Wenger, Extru-Tech launch EXPRO AI™ to revolutionize extrusion processing with predictive intelligence

USA – Wenger® and Extru-Tech®, two of the most respected names in extrusion processing technology, have announced the launch of EXPRO AI™, an advanced artificial intelligence-powered software solution developed to optimize extrusion operations.

Designed to deliver smarter, data-driven control, EXPRO AI™ is powered by TwinThread’s industrial intelligence platform and aims to boost product quality, reduce process variability, and enhance overall manufacturing efficiency.

Its deployment marks a significant step toward digitally transforming continuous manufacturing environments.

Wenger, founded in 1935 and headquartered in Sabetha, Kansas, is a global leader in customized extrusion and cooking systems for food, pet food, and aquatic feed.

With operations across the Americas, Europe, and Asia, the company serves a broad international clientele. Extru-Tech, meanwhile, offers end-to-end process solutions for extrusion, including equipment, automation, and compliance support, also serving a global customer base.

Scott Krebs, President of the Wenger Group, described the release of EXPRO AI™ as a transformative milestone for the extrusion sector.

 “This technology brings a new level of control and predictability to extrusion processes. By leveraging AI to manage complex production environments, we’re enabling customers to consistently hit quality targets and boost performance,” Krebs said.

EXPRO AI™ applies predictive modeling techniques to both historical and real-time production data. By identifying correlations between operational parameters and product outcomes, the software allows manufacturers to make more accurate process adjustments.

 As a result, users can achieve consistent quality across product batches, reduce downtime, and increase yield. One of its standout capabilities is its ability to prescribe optimum process setpoints before issues arise, rather than simply responding to them after the fact. This proactive approach helps operators maintain stable and optimized conditions throughout production.

The software features a dynamic digital twin dashboard that provides operators and plant managers with real-time visibility into operations.

EXPRO AI™ integrates seamlessly with local data sources such as IIoT devices, manufacturing execution systems (MES), and historical databases, ensuring that decisions are informed by accurate and comprehensive data.

It operates continuously, offering 24/7 intelligent guidance, functioning as what the companies describe as an “electronic subject matter expert” (eSME). This virtual advisor not only recommends setpoint changes based on evolving conditions but also helps teams anticipate and avoid deviations from desired performance outcomes.

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