When the material changes, the machine must change

Here, Nigel Smith, CEO of TM Robotics, Shibaura Machine's official distribution partner for injection moulding machines and automation systems in the UK and Ireland, explains why processors must select moulding systems to handle a broader material mix. Here, Nigel Smith, CEO of TM Robotics.

As Plastic Europe’s figures suggest, the challenge is not only increasing the share of circular plastics, but also making those materials workable in production. For processors, material choice was once fixed for the lifetime of a product.

What Happened

A component originally designed for virgin resin may later need to use recycled plastic, include more regrind from production waste or be redesigned using a more flexible material such as an elastomer, silicone or specialist polymer. That wider material mix creates a.

• Circular plastics have stagnated since 2022, with Plastics Europe reporting that they accounted for 15.4 per cent of European plastics production in 2024, only slightly above the 14.8 per cent reported in 2023.

• Meanwhile, the EU Packaging and Packaging Waste Regulation aims to make all packaging recyclable in an economically viable way by 2030 and to increase the use of recycled plastics.

• Manufacturers that build flexibility into the complete cell will be better placed to respond.

Key Details

Differences in melt flow, temperature sensitivity, mould filling and cooling or curing behaviour can all affect the result. This is where one-size-fits-all moulding reaches its limit.

• When the material changes, the process may need to change too.

• As regulation and customer specifications broaden material use, flexibility will come from matching machine architecture, injection control, auxiliaries and automation to the material and component.

• It must work with appropriate material preparation, auxiliaries, handling, downstream processes and monitoring.

Why It Matters

Tonnage and footprint remain important, but material behaviour, part geometry, filling requirements and cycle expectations should shape the production strategy. Recycled thermoplastics illustrate the challenge clearly.

• Selecting the press is only the beginning.

• This is particularly relevant for rubber, silicone and elastomer applications, where curing, insert loading, specialist tooling and demoulding access often determine the cell layout.

What Reports Say

Coverage of the story so far points to:

• Continued reporting by Robotics Tomorrow as more details emerge