Wittmann Group: Integrated Material Preparation and Process Control for High-Quality Recycling

At Fakuma 2026, the Wittmann Group will showcase an integrated injection molding application that combines material recycling, material preparation and process control within a compact production cell. The system produces the “EcoFritz” clip, a reusable fastening solution for securing media lines and cables to corrugated hoses. The application focuses on the direct return of production scrap, targeted preparation of recycled material and technologies designed to reduce material consumption.

The patented “EcoFritz” clip is intended as an alternative to conventional cable ties for installing material supply lines and other media lines in injection molding plants. Unlike cable ties, the clip can be removed without being destroyed and can be repositioned as required. Wittmann produces the clip in three sizes to suit common corrugated hose diameters.

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Inline Recycling Within the Production Cell
At Fakuma 2026, the clips will be produced in an Ingrinder work cell. In this system configuration, the injection molding machine, robot, conveyor and granulator are combined into a preconfigured production unit. The safety enclosure is also integrated into the machine concept, allowing the components required for both production and recycling to be accommodated within a relatively small footprint.

The cell consists of a SmartPower 60 servo-hydraulic injection molding machine, a WX90 servo robot and an S-Max granulator. Glass-fiber-reinforced polyamide is processed in a two-cavity mold supplied by Röttger. Sprues generated during injection molding are granulated directly inside the production cell and subsequently blended back into the feedstock.

This creates a closed material loop within the cell. Production scrap does not have to be collected, transported for external processing or temporarily removed from the production environment. Instead, the regrind is returned directly to the injection molding process.

Dedusting Helps Stabilize Recyclate Quality
For material conveying, Wittmann uses a Feedmax Clean loader with integrated dedusting. According to the manufacturer, the system achieves a separation efficiency of up to 80% for particles smaller than 1,000 µm when conveying recycled material.

Dedusting is particularly important when processing regrind and recyclates. Dust and fine particles can influence dosing behavior and affect the homogeneity of the polymer melt. Removing these fractions is intended to help stabilize processing conditions, even at higher levels of recycled content.

The application also incorporates Wittmann’s HiQ Flow digital assistance system. During the injection phase, the software continuously detects changes in melt viscosity. If deviations from the stored reference values are identified, the system adjusts the switchover point and holding pressure within the same molding cycle.

The aim is to maintain a consistent part weight despite variations in feedstock properties or changing ambient conditions. Such fluctuations can be particularly pronounced when recycled materials are used, as their properties may vary more significantly from batch to batch than those of virgin material.

Gas-Assisted Injection Molding Reduces Material Consumption
The clips are also produced using Wittmann’s Airmould gas-assisted injection molding process. Nitrogen is introduced into a mold cavity that is partially or fully filled with polymer melt. The pressurized gas displaces plastic from the interior of the part, creating a hollow section.

At the same time, the gas pressure counteracts volumetric shrinkage of the polymer melt. This can reduce sink marks and enable parts to be manufactured with lower material consumption. Particularly in thicker-walled components, the process can combine reduced part weight with shorter cooling times and consistent surface quality.

The material displaced by the nitrogen is granulated together with the sprues inside the production cell and returned to the material loop.

The nitrogen required for the gas-assisted process is generated directly from ambient air at Wittmann’s exhibition stand using the N2easy nitrogen generation system. The system can supply several consumers and eliminates the need for individual gas cylinders. According to Wittmann, on-site nitrogen generation can already be economically viable at a daily consumption level equivalent to approximately one gas cylinder. It also eliminates the associated external cylinder logistics.

Production With Up to 100% Recycled Content
The “EcoFritz” clips are also manufactured at Wittmann’s Nuremberg facility. There, the company uses weekends, among other periods, to operate the production system autonomously in its technical center. According to Wittmann, when sufficient solar energy is available, production is powered entirely by electricity generated by the company’s own photovoltaic system.

Plastic waste from injection molding trials and mold sampling is also collected, processed on site and reused. According to the company, the recycled-content share in the production of the clips can reach up to 100%.

The Fakuma 2026 application therefore combines several approaches to improving material efficiency: production scrap is returned directly to the process, recycled material is dedusted before processing, fluctuations in melt properties are compensated for during the injection molding cycle, and the amount of material required for the component is reduced through gas-assisted injection molding.

The “EcoFritz” clip serves as a demonstration part illustrating how these individual process steps can be integrated into a continuous, compact injection molding cell.

Fakuma 2026
Friedrichshafen, Germany
October 12–16, 2026
Hall B1, Booth 1204

More information: www.wittmann-group.com

Wittmann Tec Group GmbH, Vienna, Austria + Wittmann Battenfeld GmbH, Austria, Österreich + Wittmann Technology GmbH, Vienna, Austria + Wittmann Battenfeld Deutschland GmbH, Meinerzhagen, Germany

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