Davis-Standard – Smart Machine Innovation with DS Activ-Check
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May 30, 2026
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Davis-Standard – Smart Machine Innovation with DS Activ-Check
Davis-Standard is a global leader in extrusion and converting technology, supporting customers across more than 80 countries with over 10,000 extruders installed worldwide. In response to growing demand for “smart” manufacturing and predictive maintenance, Davis-Standard launched DS Activ-Check™, a breakthrough system for continuous extruder monitoring. Integrated with Davis-Standard’s Integrator, EPIC III®, and DS-eVue control systems, Activ-Check empowers processors with real-time predictive maintenance, early warnings of potential failures, and actionable data to optimize uptime and throughput.
davis-standard.com
Challenge
Extrusion processors face increasing pressure to minimize downtime, maintain high quality, and accelerate time-to-market while controlling maintenance costs. Davis-Standard identified several key challenges:
- Unplanned Downtime: Equipment failures in reducers, motors, or cooling systems could halt production unexpectedly.
- Lack of Predictive Insight: Traditional monitoring methods provided reactive data, not forward-looking alerts.
- Global Installed Base Needs: With more than 10,000 extruders worldwide, customers required scalable digital tools for ongoing aftermarket support.
- Industry Demand for Smart Machines: Customers increasingly expect connected, IoT-enabled machinery capable of sending alerts and insights to operators and OEMs alike.
Solution
Davis-Standard developed DS Activ-Check™, powered by the FacilityConneX Smart Machine Platform, to give extrusion processors continuous, intelligent monitoring.
Key aspects of the solution included:
- Predictive Maintenance: Real-time alerts via email and text before failures occur.
- Comprehensive Monitoring: Key parameters tracked include reducers, lubrication systems, motors, drive units, and barrel heating/cooling.
- Remote Access: Smart device and PC connectivity enabled operators to monitor equipment status anytime, anywhere.
- Data for Decision-Making: Collected machine performance data supported planned maintenance and production scheduling. Creation of critical calculations and KPIs like OEE and runtime analysis, temperature and pressure deviations.
- Creation of Golden Run: Template defining ideal conditions for products to help operations consistently produce optimal quality.
To broaden adoption, Davis-Standard introduced DS Activ-Connect™ at the NPE Plastics Show, the largest U.S. plastics event with 50,000+ attendees. This entry-level IoT solution notifies both customers and Davis-Standard Global Services with key performance indicators and alerts, providing a gateway to more advanced analytics with DS Activ-Check™.
How FacilityConneX Helped
FacilityConneX partnered with Davis-Standard to power its digital journey:
- Accelerated Deployment: Supported the rapid rollout of both Activ-Check and Activ-Connect platforms.
- Scalability: Enabled Davis-Standard to begin digitizing its global installed base of 10,000+ extruders.
- Customer Success: Early adopters, including Whirlpool, saw improved uptime and predictive insights, with additional customers in the pipeline.
- Aftermarket Differentiation: Provided Davis-Standard with a competitive edge by linking equipment monitoring directly with service and support.
Summary
Organization: Davis-Standard – Extrusion & Converting Technology
Platform Implemented: DS Activ-Check™ and DS Activ-Connect™ (Powered by FacilityConneX Smart Machine Platform)
Launch: NPE Plastics Show, Orlando (U.S.)
Key Benefits: Predictive maintenance, reduced downtime, scalable IoT for installed base, improved customer experience, actionable machine health insights
Results at a Glance
- 10,000+ extruders worldwide targeted for digital transformation
- Predictive alerts via email, SMS, and remote devices
- First customers including Whirlpool, with multiple pilots in pipeline
- New aftermarket revenue opportunities through IoT-enabled services
- Industry-leading visibility into mechanical & electrical system health
Davis-Standard – Smart Machine Innovation with DS Activ-Check
Davis-Standard is a global leader in extrusion and converting technology, supporting customers across more than 80 countries with over 10,000 extruders installed worldwide. In response to growing demand for “smart” manufacturing and predictive maintenance, Davis-Standard launched DS Activ-Check™, a breakthrough system for continuous extruder monitoring. Integrated with Davis-Standard’s Integrator, EPIC III®, and DS-eVue control systems, Activ-Check empowers processors with real-time predictive maintenance, early warnings of potential failures, and actionable data to optimize uptime and throughput.
davis-standard.com
Challenge
Extrusion processors face increasing pressure to minimize downtime, maintain high quality, and accelerate time-to-market while controlling maintenance costs. Davis-Standard identified several key challenges:
- Unplanned Downtime: Equipment failures in reducers, motors, or cooling systems could halt production unexpectedly.
- Lack of Predictive Insight: Traditional monitoring methods provided reactive data, not forward-looking alerts.
- Global Installed Base Needs: With more than 10,000 extruders worldwide, customers required scalable digital tools for ongoing aftermarket support.
- Industry Demand for Smart Machines: Customers increasingly expect connected, IoT-enabled machinery capable of sending alerts and insights to operators and OEMs alike.
Solution
Davis-Standard developed DS Activ-Check™, powered by the FacilityConneX Smart Machine Platform, to give extrusion processors continuous, intelligent monitoring.
Key aspects of the solution included:
- Predictive Maintenance: Real-time alerts via email and text before failures occur.
- Comprehensive Monitoring: Key parameters tracked include reducers, lubrication systems, motors, drive units, and barrel heating/cooling.
- Remote Access: Smart device and PC connectivity enabled operators to monitor equipment status anytime, anywhere.
- Data for Decision-Making: Collected machine performance data supported planned maintenance and production scheduling. Creation of critical calculations and KPIs like OEE and runtime analysis, temperature and pressure deviations.
- Creation of Golden Run: Template defining ideal conditions for products to help operations consistently produce optimal quality.
To broaden adoption, Davis-Standard introduced DS Activ-Connect™ at the NPE Plastics Show, the largest U.S. plastics event with 50,000+ attendees. This entry-level IoT solution notifies both customers and Davis-Standard Global Services with key performance indicators and alerts, providing a gateway to more advanced analytics with DS Activ-Check™.
How FacilityConneX Helped
FacilityConneX partnered with Davis-Standard to power its digital journey:
- Accelerated Deployment: Supported the rapid rollout of both Activ-Check and Activ-Connect platforms.
- Scalability: Enabled Davis-Standard to begin digitizing its global installed base of 10,000+ extruders.
- Customer Success: Early adopters, including Whirlpool, saw improved uptime and predictive insights, with additional customers in the pipeline.
- Aftermarket Differentiation: Provided Davis-Standard with a competitive edge by linking equipment monitoring directly with service and support.
Summary
Organization: Davis-Standard – Extrusion & Converting Technology
Platform Implemented: DS Activ-Check™ and DS Activ-Connect™ (Powered by FacilityConneX Smart Machine Platform)
Launch: NPE Plastics Show, Orlando (U.S.)
Key Benefits: Predictive maintenance, reduced downtime, scalable IoT for installed base, improved customer experience, actionable machine health insights
Results at a Glance
- 10,000+ extruders worldwide targeted for digital transformation
- Predictive alerts via email, SMS, and remote devices
- First customers including Whirlpool, with multiple pilots in pipeline
- New aftermarket revenue opportunities through IoT-enabled services
- Industry-leading visibility into mechanical & electrical system health
FacilityConneX can help you identify, prioritize, and solve problems before they become risks. Want help choosing the right system, or need a second opinion on your current setup? We’re just a message away. Contact FacilityConneX at info@facilityconnex.com to learn how secure cloud-based solutions can provide complete data visibility without operational disruption.
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