Regrind Process Monitoring Software Comparison: Reducing Waste in Your Plant

For many plant managers in the plastics and packaging industry, the regrind room remains a source of constant anxiety. You are likely stuck in a reactive cycle—responding to granulator jams that starve the molding lines, dealing with unexpected blade wear that creates dust/fines instead of quality regrind, and trying to explain to leadership why material yield dropped last shift.

The reality is that while your primary extrusion or injection molding lines might be digitized, the auxiliary equipment—specifically plastics regrind systems—often runs in a data black hole. This "hidden factory" of unmonitored assets is where efficiency goes to die. But it doesn't have to be this way.

This article explores how regrind waste reduction software can transform your operation from reactive chaos to proactive control. We will break down the specific challenges of material scrap rate and improve uptime in plastics packaging, compare the leading software solutions available today, and provide a roadmap for justifying the investment to your leadership.

Comparing Regrind Waste Reduction Software for Plastics and Packaging

Selecting the right software is critical. You need a solution that provides visibility without turning into a multi-year IT nightmare. Below is a detailed analysis of the leading regrind software platforms, ranging from holistic FactoryOps platforms to specialized condition monitoring tools.

1. Guidewheel: The FactoryOps Platform

Guidewheel is designed specifically for the hands-on manager who needs quick wins and broad visibility. It differentiates itself through a "FactoryOps" approach—empowering the people closest to the work with simple, actionable data.

Key Strengths:

• Universal Compatibility: Guidewheel works on any machine, from brand-new extruders to 30-year-old granulators, using simple clip-on sensors. It does not require complex PLC integration.

• No Facility Internet Required: Unlike competitors that demand robust plant-wide Wi-Fi, Guidewheel’s hubs can use cellular gateways to populate dashboards, bypassing strict corporate IT firewalls.

• Rapid Deployment: The system is designed to be "plug-and-play," often installed in minutes rather than months. This aligns with the need for immediate visibility into the "Hidden Factory."

• Operator-First Design: The interface is built for the floor, not just the boardroom. Features like the "Uptime View" and "Scoreboards" help operators self-correct issues in real time.

Real-World Impact:

According to a case study with UrthPact, a plastics manufacturer, implementing Guidewheel led to significant operational improvements.

No longer are we questioning why we are down or questioning when we were down because it is so easily acessible guidewheel. Down times have lessened. Productivity has increased... [We achieved an] 18% increase in uptime on monitored machines.

Irivera, Automation Technician, UrthPact via Guidewheel's Customer Research

Considerations:

Guidewheel is a cloud-based platform focused on operational visibility and process optimization. It is ideal for teams that want to democratize data access across the floor immediately.

2. MachineMetrics

MachineMetrics is a well-established player in the real-time machine monitoring space, often favored for CNC and heavy machining environments but applicable to plastics.

Strengths:

• High-Frequency Data: Captures granular data directly from machine controls (PLC) via ethernet, which is powerful for deep diagnostic analysis.

• Automated Workflows: Can trigger workflows in other systems (like CMMS) based on machine alarms.

Limitations:

• Complexity: Deep integration often requires modern equipment with accessible PLCs. For older plastics regrind systems (which are common), this can be a barrier compared to clip-on solutions.

• Focus: Historically stronger in precision machining than in the specific chaotic flow of plastics regrind and packaging.

3. Vorne

Vorne is known for its "XL Productivity Appliance," a hardware-centric solution that displays OEE data on large LED scoreboards.

Strengths:

• Simplicity: It focuses squarely on efficiency tracking and visual management on the line.

• Visual Impact: The large scoreboard is effective for immediate operator feedback.

Limitations:

• Scope: It is often viewed as a point solution rather than a connected platform.

• Integration: Users have noted it focuses on core tasks rather than broad integration.

Doesnt do everything that some other bigger more integrated products do, but this doesnt try to, Just focusses on its core tasks, of monitoring the production line

Nigel P., Director, Capterra

4. Redzone

Redzone focuses heavily on the "people" side of manufacturing, gamifying production targets and fostering collaboration.

Strengths:

• Engagement: Excellent for building team culture and "winning the day" through huddles and chat features.

• Compliance: Strong features for quality compliance in regulated packaging environments.

Limitations:

• Hardware Challenges: Users have reported difficulties with sensor reliability and setup.

• Complexity: The feature set can be overwhelming for teams just starting their digital journey.

5. Inductive Automation (Ignition)

Ignition is a powerful SCADA platform that allows for unlimited customization.

Strengths:

• Flexibility: You can build almost anything you can imagine. It is the "Swiss Army Knife" of industrial automation.

• Scaling: Ideal for very large enterprises with dedicated engineering teams to build and maintain the system.

Limitations:

• Resource Heavy: Requires significant internal engineering resources or external integrators to build and maintain. It is not a "plug-and-play" solution for a plant manager looking for immediate visibility.

6. Amper

Amper uses non-invasive sensors to track machine status.

Strengths:

• Ease of Install: It bypasses complex PLC integrations.

• Focus: Good for job tracking and basic utilization metrics.

Limitations:

• Differentiation: While the hardware approach is similar, some platforms place a stronger emphasis on tying machine visibility to both productivity and sustainability—an important factor in regrind operations.

7. Specialized Condition Monitoring (Augury, Asset Watch, Neuron Soundware, IPercept)

These companies focus specifically on machine health rather than production flow.

• Augury & Asset Watch: Use advanced vibration and ultrasound sensors to detect bearing failures and mechanical degradation. They are excellent for critical assets where a catastrophic failure would be disastrous.

• Neuron Soundware: Uses acoustic analysis to "listen" to machines, detecting anomalies in grinding sounds that might indicate foreign material or blade issues.

• Other providers: Offer advanced analytics for motion and performance monitoring, especially in applications such as CNC machinery and robotics.

Analysis: For a regrind operation, knowing a bearing is failing (Condition Monitoring) is valuable. However, knowing why the machine is idle, how much scrap is being produced, and if the operator is hitting targets (Production Monitoring) typically offers a faster path to improved throughput.

Comparison Matrix: Regrind Waste Reduction Software Solutions

Transforming the Regrind Room from Liability to Asset

For too long, the regrind room has been treated as a messy "back of house" liability. But in modern plastics manufacturing, where material efficiency drives sustainability, this mindset is dangerous. Treating granulators as critical production nodes is the difference between a reactive plant and a resilient one.

You do not need a multi-year "rip-and-replace" project to fix this. You need simple, high-impact visibility. By monitoring the heartbeat of your plastics regrind systems—specifically amperage and run-time—you can track baseline amperage trends to identify when blades are dulling (consistently higher load for the same material flow) and the micro-stops that starve molding lines. This turns a chaotic variable into a controlled process, empowering your operators to close the material loop and protect your margins.

Unlock the Hidden Capacity in Your Material Flow

You don’t need a six-month integration project to know what your granulators are doing. You need clear signals now. Guidewheel uses non-invasive, clip-on sensors that install in minutes on existing equipment. From brand-new beside-the-press units to 20-year-old central granulators, our FactoryOps Platform gives your team real-time visibility into hidden losses in your regrind loop.

With live load and run/idle data, your team can spot blade wear or hopper bridges sooner and prevent avoidable downtime and material yield loss.

Stop guessing and start improving. See your regrind system’s performance, focus on the biggest losses, and align your team on live data. Discover how Guidewheel’s clip-on solution can support your regrind operations.

Book a demo today

About the Author

Lauren Dunford is the CEO and Co-Founder of Guidewheel, a FactoryOps platform that empowers factories to reach a sustainable peak of performance. A graduate of Stanford, she is a JOURNEY Fellow and World Economic Forum Tech Pioneer. Watch her TED Talk—the future isn’t just coded, it’s built.