Recycled Plastics unlocks
20% productivity boost
Busroot empowers Recycled Plastics to replace manual tracking with automated, real-time reporting - immediately increasing asset utilisation.
Sustainable Plastics Manufacturing
Recycled Plastics is a leading manufacturer specialising in transforming post-consumer and industrial plastics into high-quality, sustainable products for diverse industries.
Production Facility
The site is equipped with advanced extruders and processing lines, with a focus on both productivity and environmental responsibility.
Wolverhampton, UK
Headquartered in Wolverhampton, UK. Recycled Plastics serves clients regionally and internationally, with a strong commitment to innovative, circular economy solutions.
The challenge
From manual logs to meaningful machine insights.
Manual hour-by-hour reporting and limited machine data made it impossible to pinpoint inefficiencies or confidently improve shop floor productivity.
Manual reporting lacked accuracy
Operators tracked equipment with paper logs, but these were often inaccurate and failed to reveal the true sources of lost time.
No unified downtime tracking
There was no reliable way to detect, explain, or analyse machine downtime across different machines.
Missing actionable metrics
Management needed clear reporting, visual breakdowns of lost time, and more intuitive ways to understand asset utilisation and causes of underperformance.
From Guesswork to Growth: Seamless Data and Operational Gains
Recycled Plastics implemented Busroot to automate machine monitoring, record run/stop times, and categorise downtime with actionable reasons. As a result, the production manager and team now benefit from a live, unified view of operations – enabling smarter shift starts/ends and immediate detection of inefficiencies.
By replacing manual reporting with timely, automated insights, daily downtime emails have proven to be a practical tool for driving fast response, transparency, and data-backed teamwork
Key outcomes included a 20% increase in productivity, equivalent to an extra hour of asset utilisation per machine each day.
Following adoption, the operator team developed the habit of proactively starting/stopping machines at the right times, contributing directly to output gains.
20%
Increase in site-wide productivity
8.5%
Extra asset utilisation captured from each machine, every shift
100%
Data-driven visibility replacing manual logs
Automatic downtime detection
Busroot picks up changes in machine state and logs downtime instantly
Operator input & reason codes
Operators can quickly assign a reason - so you get context, not just a timestamp
Downtime categorisation
Group stops by type (e.g mechanical, material, planned) for clearer analysis.
Root cause analysis
Drill into trends to understand what's driving the most frequent or costly stops.
Visual timelines
See when downtime happened across the shift and spot recurring patterns
Real-time alerts
Get notified when a machine goes down - action can be taken immediately.
“Busroot transformed the way we see our shop floor. We no longer rely on unreliable hour-by-hour sheets. Instead, we have a clear overview of what’s running, when jobs will be finished, and where we’re gaining or losing efficiency. The support team was always available, and implementation was straightforward. We saw a 20% productivity boost almost immediately”
Faisal Mukhtar
Managing Director
“The Recycled Plastics team’s focus on improvement made it easy to demonstrate the impact of real-time data. Their rapid productivity gains are a testament to the power of replacing guesswork with actionable insight – and we’re excited to continue supporting their journey.”
Michael Wright
CEO & Co-Founder
Ready to boost performance and cut waste?
Book your demo and see how Busroot unlocks visibility, accountability, and real-time action - without disrupting your operation.