CompletionAI Stabilize film extrusion, cut scrap, and simplify operations.
CompletionAI is an AI-enabled process control assistant for polymer film extrusion. It adapts to recycled-content variability, shifting ambient conditions, and operator turnover, without new hardware. So you can run more consistently with less intervention and waste.
Plastic film production is getting harder
Mandated recycled content increases feedstock variability, and experienced operators are in short supply. Traditional control loops and recipes weren’t built for constant change, resulting in higher scrap, longer retunes, and costly downtime
What CompletionAI Does
CompletionAI augments your existing PLC/HMI stack with a learning layer that anticipates instability and keeps your line in the sweet spot. It continuously interprets process signals, recognizes emerging drift, and recommends or applies adjustments that standardize outcomes across shifts.
Core Outcomes
- Reduce returning time duration feedstock changes
- Lower scrap and regrind during changeovers
- Consistent quality and gauge control across shifts
- Fewer nuisance alarms and faster recovery from upsets
- Less dependence on one or two veteran operators
- Measurable ROI without capital expenditure
How It Works
- Connect to your data sources (PLC tags, sensors, historian).
- Learn normal vs. unstable patterns for your lines and products.
- Guide/Act with operator-facing setpoint guidance, or optional closed-loop actions within your governance rules.
Key Capabilities
- Adaptive setpoint guidance for variable feedstocks Real-time drift detection and correction suggestions
- Recipe-to-recipe transfer learning (faster changeovers)
- Shift equalization (standardized performance across teams)
- Event playback and root-cause hints after alarms or trips
- Lightweight deployment that sits alongside existing controls
Integrations & Compatibility
- Works with your current PLC/HMI and historian (e.g., OPC UA, MQTT, CSV/historian exports)
- Cloud or on-prem options to fit IT/OT policies
- Read-only “advisory” mode or governed write-back (your choice)
- Role-based access with audit trails
Who It’s For
Converters
Prove impact on a single line; scale plant-wide when KPIs are met.
Integrators
Differentiate with recycled-ready AI modules and recurring service revenue
OEMs
Embed intelligence into next-gen platforms without redesigning your controls.
Join Our Pilot
We’re engaging OEMs, integrators, and film producers now to shape pilots in early 2026. Want
to see how CompletionAI could fit your roadmap?