The PROMATAI project addresses the critical need for advanced manufacturing solutions in processing complex hybrid materials and nanomaterials. Traditional extrusion technologies often struggle with materials that have unique rheological properties, such as high viscosity or variable particle sizes, leading to energy inefficiency and material waste. Coordinated by the Łukasiewicz Research Network – Institute of Polymer Materials (Poland), the consortium includes academic and industrial partners from Poland, Slovakia, Greece, Lithuania, and Bulgaria.
The project aims to exchange scientists, strengthen cross-border and cross-sector collaboration, and develop the world’s first “smart extruder” prototype. This innovative machine uses Artificial Intelligence (AI) algorithms to adjust its internal geometry in real time based on the material’s characteristics. It will improve efficiency, reduce waste and energy consumption, and enable processing of complex materials—ranging from polymers and composites to bio(nano)composites—used in food, cosmetics, packaging, construction, and chemical industries.
R&D focuses on three novel extruder components: the Feed Opening Section (FOS), Adjusted Grooved Feed Section (AGFS), and Rotating Barrel Section (RBS). Prototypes will be tested with bio(nano)composite pellets to generate data for machine learning models, enabling flexible, optimized control of extrusion processes. The results will benefit researchers, entrepreneurs, and industry by improving productivity, homogenization, and sustainability. A review of the market and literature confirmed that no similar “smart extruder” exists, ensuring the project’s novelty.
