, coming soon, adds the proof when a customer or an auditor asks for it.
Melt Monitor
See what your line is really doing.
€190 per line / month
First line with the platform: €680/ month
- Connects to your extruder, gauges, dosing, dryers and winder
- The recipe that actually ran, next to the stored one
- Startups, changeovers and running states detected automatically
- What every changeover costs in scrap kilos and minutes
- Thickness profile at any metre of any roll
- Energy per kilo by line, product and shift, with an idle-energy alarm
- Screw, barrel and screen wear tracking
- Sensor health: know which data you can trust
- Operator tablet with reject and stoppage reasons
- Automatic shift handover and a morning view
Melt Optimize
Cut scrap and material, line by line.
€590 per line / month
First line with the platform: €1,080/ month
Everything in Monitor, plus
- Golden run: live deviation from your best run, causes ranked
- Melt-state watch that catches a bad lot before it becomes scrap
- Setpoint advice within your limits, operator-confirmed and logged
- Every setting change gets a reason. Good tweaks become recipes
- Recipe management with approval and rollout to lines
- Downgauging assistant: a safe thinner target and the money it saves
- Quality-risk events linked to the lot and the rolls they hit
- SPC, lab results and certificates of analysis
- Schedule board that prices every changeover
- Orders from your ERP, produced quantities back
- Search across past runs and tweaks
Add-on to Monitor or Optimize
Melt Trace Coming soon
Recycled content you can prove.
Trace is in development. Ask about pricing and timing in your line review.
- Incoming lot QC: supplier claim against measured, with a scorecard
- Supplier certificates read automatically
- Silo contents with fill order. Held lots flagged everywhere they are
- Regrind traced back to its parent rolls
- Genealogy with mass balance, plus a daily mass balance
- Recycled content under each certification scheme
- One-click packs: PPWR, ISCC PLUS, RecyClass, EN 15343, DPP, EPR, CSRD
- Complaint root cause in minutes: enter a roll and a metre
- Delivery bundle with certificates per roll
- Customer QR trace page and time-limited auditor access
- Pellet loss reporting under EU 2025/2365
- EPCIS 2.0 traceability feed
For your plant of 3 lines
Change the number of lines- on Monitor
- €1,640/ month
- on Optimize
- €2,840/ month
- Trace
- Coming soon
Prices are on top of the Owl platform: €490 a month for the first line, €290 for each additional line. Unlimited users and standard connectors included.
Onboarding is €5,000 for the first line and €1,500 for each additional line, payable over ten months.
From first call to your own numbers.
- 1
A 30-minute line review
Tell us about your lines, their controllers and where you think the scrap goes. We tell you plainly what Melt can and can't see on your equipment.
- 2
Typically connected in two working days per line
Read-only, through the controller's existing interface. Lines without an accessible controller get a retrofit sensor kit. Your OEM doesn't need to be involved.
- 3
Your own baseline
Within the first weeks you see what your changeovers cost, scrap by reason and energy per kilo, from your own line rather than an industry average.
- 4
Go deeper where the money is
Move a line to Optimize when the baseline shows where its scrap comes from. Trace, coming soon, adds the proof when a customer or an auditor asks for it.
What plant managers ask us first.
Do you change anything in our PLC?
Not if your controller already exposes its data, for example over OPC UA. Then Melt reads through that supervisory interface and never touches the PLC program or a safety circuit. If the data can't be reached without changes, we go through the options in the line review, such as a retrofit sensor kit. Setpoint advice is only written back if you switch it on, within limits you set per recipe, after the operator confirms, and with a one-tap revert. You can keep Melt read-only for as long as you like.
Our extruders are from different OEMs and different decades.
That is the normal case. Melt speaks OPC UA, Siemens S7, Modbus TCP and RTU, EtherNet/IP, PROFINET, Beckhoff ADS and B&R, plus serial gauges and scales. A line with no accessible controller gets a retrofit kit with an energy meter, melt sensors and an encoder. Every signal is mapped to the same names, so every screen works the same on every line.
What happens when the internet goes down?
With an on-prem install, production doesn't notice. The edge computer on site keeps 14 days of data at full resolution, and the operator tablet, roll labels, scrap logging and genealogy keep working. When the connection returns, the data catches up with no gaps. A cloud install needs a working internet connection.
Who owns the data?
You do, raw and derived. Export everything at any time as CSV, JSON or EPCIS 2.0. Auditor and customer access is granted per product and period, logged, and revocable with one click.
Our operators don't want another screen.
The operator tablet has six controls at most: what is running, how it compares with the golden run, the open advice, a scrap-reason pad and the next job. It speaks Finnish, Swedish and English, and you can rename terms to the words your floor already uses.
We already have an ERP and an MES.
Melt sits underneath them. Orders come in from your ERP, including Lemonsoft, Netvisor, Visma and Odoo, and produced quantities go back, counted from actual rolls rather than typed in. Melt adds the extrusion detail a general MES doesn't have.
Is it only for blown film?
No. Melt covers film and pipe. For pipe it tracks wall thickness, outside diameter, ovality and eccentricity, and checks the printed marking against the order.
Bring one line. We'll show you what it's costing you.
In 30 minutes we go through your line with you and tell you which numbers Melt would put on it first. An engineer, not a sales deck.