K Show 2025 Kistler offers solutions for cost reductions in plastics manufacturing

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At K 2025, Kistler will showcase a comprehensive range of solutions to cut costs and improve quality in plastics manufacturing — from advanced cavity pressure sensors and process monitoring software to innovative joining systems and AI-supported optical inspection.

Kistler will be demonstrating how current challenges in plastics manufacturing can be mastered at K 2025in Düsseldorf. Visitors will find new and optimized solutions along the value chain, from cavity pressure sensors, systems and software for process optimization and quality monitoring. A new assembly system and an optical inspection machine for end-of-line inspection will also be on display at the booth. The focus is on applications in medical technology and electronics production.

Kistler already presented its updates for the Comoneo process monitoring and control system for plastic injection moulding at the beginning of the year. In addition to optimized user-friendliness, version 7.0 focuses on the additional Multiflow function, which enables automatic control of the individual hot runner nozzles in multi-cavity moulds. This gives injection moulders maximum control over product quality. The improved hot runner balancing helps both with the processing of recyclates and with cost savings. In addition, Comoneo has now received a hardware upgrade, giving it significantly more computing power, which shortens processing times and makes the system fit for future functionalities, such as those based on AI.

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While Comoneo actively controls ongoing injection moulding processes, the Akvisio process data management software provides insights into the production history and ensures seamless documentation, as required in medical technology, for example. Akvisio also evaluates large data sets in just a few seconds and helps to identify cost drivers in the process.

With its new NCFQ 2166A joining solution for sensitive plastic parts (product introduction in October 2025), Kistler is particularly addressing the quality and efficiency requirements of medical technology and electronics production. The innovative high-speed joining system combines the high dynamics of linear direct drives (linear motor) with the precision of piezoelectric sensors. Kistler uses Linmot’s proven drive technology and supplements it with piezoelectric force sensors and acceleration compensation. This particularly benefits highly dynamic applications with small forces of up to 500 N — such as in the production of auto-injectors and insulin pens. The magnet-based technology of the joining module with linear motor accelerates at up to 50 m/s² and achieves a speed of up to 5 m/s. In addition to the linear motor, the module has a magnetic spring for weight compensation in a vertical installation position. For particularly demanding applications, Kistler offers a version with an additional piezoelectric acceleration sensor for automated acceleration compensation. Kistler also supplements the system with the ICAM-B industrial charge amplifier and the maXYmos NC process monitoring system for maximum data transparency, process reliability and control.

Optical quality assurance is the final stage in the value chain presented at the Kistler K 2025 booth. The KVC 821 vision inspection system demonstrates how the 100 percent inspection reliably detects typical sporadic injection molding surface defects and assembly defects — at cycle times of up to 800 parts per minute. To detect previously unknown or rarely occurring anomalies, Kistler also uses artificial intelligence in its Kivision image processing software.

In addition to the vision inspection system, another image processing solution with two camera stations from Kistler can be seen at the K at the stand of the Institute of Plastics Processing (IKV, Hall 14 / Stand C 16). The IKV will be demonstrating the optical inspection in the interlinking process directly after injection moulding.

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