Ask the Expert: What is Prodigi and How Does it Improve Processes?

What Is the Prodigi™ Motorized Lip Adjustment System?

Prodigi™ is an automatic lip adjustment system for flat die extrusion and represents the future of plastics processing equipment. The Prodigi™ System uses precision motors to automatically adjust the die lip profile. 

Where It Started: Manual Lip Adjustments

To fully understand Prodigi™, it is helpful to compare it with existing technologies, including manual dies and thermal bolt dies. Manual dies require operators to adjust each lip bolt individually to achieve the desired lip gap tolerance. This process is time-consuming, requires highly skilled operators, and often results in hours of lost production. In addition, final tolerances can vary significantly depending on the operator, leading to inconsistent product quality. 

Thermal bolt dies require the lip gap to be set within the limited stroke range of the thermal bolt inserts. With only a 0.015” stroke, operators must still manually adjust the bolts to achieve acceptable tolerances. The thermal bolts receive high‑ and low‑spot input from the gauging system and rely on thermal expansion to adjust the die lip. Launching a saved recipe typically takes approximately 8 minutes, which can slow production startups and changeovers. 

The Future Is Now: Prodigi™

The Prodigi™ System uses precision motors to automatically adjust the die lip profile. It is typically operated in a closed‑loop configuration with a gauging system, though it can also be run manually if needed. 

Increase Set-up Speed 

Prodigi™ stores recipes for rapid recall and averages just 30 seconds to reach good gauge when starting a saved recipe. The entire process is approximately 80% faster, taking only a few seconds compared to several minutes with traditional lip adjustment systems. This makes it an ideal solution for customers with frequent product changeovers. 

Gain Additional Stroke

The Prodigi™ system features a series of motorized actuators, with a wide range of stroke, that control the adjustment bolts. 

The system can traverse the entire useful flexible lip travel range without the need for any manual intervention. A more precise product can be accomplished by fine tuning the cross-web distribution with such lip adjustments. When the product’s profile changes with high or low spots, Prodigi™ adjusts for optimal uniformity. 

Achieve Optimal Repeatability

While repeatability is possible with traditional die adjustment systems, it's difficult to reach absolute consistency from production run to run. This is often due to a variety of factors that can influence how the thermal bolts react. The Prodigi™ system operates with computer-based programming, designed to save the exact location of each bolt during a production run. By collecting and storing this data for future production runs, the exact bolt positions can be easily repeated.

Increase Set-up Speed Boost Energy Savings

Compared to thermal bolt technology, Prodigi™ is also a more environmentally friendly option. Standard thermal bolt heaters typically operate at approximately 50% power demand throughout a production run. In contrast, Prodigi™ motors enter a steady‑state condition once adjustments are complete, significantly reducing energy consumption and operating costs.

Improve Team Safety

As the extrusion industry continues to move toward closed‑loop systems that minimize or eliminate operator intervention, Prodigi™ stands out as one of the safest technologies available. Its fully remote-control capabilities reduce manual adjustment, lowering the risk of operator injury while improving process consistency.

 

Return on Investment 

The Prodigi™ motorized lip actuator system delivers exceptional value, with material, time, and energy savings quickly adding up as a return on your investment. When you upgrade your die system, you increase your revenue. 

Have questions or want to see how Prodigi™ can improve your process? Contact Nick to start the conversation.