More Sustainability, Consistent Quality: How to Successfully Process PCR Plastics

Tuesday, December 3rd, 2024 at 9 AM ET | 3 PM CET

Production Process

Sustainability in Plastics Manufacturing

Welcome to sensXPERT – your go-to for sustainability in plastics manufacturing. Explore how we meet CSR Directive requirements through innovative technologies and data-driven solutions. Discover how we’re shaping the future of plastic production together, making it more environmentally friendly, transparent, and sustainable.

Maximizing Production Outcomes Through Sustainable Practices

The plastics production industry is undergoing rapid evolution, driven by the need for greater sustainability and efficiency. The circularity landscape in plastics production is marked by a mix of challenges and innovations. While mechanical recycling is common, the industry is actively striving to improve recycling rates and enhance the quality of recycled materials.

Sustainable plastics manufacturing, particularly within mold processes, is not merely an ethical choice but a strategic imperative that aligns with environmental stewardship, market demand, and the roadmap to long-term business success. In the dynamic landscape of plastics manufacturing, embracing sustainability, particularly in mold processes, is imperative for several reasons.

Beyond mitigating environmental impact and complying with regulations, sustainable practices align with consumer preferences, bolster brand reputation, and foster innovation. Cost-efficiency, long-term viability, and supply chain resilience further underscore the strategic significance. As a beacon of responsible business, sustainable plastics manufacturing is not just an ethical choice but a pathway to success, attracting engaged employees, global recognition, and ensuring a resilient, innovative, and competitive future.

The Crucial Role of Sustainable Plastics Manufacturing

Environmental Impact

By embracing sustainable practices, manufacturers contribute to reducing the environmental footprint associated with plastics production, curbing pollution, resource depletion, and excessive waste generation.

Regulatory Compliance

The ever-growing emphasis on environmental regulations necessitates adherence to sustainable practices, ensuring compliance with stringent standards and safeguarding against potential legal ramifications.

Consumer Preferences

In the contemporary marketplace, consumers exhibit a strong preference for eco-friendly and sustainable products. Incorporating green practices in plastics manufacturing aligns with consumer expectations, bolstering brand reputation and market competitiveness.

Circular Economy

Sustainable manufacturing principles play a pivotal role in fostering a circular economy, where materials are recycled, reused, or repurposed, contributing to a more efficient and closed-loop production system.

Cost-Efficiency

Sustainable practices often lead to more judicious resource utilization, energy savings, and minimized waste. Over time, this translates into tangible cost savings for manufacturers.

Long-Term Viability

As sustainability evolves into a cornerstone of business practices, companies that integrate eco-friendly measures are better positioned for long-term success, adept at adapting to evolving market expectations.

Innovation and Technology

The pursuit of sustainability often catalyzes innovation in materials, processes, and technologies, fostering continuous improvement and ensuring a competitive edge in a rapidly evolving industry.

Supply Chain Resilience

Sustainable practices contribute to a resilient and responsible supply chain, addressing concerns related to resource scarcity and ensuring stable and ethical sourcing.

Employee Engagement

Embracing sustainability aligns with the values of a modern workforce. Employees are more likely to be engaged and motivated when working for a company that prioritizes ethical and sustainable practices.

Global Reputation

Companies committed to sustainable plastics manufacturing build a positive global reputation, attracting partners, investors, and customers who share similar values

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Our contributions to a more sustainable manufacturing

Our Solution

Tomorrow’s sustainable technology here today

sensXPERT empowers manufacturers to enhance sustainability in their production processes. By leveraging in-mold sensors and advanced data analytics, our solution provides real-time insights into material behavior, allowing manufacturers to optimize cure cycles, reduce scrap, and achieve precise crystallization. This not only improves efficiency but also contributes to resource conservation and waste reduction. SensXPERT's commitment to innovation and sustainability aligns with the evolving landscape of responsible manufacturing, enabling plastics companies to achieve higher standards of environmental and operational excellence.

sensXPERT Digital Mold

Key benefits of our solution

Reduce waste, cost, increase process capability to ensure enough product is available to meet industry need.

01

Lower Embedded Energy

Reduce cycle time, scrap, energy needs to produce more parts faster at lower cost and carbon footprint.

02

Reduce Costs

Reduce scrap, improve process efficiencies to produce more parts faster at more competitive cost.

03

Ensure Reliability

Design closer to engineering limits of materials to reduce mass and cost but ensure products meet structural requirements long-term in demanding environments.

Up to 50% reduction

of the existing rate of scrap produced

Up to 23% increase

in energy savings

Up to 30% reduction

in length of manufacturing cycle times

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The complete sensXPERT product solution

Process control with sensXPERT Product integration of sensXPERT Digital Mold

The sensXPERT Dielectric Sensor

The sensXPERT Dielectric Sensor maintains direct contact with the raw material inside the mold, continuously collecting real-time data about the material’s behavior, calculates parameters like as the degree of cure, the degree of crystallization, a glass transition temperature, flow behavior or other relevant thermal/mechanical properties of the polymer being processed, and connects to the Edge Device. Durable in extreme conditions, it operates up to 280˚C and 400 bar pressure.

The sensXPERT Edge Device

Designed for close proximity to machinery, is compact and robust to meet industrial demands. It processes digital and analog signals, offers various industrial interfaces, and hosts machine learning models for dynamic process control. Plus, it provides direct remote customer support.

The sensXPERT Web App

Enables real-time monitoring by collecting and centralizing material data. Machine learning models predict material properties, and the Web App offers precise insights for informed real-time decisions during production.

The sensXPERT Cloud Service

In partnership with AWS, the sensXPERT Cloud Service empowers Manufacturing 4.0. It validates and stores data, provides process insights, and refines machine learning models. Users can remotely access and correlate data from multiple global sites and manage permissions.

A whole new raft of manufacturing capabilities

In-mold dielectric analysis

Powerful in-mold dielectric analysis data for an unparalleled insight into material behavior in real time. Understand what’s really happening inside the mold and achieve dynamic control over your manufacturing process.

Process tracking

Plug into and easily utilize vast amounts of live data from multiple sources around and inside your mold, so as to benefit from a more holistic and transparent view of your entire process in real time. All this data is used to calculate and track important parameters in real time and create a more transparent production process, thereby reducing your reliance on post-process testing.

Process optimization

By leveraging real time material characterization and data analytics, sensXPERT uses advanced AI to achieve process optimization. These machine learning models are instrumental in forecasting properties like the degree of cure or crystallization, glass transition temperature, and other relevant thermal or mechanical attributes of the raw material in processing.

Webinar

Is plastics manufacturing sustainable?

Paving the Way Towards Sustainable Part Production: Approach and Case History

Dive into the curing process details, including Tg and degree of cure, in our webinar with Mississippi State University. Explore a comprehensive approach to optimize composite production, addressing energy savings and waste reduction for sustainable processes aligned with ESG goals. Join us to revolutionize your composite part manufacturing.

Watch Webinar

Whitepaper

Enabling Sustainability in the Plastics Industry

Enabling Sustainability in the Plastics Industry

The European Green Deal, effective in 2023, compels plastics processors to demonstrate sustainable and cost-effective production aligning with new taxonomy legislation. Amid global environmental concerns, this legislation mandates companies to reduce carbon footprints, fostering a circular economy. Meeting these requirements is crucial for the plastics industry, and investing in technologies like sensXPERT Digital Mold can enhance sustainability, transparency, and facilitate compliance with taxonomy reporting, giving companies a competitive edge.

Get our free whitepaper

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