Smart Utility & Material Handling System for a 108-Machine Injection Molding Plant

Challenge

The customer required a factory-wide utility and material handling system capable of supporting 108 injection molding machines producing high-end precision components. The first challenge was energy management. A conventional cooling system sized only for peak demand would consume unnecessary energy during partial production loads. The customer therefore required a cooling architecture capable of automatically matching operating capacity to actual production demand. Material management presented another major challenge. Some raw materials contain glass fiber and create significantly higher wear on conventional conveying pipes and elbows. At the same time, incorrect material selection, excessive drying, material segregation, and improper machine-side material levels could directly affect production quality. With more than one hundred injection molding machines, the compressed-air network also needed to maintain stable pressure at every consumption point. The complete system therefore had to combine utility stability, material traceability, error prevention, wear resistance, and automated control within one coordinated factory infrastructure.