As compounders face increasing demands for efficiency, consistency and innovation, understanding exactly what happens inside an extrusion process has become more important than ever. At the AMI Compounding & Recycling Expo Europe, Laurent Ratte, General Director of Sciences Computers Consultants (SCC), will explore how simulation technologies are helping processors gain deeper insight into their operations and make better decisions when it comes to extrusion and mixing.

Having spent 19 years with SCC, Ratte has dedicated his career to helping manufacturers better understand the relationship between materials and processes. The company develops numerical simulation software specifically for extrusion and mixing applications, enabling users to analyse and optimize manufacturing processes through a detailed understanding of material behaviour.

"Our virtual approach relies first on the in-depth thermo-mechanical behaviour of the material during the process," explains Ratte. "The goal is to provide industrials with the proper keys to first analyze and understand their process, and then be able to optimize it."

That optimization can deliver benefits across multiple areas, from improved product quality and lower operating costs to reduced energy consumption and more efficient use of resources.

According to Ratte, simulation tools are becoming increasingly relevant as manufacturers embrace digitalisation and seek new ways to improve process performance.

"Numerical simulation for extrusion and mixing has been considered as far from the industrial process," he says. "Today, new technologies, like AI, digital twin and online measurements make data collection easier and more relevant. In this context, simulation is a must-have tool to anticipate the process impact on the product."

His presentation will focus on one of the most critical challenges facing compounders today: optimizing screw design in co-rotating twin-screw extrusion.

"The idea is to deal with the screw design, which is today a key issue for compounders, especially for those who produce very technical materials."

While processors have become increasingly effective at optimizing operating conditions, Ratte believes screw configuration remains one of the industry's most difficult variables to master.

"Operating conditions optimization is not that easy, but industry can manage. Screw design optimization is much more challenging."

One of the key messages attendees can expect from the session is that there is rarely a single perfect solution.

"People look for the perfect profile, potentially universal," he says. "But for a given application, there might be different solutions and profiles, according to the user's targets and environment."

By combining detailed process simulations with a better understanding of material behaviour, manufacturers can evaluate alternative screw configurations before committing to costly trials or equipment modifications. This allows processors to make more informed decisions and identify solutions that are best suited to their specific objectives.

Ratte also sees significant potential in the growing convergence of artificial intelligence and simulation technologies.

"AI capabilities are quite interesting for digging more into the details of specific relationships between physical material properties, process impact, chemical reactions and so on."

However, while AI continues to attract attention across the manufacturing sector, he believes it is most effective when combined with robust engineering knowledge and proven scientific models.

"Coupled with AI, numerical simulation is an open window into the thermo-mechanical relationship between the material and the process."

The session is expected to be particularly valuable for process engineers and technical specialists involved in process development and optimization. Ratte hopes they will leave with a clearer understanding of how simulation can complement practical experience and provide a new perspective on problem-solving.

Most importantly, he wants attendees to remember that simulation should be viewed as a powerful support tool rather than a replacement for engineering expertise.

"Simulation is not a magic wand," he says. "It is based on robust and well-established models."

"As every software, it remains a tool. It is a strong support to help industrials analyze and understand their materials and process. But in the end, the smart brain is the user's one."

His passion for the subject has been shaped largely by conversations with customers and their operational challenges. Through years of working with manufacturers, he has observed a natural reluctance to alter successful production processes, even when opportunities for improvement exist.

"Industrials do not like changing a screw profile. They dislike changing a well-running process," he says. "But we are deeply convinced that it is worth looking at tools on the market that help optimize industrial processes, including a theoretical approach."

Beyond his presentation, Ratte is looking forward to reconnecting with industry professionals and exploring how digital technologies are being adopted across the sector.

"Meeting industrials and users is always a good experience to understand what they do now," he says. "I am also especially interested to check how and if AI is now used and appreciated for such challenging topics."

For anyone involved in compounding, extrusion process development or materials engineering, Ratte's session promises practical insights into how simulation, digitalization and AI are helping manufacturers better understand and optimize complex production processes.

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Want to hear Laurent Ratte's insights on simulation, AI and twin-screw extrusion optimization, alongside a packed programme of expert presentations covering plastics compounding, recycling, process engineering, materials innovation and industry trends?

Join us at the AMI Compounding & Recycling Expo Europe, taking place 23–24 September 2026 in Frankfurt, Germany.

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We look forward to welcoming you to Frankfurt for two days of insight, networking and innovation at the heart of the plastics industry.