Sumitomo (SHI) Demag and Mapag Maschinen AG will once again present a joint exhibit at Swiss Plastics Expo 2026 in hall 1 / B 1031. The partners will demonstrate a high-precision medical application on a fully electric IntElect S production cell. The setup is designed to illustrate how energy efficiency, reproducibility and digital quality prediction are shaping current injection moulding processes, particularly in demanding medical applications where process stability and cleanliness are critical.
The showcase revolves around the production of insulin caps using an 8-cavity mould and automated part handling. In addition to the injection moulding machine, the cell integrates an in-house linear robot, digital quality analytics and connectivity based on OPC UA communication. The exhibit also links to a manufacturing execution system (MES) platform presented by bfa solutions, aimed at giving processors an overview of equipment effectiveness, downtime and process data across the shop floor.
Fully electric Intelect S for insulin cap production
The medical exhibit is built around an IntElect S 100, which is equipped with an 8-cavity mould from Kistler for the production of insulin caps. With this configuration, Mapag Maschinen AG and Sumitomo (SHI) Demag are targeting one of the most demanding segments in plastics processing. In insulin delivery components, dimensional precision, process stability and a high level of cleanliness are decisive factors throughout the moulding process and handling sequence.
Automated part removal is performed by the in-house SAM-C5 robot. In its standard configuration, this robot features a robust, space-saving design combined with SHI servo motors. The robot concept includes an enhanced cleanliness approach, using optimised linear guides and drive technology to effectively reduce the risk of contamination in both the product and mould area. This is intended to support the requirements typically associated with medical production environments.
From a software perspective, the robot is designed to integrate into modern production environments. Intuitive low-code programming serves as the basis for operation. This is supplemented by an extensive macro function library intended to simplify the creation of motion sequences and handling programs. Additional functions include a program generator and the option to create external peripheral sequences, enabling the implementation of complex handling operations that involve external equipment without functional limitations.
Real-time component quality prediction
A central element of the exhibit is the integration of the ComoNeoPREDICT prediction system from Kistler Instrumente AG into the myAssist data analytics tool. This combination focuses on predicting the quality of each component during the injection moulding cycle, rather than relying solely on downstream inspection.
The ComoNeoPREDICT software automatically generates test plans and supports the creation of predictive models. During production, it evaluates in real time whether the predicted quality characteristics of each part remain within the defined tolerance window. By linking ComoNeoPREDICT with myAssist, processors can access quality and process monitoring functions that are intended to be both consistent and easy to interpret. According to the description, this monitoring is provided without additional manual effort for the machine operator.
The emphasis on prediction and inline assessment reflects growing interest in using process signatures and sensor data in medical moulding, where a high proportion of parts must meet strict specification limits. The approach presented in the cell is focused on integrating these functions directly into the machine and cell control structure rather than treating them as stand-alone add-ons.
Digital connectivity and OPC UA-based data exchange
The partners underline that fully integrated digital connectivity is becoming increasingly important, particularly in sensitive sectors such as medical technology. Open platforms are described as the basis for seamless data exchange between machines, devices and systems from different manufacturers, which is a prerequisite for cross-line analytics and coordinated quality assurance.
In this context, myAssist is positioned as a central element for enabling digital synergies within the cell and the wider production environment. According to Andreas Pittermann, CEO of Mapag Maschinen AG, high data transparency allows early identification of deviations, consolidation of data from all OPC UA sources and immediate reaction to changes in the production process. Users can compare live data with historical records and analyse different time intervals to identify trends or deviations.
For communication to function smoothly across all machines and robots within a plant, all elements from sensors to process parameters must use a common communication language. OPC UA is presented as the foundation for this interoperability. At the same time, Sumitomo (SHI) Demag is demonstrating how modular future extensions can be integrated to adapt the system flexibly to specific process requirements. Pittermann notes that modules are being developed for processors with limited resources to simplify the acquisition and analysis of quality-relevant information during ongoing production.
Alignment with Swiss market requirements
The exhibit is also intended to reflect specific requirements of the Swiss plastics processing market. Under the motto "Today. Tomorrow. Electric." visitors to the stand will be able to gain insight into the precision, reproducibility and energy efficiency of Sumitomo (SHI) Demag's fully electric machine technology. According to the description, this includes the seamless integration of automation, modern sensor technology as well as digital quality analysis and forecasting within a single production cell.
The focus on a compact cell with integrated robot, inline prediction and open connectivity is directed at processors looking to combine moulding performance with traceable quality and higher equipment utilisation, particularly in medical and other regulated applications prevalent in the Swiss market.
Mes integration with PiSolutions from bfa solutions
As a partner on the joint booth, bfa solutions will present its MES software platform PiSolutions, including an industry-specific solution for injection moulding. The PiSolutions BASIC Bundle covers the essential functions of a modern MES, from monitoring overall equipment effectiveness (OEE) and alarm reporting to recording and classifying downtimes and production stoppages.
With modular ADD-ON extensions, bfa solutions offers additional performance packages in the areas of production planning, quality monitoring and maintenance management. These solutions are aimed at helping injection moulders manage their production more transparently, reduce unplanned downtime and increase overall equipment effectiveness in a sustainable way. The link between the demonstrated IntElect S cell, myAssist analytics and the MES platform is designed to illustrate how machine-level data can be used at the manufacturing execution level.
