Test & measurement
PLASTICS PROCESSING AT THE HIGHEST LEVEL
Injection molding processes ready for series production: GEMÜ optimises process development with software from Kistler
Data-backed process development at a hidden champion: GEMÜ is the market leader in valve technology, particularly for sterile processes, and is also raising the bar in terms of injection molding.
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o design a reliable manufacturing process for a valve with a certain surface quality, GEMÜ used STASA QC Optimize software from Kistler. With the help of comprehensive data analysis, they were able to develop an injection molding process that
was ready for series production and offered a high degree of productivity and process stability – a model of success, also for future development processes at GEMÜ.
When Fritz Müller founded Gebrüder Müller Apparatebau GmbH & Co. KG (GEMÜ) in 1964, no one could have foreseen the unique success story that would emerge. Today, with the second
generation at the helm, this hidden champion from the northeast of Baden-Württemberg has more than 2,500 employees and is a global market leader in valve, measurement and control technology. In addition to two factories in Germany, GEMÜ also operates production facilities in Brazil, China, France, India, Switzerland and the US. In many sectors, such as medtech and pharmaceuticals, semiconductor production, and the food and beverage industry, control of process media (gases, steams and liquids) is essential.
Working together for more productivity in injection molding (from left): Martial Willimann, Jürgen Stahl (both Kistler), Marcel Fritzsche and Hekuran Pllana (both GEMÜ).
GEMÜ has had a long tradition of plastics processing ever since Fritz Müller achieved a milestone in valve technology with the first process valve made of plastic (PVC) in 1964. Today, GEMÜ uses over 100 different plastics in various processes to manufacture its comprehensive product portfolio. GEMÜ’s Development department drives innovation and develops customer-specific solutions that comply with the strictest standards – all tool and mold manufacturing takes place in-house. To meet the increasingly strict quality requirements in the field of injection molding, GEMÜ is already using measurement technology and process monitoring systems from Kistler at its locations in Germany, Switzerland and France. The combination of cavity pressure sensors and monitoring and control systems that are directly integrated into the machinery allows for targeted development and optimisation of the injection molding process on the basis of case- specific criteria.
EFFICIENT PROCESS DEVELOPMENT SUPPORTED BY DATA ANALYSIS This year, GEMÜ began using STASA QC Optimize software from Kistler that allows for process optimisation on the basis of statistical test planning known as “design of experiments” (DoE). Marcel Fritzsche, process engineer and Technology Scout at GEMÜ, says: “I first became familiar with technology from Kistler for plastics processing during my time at university. With STASA QC, we have a development tool that allows us to develop processes based on data, and thus optimise the development of new, complex products – or even make these products possible in the first place.” Together with bachelor’s degree candidate Hekuran Pllana, Fritzsche tested out the potential of the software and is impressed with what it has to offer: “DoE-based process development is systematic and structured. This objective approach provides greater clarity in collaboration and shortens the path to injection molding processes that are ready for series production.”
October 2025 Instrumentation Monthly
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