TECHNOLOGIES & PROCESSES · AUTOMATION

Fully automated inline processes

Efficiency. Stability. Resource efficiency.

Fully automated inline processes are at the heart of manufacturing at VARIOPLAST. Instead of isolated production cells, VARIOPLAST integrates all production steps—injection moulding, surface finishing, assembly, and packaging—into a single, fully automated process network. The result: maximum process stability, consistent quality, minimal resource consumption, and cost-effective production even for smaller batch sizes. Made in Germany. Certified. Measurably better.

54% reduction in production costs* 80% increase in internal efficiency* 75% lower carbon footprint Collaborative Robots & AI-Powered Processes

* Source: Analysis by the South German Plastics Center (SKZ) in Würzburg

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THE VARIOPLAST INLINE APPROACH

What makes VARIOPLAST's fully automated inline production so special?

At VARIOPLAST, inline manufacturing means more than just the use of robots. It is a comprehensive manufacturing concept that integrates all process steps into a continuous line—without manual intermediate steps, without buffers, and without any loss of quality at the interfaces. The South German Plastics Center (SKZ) in Würzburg confirmed in an analysis: a 54% reduction in production costs, 71% greater process transparency, and an 80% increase in internal efficiency.

01 – End-to-end process integration – from granules to shipping packaging

At VARIOPLAST, the inline process begins with the injection of the plastic and does not end until the finished, surface-treated, and assembled component is placed in its product-specific packaging. Injection moulding, CO₂ cleaning, painting, PVD metallization, laser marking, assembly, and packaging all take place on a single line—fully automated.

02 – Collaborative robots & smart manufacturing cells

New collaborative robots expand the capabilities of traditional industrial robots. They operate safely alongside humans, enable flexible task allocation, and can be quickly reconfigured to meet new product requirements. Intelligently structured manufacturing cells, combined with optimized intralogistics, ensure the shortest possible transport routes and streamlined workflows.

03 – Resource-efficient production through inline integration

Fully automated inline processes are directly linked to resource conservation. Inline coating saves up to 96% in coating material compared to conventional methods. VARIOPLAST’s total carbon footprint is 75% below the industry average—verified and measurable.

04 – Cost-effective even for small production runs

Thanks to customized automation concepts and flexible manufacturing cells, inline processes are cost-effective even for small and medium-volume production runs. This allows niche products and technically complex small-batch production runs to benefit from the advantages of mass-production automation.

Range of Services

An overview of inline process combinations

In-line injection moulding combinations

Injection moulding + inline painting: The part leaves the line fully painted
Injection moulding + CO₂ cleaning + 2-coat painting + 2× drying (≃ 75% resource savings)
Injection moulding + inline PVD metallization + painting
2K injection moulding + Variothermie + laser cutting + pad printing + PVD metallization
Injection moulding + printing (pad printing)
2K injection moulding + ultrasonic welding
Injection moulding + laser marking + quality inspection (automated)

Robot-integrated processes

Robot-assisted removal and transfer directly from the injection moulding machine
Camera-assisted robotic gripping technology for insert moulding and hybrid technology
Robotic painting: precise, repeatable, up to 96% paint savings
Collaborative robots for flexible tasks on the assembly line
Automated quality inspection and sorting in an inline system

Fully automated inline finishing

CO₂ Pre-cleaning (Inline) for Optimal Surface Preparation
Plasma Cleaning & Surface Activation (Inline/Automated)
Inline PVD Metallization (Sputtering Technology, Cr6-Free)
Inline Robotic Coating (1K/2K, Multi-Layer)
Inline laser marking and laser cutting
Inline pad printing and hot stamping

Test results from SKZ analysis (Würzburg)

Reduction in production costs: 54%
Transparency in production processes: 71%
Increase in internal efficiency: 80%

EXAMPLES OF USE

Typical inline process chains at VARIOPLAST

These inline combinations are already in production and demonstrate the capabilities of the VARIOPLAST manufacturing network:

Black Panel Technology: 2K injection moulding + Variothermie + PVD metallization + painting + laser contour cutting
Automotive control element: 2K injection moulding + CO₂ cleaning + robotic painting + laser engraving
ESD electronics housing: Injection moulding + PVD metallization (conductive coating) + ESD-compliant assembly + packaging
Reusable packaging line: Injection moulding + inline inspection + VARIOBOXX® filling
Insert moulding: Camera-assisted insertion of metal parts + overmoulding + automated removal

FREQUENTLY ASKED QUESTIONS – FAQ

Frequently asked questions about fully automated inline processes

What is the difference between inline manufacturing and traditional single-process manufacturing?

In traditional single-process manufacturing, components are transferred manually or via conveyor to separate processing stations (painting, assembly, packaging) after injection moulding. Inline manufacturing means that all process steps take place within a fully automated, integrated system—without buffers, without manual intervention, and without the risks associated with transportation. This reduces sources of error, shortens lead times, and lowers unit costs.

At what production volume do fully automated inline processes become cost-effective at VARIOPLAST?

Thanks to customized automation concepts and flexible manufacturing cells, VARIOPLAST can operate inline processes cost-effectively even for small and medium-sized production runs. The South German Plastics Center (SKZ) in Würzburg confirmed a 54% reduction in production costs—a benefit that takes effect from the very first unit produced.

Which processes can be combined in an inline composite system at VARIOPLAST?

VARIOPLAST combines injection moulding (1K, 2K, multi-component), CO₂ pre-cleaning, plasma cleaning, PVD metallization, robotic painting (1K/2K, multi-layer), laser marking, pad printing, hot stamping, ultrasonic welding, laser cutting, and fully automated assembly in an inline process. The combination is configured on a project-specific basis.

How does inline manufacturing contribute to sustainability?

Inline production is a direct driver of resource conservation: Inline robotic painting saves up to 96% of paint material. Short internal transport routes and optimized logistics processes reduce energy consumption and CO₂ emissions. VARIOPLAST achieves an overall CO₂ footprint that is 75% below the industry average—certified to ISO 14001:2015.

What are collaborative robots (cobots), and how does VARIOPLAST use them?

Collaborative robots (cobots) are robots that can work safely right alongside humans—without the need for protective barriers. At VARIOPLAST, cobots are used for flexible assembly and handling tasks in inline production. They complement traditional industrial robots where flexibility and quick changeover are required, and expand the scope of automation into new application areas.

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Would you like to learn more or request a quote right away? Contact us—VARIOPLAST is here to serve you as a reliable partner with over 50 years of experience.

Contact: contact@varioplast.de | www.varioplast.de

Location: Enzkreis, Baden-Württemberg, Germany – Made in Germany since 1970