Automation, AI help molders deal with labor, sustainability challenges

Automation is one facet of injection molding where investment continues.

"The industry is seeing a downward trend for new molding machines, but robots and automation remain strong as processors still battle labor issues and staying competitive," said Jason Long, vice president of sales at Wittmann USA.

Machine builders like Krauss-Maffei offer automation to leak test, label, laser mark, feed parts, weld, convey, trim, fold and pelletize.

"There's a need for automation in the industry, but it can be daunting if you've never had to use a robot interfaced with a machine before. We are offering automation to companies that never considered it before, and we're cognizant we have to help them through this learning curve," said Sven Skowronek, KM's vice president of IMM sales and project management.

"Assembly or quality inspection functions after the part is taken out of the mold is very common, not just because of the labor issue but equally because of a decrease in scrap, which means cost reduction," Arburg Inc. CEO Martin Baumann said.

Most processors that are purchasing new presses request automation for a more efficient overall molding process, according to Milacron's Ron Gulbransen, senior product manager, auxiliaries.

"Rarely do we see presses being tended by operators vs. robotics these days," he added.

The most common form of automation continues to be three-axis and five-axis servo machine-tending robotic cells to remove parts from the press and set them on a conveyor, Gulbransen said.

Processors also are turning to automation for in-mold labeling (IML), insert molding and feeding of inserts, the assembly of multiple components after the molding process is completed, visual inspection of critical dimensions in finished parts, and finished goods palletizing and part removal, Gulbransen said.

All automation is important, and processors are increasingly drawn to it, added Absolute Haitian President Glenn Frohring.

"They realize they cannot be left behind and remain competitive," he said. "We have seen companies go out of business because automation requires updating their tooling and procedures and investing in robots, and customers do not like change."

Absolute Haitian supports rising demand for automation in two ways, Frohring said, pointing to injection molding machines built with the necessary interfaces and flexibility in mind as well as the product line of its sister company, Absolute Robot. Machine controls can be connected to a wide range of auxiliaries and process and production monitoring systems, Frohring noted.

"On the automation front, Absolute Robot sees more requests for sophisticated, dedicated automation, not just pick-and-place functionality. But it must remain user-friendly, despite the level of sophistication," Frohring said.

Looking ahead, Nissei America Inc. President Masahiko Miyajima said, "Automation that can help with labor shortages will grow in the future."

Stork IMM USA LLC CEO Gert Boers agreed. He said robotic automation, particularly for in-mold labeling, takeout and quality inspection is becoming increasingly common and an industry standard. "Labor shortages and rising costs are driving broader adoption," Boers said.

Artificial intelligence is creating an era of smarter factories in terms of improving precision and productivity; reducing scrap and energy usage; enabling predictive maintenance; and bridging the skills gap.

From monitoring the behavior of raw materials to detecting process variations to real-time assistance for problems, AI tightens control over the entire production process, which can shorten the time to market.

Who's in?

The rate of incorporating AI varies greatly among plastics processors, according to Dan Barlow, Milacron's senior product manager of controls and M-Powered, which is an industrial Internet of Things (IIoT) platform.

"Some are at the leading edge and are progressing toward AI by making real-time changes to their machine processes, while others are taking a more cautious approach and using the data to make predictions and then implementing changes manually and/or testing the changes prior to implementation," Barlow said.

Milacron facilitates the gathering and organizing of data required for constructing AI logic, Barlow added, with M-Powered's portfolio of observational, analytical and support services aimed at providing processors with unique intelligence and competitive advantages.

"It leverages sophisticated algorithms that utilize real-time machine learning to monitor machine operations," Barlow said. "When combined with Milacron's suite of aftermarket services, M-Powered offers a unified, holistic view of customers' plastic manufacturing processes by connecting parts, service, rebuilds, retrofits and preventative maintenance."

So far, most of the AI-related steps taken by plastics processors "lean more toward data collection," according to Boy Machine Inc. President Marko Koorneef.

That's a good place to start.

"Robust data collection is essential for powering any AI application," said Ranjith Babu Pola, Krauss-Maffei's digital solutions and controls director. "To enable this, we offer a wide range of products tailored to our customers' requirements for effective data collection from our machines. For instance, our dataXplorer facilitates real-time data collection and analysis, delivering profound insights into the injection molding process."

Other Krauss-Maffei products identify production irregularities at an early stage (processSupport), support operators with simple instructions (SmartOperation) and control processes for part quality and lower scrap rates (APC Plus).

AI opens up completely new prospects and possibilities when it comes to processing large amounts of data and drawing meaningful conclusions from it, Arburg's Baumann said.

"For example, the relevant data can be used to create forecasts for maintenance requirements [predictive maintenance], generate paperless evaluations and documentation in real time and access injection molding knowledge with the help of AI-supported apps," Baumann said.

A new AI-supported tool is the "Ask Arburg" premium app, which Baumann said is based on the well-known language model ChatGPT "but with the advantage of a secure, self-contained environment."

Machine builders have integrated AI solutions into digital products for years.

Engel North America President Vanessa Malena said AI-powered tools let machine operators gain insights from process data, which improve decision-making and optimizes production.

"These digital solutions not only improve productivity but also enhance product quality by monitoring and adjusting key parameters in real time," Malena said.

Plustech Inc. helps processors incorporate AI into their facilities with its own IoT and by collaborating with other vendors.

"This is becoming a standard for many customers," Senior Vice President Kohei Shinohara said.

Haitian's Generation 5 injection molding machines incorporate intelligent functions, called HT·Xtend, to provide easy operation so no training is required. Frohring said there are 12 different software features.

"Examples taking advantage of algorithm-based software include HT Inject to optimize the injection process in real time and improve process stability, HT Energy for automated energy control, and HT Lubricate for automated lubrication," Frohring said. "Our machine platforms intelligent machine operation that is easy to use to enable a newer workforce to quickly come up to speed, even if they are not so familiar with operating a molding machine."

Wittmann's Long also pointed to efficient communication and error-proofing of processes.

At Stork, Boers said the machine builder is integrating AI-driven process optimization tools into existing manufacturing systems. This includes preventative maintenance data and real-time machine performance monitoring.

"By partnering with processors, we ensure seamless integration and measurable ROI," Boers said.

Many processors are embracing performance monitors like sensors for molds and clamp force fluctuations to prevent downtime, Boers added. "While generative AI is gaining interest, its application in plastics processing is still nascent," he said.

LS Mtron President Peter Gardner agreed, saying the plastics industry is still an early-adopter phase.

"Most of our experience comes form our own LS group molding facilities, or within our founding company's [LG Electronics] molding facilities," Gardner said. "We do feel this real-world experience is beneficial to our offerings, and even the data we scooped up from our own plants can be analyzed and used in the application of AI molding."

LS Mtron's AI-based technology features two systems: the AI Molding Assistant, which the company says saves time for the initial molding setup process by learning and imitating the behavior of highly skilled molding specialists, and Smart Weight Control, which detects weight change of products and then alters the processing conditions in real time to fix any deviations and meet the correct product specifications.

Wittmann's Long said: "We are working on using AI in our service group for manuals and technical support but are in the early stages of development."

Nissei America's Miyajima was vague. "We have something currently under development; however, we are not able to reveal at this moment," he said.

For many processors, the next step is simply getting started, usually at the recommendation of the information technology (IT) department.

"AI holds significant potential for future advancements, but getting everyone on board still is a challenge, with bigger companies especially wary of the possibility of security hacks," Malena said. "Engel believes that it is the complexity and large investment of IT projects, which are the biggest challenges. Buy-in across the entire company is important, but the systems are safe. You need a champion in the company for digitalization, and the IT department must be deeply involved."

The Engel North America president said one processor that is currently using pen and paper for manual data collection is taking a big step forward.

"They've hired for an IIOT position to kick-start their digital transformation," she said.

Over the next five years, Malena expects AI to become even more integrated into plastics processing, especially to enhance automation, minimize downtime and further improve energy efficiency.

"However, we see digitalization and AI not as replacements but as complements to human expertise," Malena added. "Our approach is based on the synergy between human creativity and machine efficiency. This combination allows us to solve existing challenges in new ways while maintaining high safety and efficiency standards. AI can help address labor shortages by handling routine tasks and optimizing processes — but human experience remains irreplaceable."

Plastics processors are taking more steps to make their operations more environmentally sustainable with machine builders often leading their way.

At Krauss-Maffei, management "firmly believes that sustainability is both an ecological and an economic imperative. In other words, a business imperative," Skowronek said.

"For us, successful business means sustainable business. This applies in particular to us as a major player in the plastics industry. We are therefore mindful of our responsibility to both present and future generations. In doing so, we do not only focus on our own actions. Instead, we also see ourselves as paving the way for our customers and suppliers so that they too can achieve their sustainability goals," Skowronek said.

At NPE, Arburg's Baumann said the staff detected growing awareness about processing biomaterials, post-industrial and post-consumer recyclates, and carbon footprints.

"We are helping with several measures in different fields," Baumann said. "Energy-efficient hybrid and electric machines are the first examples. But we are able to also provide companies with the CO2 footprint of machines, which means what it took to build the machine. Some of the larger companies have CO2 reduction goals, and, in order to achieve such, they need to measure CO2. Therefore, such companies are asking about the machine's CO2 footprint."

Energy savings is the most important way press producers help processors meet sustainability goals, Absolute Haitian's Frohring said.

"The new Generation 5 machines deliver energy savings of 20-40 percent compared with our previous generation of molding machines, which were already efficient," he said.

Engel builds machines that can process higher contents of recycled material, Malena said, which in turn lets processors reduce energy consumption, greenhouse gas emissions and the use of primary materials.

"Engel is a part of the value-added chain in recycling and evaluates which parts of the recycling loop it can and should sustainably serve with its products and services," Malena said. "In particular, the intent is to ensure that the value-added chain segment which extends from regrind to the finished product is increasingly served by in-house products and services."

Engel supports the "design for recycling" approach with technology that allow a higher proportion of recycled materials in the product, Malena said.

"This is how the company intends to assist its customers in finding their way to adopt the circular economy for themselves," she added.

The parent company also demonstrated its leading position in the field of sustainability by earning platinum status in the global sustainability ranking by EcoVadis, the world's largest provider of sustainability rankings, for the second time in a row.

Arburg likewise received a gold award from EcoVadis.

For its part, Nissei America has introduced recycled plastics utilization technology, bioplastics molding technologies and energy-efficient injection molding machines, Miyajima said.

Milacron developed the M-1070 pail machine, featuring Mold-Masters coinjection technology, that can inject and control up to 50 percent post-consumer (PCR) content, according to Andy Stirn, general manager of business systems.

"Coinjection provides a unique advantage, the capability to achieve the highest PCR percentage, ensuring uniform distribution and complete coverage of PCR resins, which in turn prevents contact of PCR with any product," Stirn said.

Another sustainable trend Milacron staff members have seen is within the low-pressure injection molding (LPIM) space for producing large-part plastics, like pallets and beverage crates, with 100 percent regrind.

"These products don't have to look aesthetically pleasing since they get beat up all day long in their general use," said Eric Hallstrom, business manager if LPIM technologies.

LPIM structural foam technology also is ideal for molding ultra-large and thicker plastic parts with a high strength-to-weight ratio for lightweighting.

LS Mtron developed AI molding to help reduce plastics usage and encourage better use of recycled materials, Gardner said. The system, which was introduced in October at the Korea Mold & Die Vision Forum 2024, also reduces production preparation time, maintains consistent settings regardless of the operator's skill and reduces carbon emissions, according to Hyunjae Yoo, senior researcher at LS Mtron.

"Our system uses algorithms to derive optimal molding conditions based on product information and CAD (computer-aided design) data provided by the customer," Yoo said. "The AI engine automatically extracts key geometric information from the molded product modeling and adjusts process variables in real time to derive optimal molding conditions. These conditions compensate for potential variations during production and contribute to maintaining consistent quality."

Stork's Boers said the company helps processors achieve sustainability goals by offering energy-efficient equipment and advanced monitoring systems to reduce waste and energy use.

Stork also supports efforts to integrate recycled resins through its Stork Injection Control (STiC) software tool, which reduces part rejects by detecting changes in the melt flow index, correcting settings and maintaining stability of the shot weights in the same cycle.

At Sodick IMM by Plustech Inc., National Sales Manager Len Hampton said the goal is to help processors meet and exceed their sustainability goals. "Sodick extreme acceleration/deceleration capabilities in the injection unit allows molders to downsize cold runners dramatically, taking away variability in the process. This can also reduce cycle time and minimize waste," Hampton said.

Industry regulators, the public, innovating machine builders and policies related to environmental responsibility, social impact and corporate governance (ESG) are calling for and paving the way to use more recycled content in products.

"It's driven by consumer demand and the marketing to such customers by the large brands. We can help our customers achieve their sustainability goals for their customers faster and better with technology and materials," Arburg's Baumann said.

Gardner said LS Mtron encourages and supports ESG efforts, including the initiatives of its own company.

Stork's Boers said recyclability also is driven by advancements in resin technology.

"ESG goals remain a significant motivator, with many processors investing in innovative machinery to handle recycled materials and reduce their carbon footprint," Boers said. "However, for most of our customers, economic headwinds and the competitive environment are also factors taken into consideration."

In North America, Haitian's Frohring said Canadians have been taking the most steps recently toward greener ways.

"In the plastics division of the Chemistry Industry Association of Canada (CIAC), they have specific requirements for the use of resins, and government-mandated post-consumer recycled material is required of our Canadian customers. But we have not had to make major changes to the machinery platform outside of a special screw, which is no big deal for us," Frohring said.

At Milacron, Stirn said, "Government regulations in California and a few other states are driving attention across the country with a ripple effect. Everyone is aware and taking it into consideration. Milacron continues to offer solutions to processors that make production more sustainable, help them reduce scrap and, in some cases, utilize up to 100 percent regrind flake material during production."

At the heart of it, all parties need to step up, according to Nissei America's Miyajima.

"For corporations, working toward meeting ESG is necessary. For individuals, it is necessary to separate types of items to be disposed such as plastic containers and bottles to maximize the efficiency of recycling process and reducing environment impact," Miyajima said.

Engel's Malena agrees. She said plastic isn't bad but that plastic waste is, which is why machine builders support circular economy initiatives.

"The push should be on forcing society to take more responsibility for proper handling of plastic waste," Malena said. "Companies like Engel are already stepping up by developing technologies and machinery that support the widespread use of recycled materials. Our sustainability goals are further strengthened by close collaboration among companies across the value chain. Market participants are working together on horizontal platforms to share data and insights, from raw material production to processing, recycling and, ultimately, reaching consumers.

"The problem isn't plastic itself — it's plastic waste," she reiterated. "The focus should be on encouraging society to take greater responsibility for properly managing plastic waste."