PLASTIC PROCESSING
WHY PLASTIC PROCESSORS NEED A COMPLETE PRODUCTION SOLUTION
Nigel Smith, CEO of TM Robotics, examines what a real-world transition to integrated, all-electric moulding can teach manufacturers about planning the complete process
P
lastics processors are under pressure to increase output, manage labour constraints and produce a wider variety of components without sacrificing quality. Deloitte’s 2025 Smart Manufacturing and Operations Survey found that 92 per cent of respondents believe smart manufacturing will be the main driver of competitiveness over the next three years. The same research reported average improvements of ten to 20 per cent in production output, seven to 20 per cent in employee productivity and ten to 15 per cent in unlocked capacity following smart- manufacturing initiatives. Make UK has separately estimated that matching best-in-class manufacturing digitalisation could add around £150 billion to UK GDP by 2035. Yet advanced equipment does not automatically
create an integrated factory. A moulding machine may achieve a stable cycle, while downstream handling, decoration or data collection remains manual. Components may wait for an operator, move to a separate finishing station and be handled again before inspection or packing.
The experience of an Italian automotive manufacturer shows what this transition can involve. The company produces electric fans for vehicle applications and wanted to expand moulding capacity while achieving faster cycle times, lower energy consumption and more efficient internal logistics. Moving from hydraulic to all-electric presses
required more than buying replacement machinery. The manufacturer also had to consider infrastructure, compatibility with existing systems, operator training and the risk of disrupting output. Working with equipment integrator EPF, Shibaura Machine’s Italian injection moulding partner, it expanded its production department to include 21 all-electric Shibaura Machine presses ranging from 50 to 1,800 tonnes.
Performance testing established the business case. A 650-tonne press recorded a 51 per cent reduction in energy consumption compared with a hydraulic servo alternative, while testing on a larger machine showed improved cycle performance and a 30 per cent overall energy-efficiency gain against competing equipment. Connected monitoring supported remote diagnostics and earlier intervention, while the manufacturer also reported improved material handling, workflow management and production flexibility. Together, the changes increased moulding capacity, shortened cycle times, reduced energy
8 PROCESS & CONTROL ENGINEERING | JUNE 2026
Shibaura Machine’s EC-SXIII all-electric injection moulding platform Below: Injection-moulded plastic components move through an automated handling system
consumption and improved internal logistics. A complete solution does not mean specifying the
greatest possible amount of automation. It begins with understanding the component, material, required output, quality standard and downstream operations. Energy consumption, injection performance and cycle time were tested against the application rather than relying on assumptions about one technology being universally superior. All-electric platforms can offer precise, repeatable
control where energy use, cleanliness and consistency are priorities. Hydraulic systems remain appropriate where the material, component or production economics require their characteristics. Shibaura Machine’s EC-SXIII all-electric injection moulding series, for example, is designed for high-precision thermoplastic applications where repeatability, process stability and energy efficiency are priorities. Available in clamping forces from 50 to 3,000 tonnes, the range supports applications across sectors including automotive, medical and packaging. Once the press has been selected, manufacturers should map what happens after the mould opens. Part removal, cooling, orientation, inspection, decoration and packing should be considered as a connected sequence.
Automated handling can maintain the rhythm established by moulding and reduce avoidable waiting or manual transfer.
A separate development programme involving Roboprint, Shibaura Machine and TM Robotics
illustrates how secondary processes can be brought closer to moulding. Roboprint’s T-TRANSFER plastics- decoration system uses a heated silicone pad to apply designs from pre-printed transfer reels to three-dimensional plastic surfaces. Shibaura Machine and TM Robotics supported the integration of the technology with the moulding and automated handling process. Typical decoration cycles are five to six seconds per component. Because the process can operate beside the moulding press, parts do not need to be accumulated and transported to a separate decoration department. This can reduce handling and help balance moulding and finishing as one sequence. In the automotive application, connected monitoring supported remote diagnostics and proactive intervention. Useful questions include whether output is being lost at the moulding cycle or downstream, whether energy use is changing and whether maintenance can be scheduled before performance deteriorates. Shibaura Machine’s machiNetCloud platform can support real-time monitoring, energy tracking and predictive maintenance, but its value comes from linking each data point to a decision or action. The strongest projects begin with measurable objectives. Required cycle time, material behaviour, component quality, energy use, traceability, maintenance access and downstream capacity should be defined before the equipment list is finalised. New machinery must fit the plant’s infrastructure, operators need appropriate training and performance must be validated before production depends on the new process.
The automotive manufacturer’s transition shows that improvements in capacity, cycle performance and energy efficiency can follow when machine selection is combined with testing, monitoring, workforce preparation and improved material flow. It also shows why a “complete solution” should describe an engineering approach, not simply a larger equipment package.
TM Robotics
www.tmrobotics.com
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40
