AI Unlocks Profitability in Quality Control Processes

QA aims toward ensuring error-free goods, secure and efficient processes, and reduced material usage. Artificial intelligence (AI) technologies are increasingly assisting QA procedures, such as in terms of automation through closed-loop processes, evaluation of measurement data, and speeding of measuring operations. A panel of experts will address which AI systems are already in use in industry, which are already in existence, and what particular outcomes they are attaining in terms of efficiency and cost-effectiveness as part of the 2025 Control Quality Talks. In the framework of complete automation, it will also be investigated to what degree future AI systems will streamline quality assurance and open the door for error-free goods and procedures.

Distinguished Guests at the Expert Round Table:

„The aim of implementing AI should be to create real benefits and to integrate these into the CAQ system in a robust manner that simplifies the daily work of the software users – the focus must be on achieving the necessary maturity for real industrial added value for the masses. I am looking forward to the discussion. “

“AI can be put to good use in measuring technology, for example in order to support equipment operators via chatbots. A further example involves the intelligent optimisation of image quality in image processing or X-ray computer tomography. However, it’s very important to ensure that traceability of measurement results is not jeopardised as a result. AI must not alter measurement results. Utmost care is essential during project development.”

‘With AI, we can enable new applications and rethink workflows in measurement technology!’

„The use of artificial intelligence opens up a new dimension in quality assurance. in quality assurance. AI can be used to automate and objectify a large number of testing tasks that previously had to be carried out manually. But it can also be used as an assistance system for recording measurement data, planning measurement sequences or the virtual configuration of optical measurement and inspection systems, AI-based solutions also offer considerable potential for efficient quality assurance. “

„As developers, but also users, of AI-based quality assurance and assessment methods, we know both the challenges,
but also the enormous potential and benefits of these AI tools for our workflows. “

Exhibitors, expert visitors and guests will be able to gain extensive background information and further inspiration from this dialogue, because AI is clearly one of the key technology trends in quality assurance.

https://www.control-messe.de/

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ZAHORANSKY Supports Eco-Friendly Toothbrush Production with Plastic Anchors

Small machine adaptation, big impact for the environment
From now on, toothbrushes can also be produced on the proven ZAHORANSKY Z. ORCA and CUBE machines without the use of metal anchors. Instead, plastic anchors can be used. Existing machinery or new acquisitions only need to be minimally adapted for this. They thus offer their customers the opportunity to further develop their product range in line with current consumer wishes and market trends easily without high investments. In the oral care sector, consumers are also increasingly making their purchasing decisions based on the eco-balance of the products – pure plastic toothbrushes perform better than conventional toothbrushes with a metal anchor. For example, fully recyclable toothbrushes or models where only the brush head needs to be replaced are in vogue. Their aim is to provide manufacturers with technologies with which product innovations can be realized in terms of sustainability. With this aspiration, the EDGE was launched in 2024 – a machine that enables the production of anchorless mono-material toothbrushes with maximum design freedom thanks to an innovative process.

More sustainability, more efficiency, familiar performance 
To be able to produce the so-called mono-material toothbrushes on the ZAHORANSKY Z.ORCA and CUBE machines, only the corresponding assembly needs to be adapted. Instead of the previously used metal anchors, the filaments in the brush head are then fixed with plastic anchors. As the toothbrush body, filaments and anchors are made of plastic, toothbrushes that are no longer used can be easily and completely recycled – a plus for the eco-balance. At the same time, the machines score points with the usual safety and product quality. With a tufting speed of up to 1,200 bundles/min, the same performance is possible as when using metal anchors. The use of plastic anchors can also be interesting in terms of more economical production, as the material price is lower than for the metal version.

www.zahoransky.com

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HASCO Tools Help Designers Work Faster and Smarter

With the extension of two databases, HASCO offers its customers time and cost savings through efficient and precise data processing. 

HASCO standard mould units in the Mold Wizard of the Siemens NX auxiliary application

A large number of new HASCO products are now available in the Mold Wizard for Siemens NX. With intelligent standard mould units and innovative features, the system offers tailor-made solutions to meet the demands of modern mouldmaking. The extension enables engineers and designers to work more efficiently and precisely by being able to access a wide range of high-quality components.

A new feature of the Mold Wizard is a tool called “Mold Cost”. It optimises the process of drawing up offers for moulds by simplifying and speeding up the gathering of information and the drawing up of the offer. At present, the process of compiling an offer involves several steps in various systems. With the new tool, mould costs can be efficiently prepared and reports quickly generated, thereby increasing the plannability and saving time. Other features include increased efficiency, fast reporting and improved precision of the mould costs calculation. “Mold Cost” sets a new standard in the mould industry and helps the customer to optimise processes and remain competitive.

HASCO database for standard mould units increased in TopSolid

With HASCO’s standard mould units integrated in TopSolid, highly complex moulds can be efficiently designed and manufactured. The database has been increased by 60% and is automatically updated, which means that access to a larger selection of high-grade components is guaranteed. The automatic update ensures that users are always working with the present information and can benefit from the latest developments.

The enlarged database includes the latest standard mould units, with improved guide elements and high-precision ejector pins. These components increase the reliability of the construction and can be integrated seamlessly into 3D-CAD data. In this way, design processes are optimised and productivity increased.

The integration of the products into the two systems underlines the HASCO commitment to continuously offer forward-looking and reliable solutions that meet the highest standards of the industry.

https://www.hasco.com/

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Tosca’s Reusables Drive Sustainable Change for Il Visone

Il Visone, a key player within the Agricoper Italian group specializing in the cultivation and supply of fresh grapes, has partnered with Tosca to address their operational challenges, maintain the quality of the produce during harvesting and storage, and achieve their sustainability goals. By adopting Tosca’s innovative reusable plastic crate solutions, Il Visone has transformed its supply chain, enhancing efficiency, reducing waste, optimizing processes, and reinforcing its commitment to environmental responsibility.

Overcoming Storage and Logistics Challenges – Preserving Freshness

Maintaining the quality and freshness of grapes from harvest to market requires precision and care. Il Visone encountered significant challenges with traditional storage and transportation materials. Cardboard and lightweight plastic packaging often failed under the strain of cold storage conditions, frequently buckling and risking damage to the grapes. Inconsistent packaging also resulted in frequent pallet collapses, causing inefficiencies, safety hazards, and unnecessary waste. Moreover, bulky, non-foldable crates consumed time and resources, restricting logistical capacity.

Seeking a more reliable, efficient, and sustainable solution, Il Visone turned to Tosca for an innovative approach that would ensure consistent quality across its supply chain while streamlining operations.

Tosca’s Reusable Crates: A Game-Changer for Efficiency and Sustainability

They have introduced its reusable, foldable plastic crates, a solution designed to tackle Il Visone’s key challenges while enhancing overall supply chain performance. These crates, which feature pierced holes for airflow, promote optimal air circulation in cold storage, keeping grapes fresh from August to November. Their sturdy, stackable design significantly improves pallet stability, reducing the risk of collapses and ensuring safer and more reliable storage. Additionally, the foldable design allows for more efficient storage and transport, enabling Il Visone to move more crates of grapes per trip, consequently lowering logistical costs and environmental impact.

The switch to their crates has also streamlined Il Visone’s operations from the field to storage. The foldable crates minimize transport back and forth between the fields and packhouses, saving time and reducing emissions. Workers can easily fold and store the empty crates, improving operational efficiency. Additionally, they have customized the crates with Il Visone’s branding, enhancing visibility and traceability within the supply chain, while promoting brand recognition.

A Sustainable Partnership with Growth Potential

Beyond operational efficiency, Il Visone’s transition to their reusable crates seamlessly aligns with its commitment to sustainability. By replacing single-use packaging with durable, washable, and fully reusable crates, the company significantly reduces waste. The enhanced protection offered by their crates also helps to minimize product damage, reducing food waste and ensuring that more grapes arrive at their destination in perfect condition. The stackable and foldable crate design contributes to lower carbon emissions by optimizing transport efficiency, while Il Visone’s in-house washing system further reduces environmental impact by eliminating the need for external cleaning services.

Building on the success of this collaboration, Il Visone is keen to explore new opportunities with Tosca to further enhance its operations. The company is already utilizing their plastic pallets for internal handling and their wood-effect crates for the CRAI retail circuit. Looking ahead, a rental service with Low Bins or similar products may be considered to improve operational efficiencies further.

Reflecting on the partnership, a representative from Il Visone remarked: “Tosca’s reusable plastic crates have simplified our operations and improved efficiency at every stage of our supply chain. From their durability and design to the excellent service provided, Tosca has been an invaluable partner.”

As Il Visone’s operations continue to grow, Tosca remains dedicated to providing innovative solutions that drive operational success while supporting environmental sustainability. This partnership demonstrates the power of innovation and collaboration that can transform supply chain operations, paving the way for a more efficient and sustainable future in fresh produce logistics.

https://www.toscaltd.com/en-gb/

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Breakthrough Equipment Enhancing Plastics Process Efficiency

At this year’s Chinaplas (15-18 April 2025, Shenzhen World Exhibition & Convention Center (Bao’an), PR China) Coperion will present key technologies for the entire process chain of processing plastics and recycling at booth 10K25 in hall 10.

Coperion will showcase two extruders that are ideally suited to current challenges in plastics compounding and recycling. The 4th generation STS 75 Mc PLUS twin-screw extruder features an increased specific torque of 13.6 Nm/cm³, enabling it to achieve up to 20% more throughput with significantly higher product quality. A ZSK 58 Mc 18 twin screw extruder with maximum torque for highest throughput demands, especially designed for products with high torque requirement such as engineering plastics, will also be on display. In addition, they will highlight its reliable and highly accurate feeding solutions, including their K-Tron T35 gravimetric feeder paired with a 2415 vacuum receiver for ingredient refill, as well as a C/S-LW- NS 60 single screw feeder from Colormax Systems. A ProRate PLUS-M feeder, part of the new line of robust gravimetric single and twin-screw feeders, will be on display as well. For efficient conveying processes, a CVH 550 high pressure rotary valve and the two-way diverter valve WEK 265 for granulates will also be shown.

For the recycling of plastics Coperion and Herbold Meckesheim collaborate to provide operators with extensive expertise in technology and process solutions. At Chinaplas, they will showcase a virtual 3D recycling installation. Visitors to the booth will have the opportunity to explore key components of the recycling set up, allowing them to observe the technical details of each process step and the high efficiency of each component.

STS Mc PLUS Extruder: Economic and Efficient Solution for Various Applications

Over the years, the STS extruder series has established itself on the market as a quality product for a wide range of extrusion and compounding tasks such as engineering plastics and masterbatch but also cable masses, the recycling of regrind plastics, powder coating, and much more. The extruders are produced at Coperion in Nanjing, China, in accordance with CE guidelines and the highest Coperion standards of quality. They are distinguished by their very attractive price-to-performance ratio.

The STS 75 Mc PLUS presented in the Coperion booth 10K25 is the 4th generation of STS technology and is equipped with a specific torque of 13.6 Nm/cm³ at screw speeds of up to 900 min -1. This advancement allows the compounder to deliver enhanced product quality while increasing throughput by up to 20% across all applications compared to earlier models. Key to this performance boost, alongside process-related modifications, is the optimization of the drive’s key components. The STS 75 Mc PLUS extruder features a high-power motor and a gearbox specifically designed to handle high torque. Proven high-performance materials are used for the screw shafts to ensure effective torque transmission from the gearbox to the screw elements. The higher fill level in the process section is crucial to the improved compound quality achieved by the STS 75 Mc PLUS, as it reduces both shear stress and melt temperature while enhancing mixing behavior. This results in an exceptionally gentle product handling at high throughputs.

ZSK Mc 18 Extruders: Made for Highest Demands

Visitors to the booth can also learn more about the advantages of the renowned ZSK extruder series. These high-performance extruders such as the ZSK 58 Mc¹⁸ on display achieve the highest throughput rates and maximum economic efficiency. The extruder with a specific torque of 18 Nm/cm³ is characterized by its consistently high throughput capacity with first-class product quality. With the assembly in China, Coperion is able to react as fast as possible to customer demand. Customers benefit from local added value, transport and tax savings as well as from shorter delivery times.

Complete Plastics Recycling Plants from a Single Source

Coperion and Herbold Meckesheim realize plants for a wide variety of plastics recycling applications, excelling in their reliability and the high product quality they achieve. From mechanical processing – shredding, washing, separating, drying and agglomerating of plastics – to bulk material handling as well as feeding and extrusion all the way to compounding and pelletizing, such plants cover the entire plastics recycling process chain. Together, Coperion and Herbold Meckesheim offer solutions for different recycling processes such as mechanical recycling of post-industrial and post-consumer waste, chemical recycling, PET recycling or solvent-based recycling.

Especially for recycling of post-consumer recyclate (PCR) or any highly contaminated polymer, Coperion offers the innovative ZSK FilCo filtration compounder that allows filtration and compounding in a single production step. Compared to the two-step production lines that have been the norm until now, Coperion’s ZSK FilCo is distinguished by a markedly more streamlined equipment set-up. Energy consumption and emissions for the extrusion process are reduced by more than 50%.

Robust, Flexible and Precise Feeding Solution: ProRate PLUS

The ProRate PLUS feeder line integrates state-of-the-art European weighing technology and controls, ensuring high accuracy and reliability in loss-in-weight feeding processes. This line meets the growing demand for robust and efficient feeding solutions in the plastics industry. The ProRate PLUS continuous gravimetric feeder line is an economical solution and offers a quick return on investment due to its good price-performance ratio and fast delivery times.

The ProRate PLUS feeder line features a space-saving trapezoidal shape which allows up to six feeders to be easily grouped around an extruder inlet within a 1.5 meter [5 ft] radius. Three single screw feeder models PLUS-S, PLUS-M and PLUS-L along with the PLUS-MT twin screw model cover a wide range of throughputs and bulk materials. ProRate PLUS feeders are capable of handling feed rates from 3.3 up to 4800 dm 3 /h [0.12 up to 400 ft 3 /h], depending on the material. Theoretically, a feeding system with six ProRate PLUS-L feeders can feed up to 28.8 m 3 /h [1017 ft 3 /h] on a footprint of only 7 m 2 [75 ft 2].

Smart Feeding Solutions

In addition, Coperion will demonstrate its expertise in all feeding tasks at this year’s Chinaplas with its high-accuracy Coperion K-Tron K2-ML-D5-T35 gravimetric feeder equipped with ActiFlow smart bulk solid activator and EPC (Electronic Pressure Compensation). The feeder is equipped with a 2415 vacuum receiver for refill.

The ActiFlow smart bulk solid activator offers an innovative method to reliably prevent bridging and rat-holing of cohesive bulk materials in stainless steel hoppers without internal hopper agitation. The smart flow aid applies gentle vibrations to the hopper wall, hereby carefully activating the contained material with the optimal amplitude and frequency, automatically adjusted by the controller based on bulk material flow. It is designed specifically to work with Coperion K-Tron’s line of gravimetric loss-in-weight feeders.

All-around worry-free service

Coperion conducts its intensive research & development work both for new plants and for their integration into existing systems. For this purpose, Coperion offers comprehensive maintenance and modernization packages for all its technologies, which increase the productivity, flexibility and reliability of the plants to a significantly improved level. Such services allow plant operators to fully exploit the improved performance potential of the plant after shortest time.

https://www.coperion.com/en/

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