Jug and filter systems coming into contact with water are very demanding and sensitive to produce. We are very familiar with them and the leading manufacturers trust us.

According to the designers at GRAFE Blankenhain, the "haute couture" of individual color and surface design of plastics consists of adding contrasting fibers or plastic particles to the desired base color. The result is customized surfaces and structures that raise product design possibilities to a new level. In the automotive sector, manufacturers' concept cars demonstrate this new trend. "Bumpers, sills, underride guards or wheel arch liners that appear to be made of stone with their marbled look are all the rage, especially for SUVs," reports Danny Ludwig, Head of Product Management, Color & Functional Masterbatches. "There is a lot of demand from German and French OEMs, specifically for exterior parts." The first components have already been realized with GRAFE's masterbatches at parts suppliers and have met with great approval, Ludwig says. "Flakes and fibers of different structures are incorporated into the batch. What's completely new is that this can now also be realized with automotive-grade PP grades with a high recycled content, thus going some way toward fulfilling the sustainability promise." The main plastics for which the newly developed effects are used are PP for exterior and PC/ABS for interior applications. A 20 to 30 percent recycled content in PP is currently possible while still meeting the high demands placed on plastics regarding durability, emissions, component mechanics, and quality. "For automotive manufacturers, black and gray are the most interesting, but for other industries, many colors are possible." Whether flower pots, furniture, caravans, or toys. The applications are endless, Ludwig says. The development and identification of new raw materials that are suitable as additives are in constant motion within the company.

When correctly deployed, plastics analysis and testing are vital tools when it comes to describing the state of a material. With the aid of an expertly devised analysis, it is usually possible to take a plastic product and deduce the type of material used, the quality of the processing and the conditions it has experienced in use. Through suitable tests, the material data can be identified for subsequent product and process development. This is invaluable for product quality, product reliability and product safety in every respect. Experience is key here. And you can benefit greatly from combining your experience with ours. In this way it is possible to quickly gain valuable information on material and process development, product testing, quality assurance, and systematic failure and damage analysis.

Sustainable processing of automotive parts for the engine compartment as well as exterior and interior For the automotive industry, our technologies are mainly used in special machines. But we also offer ultrasonic components for existing or new machine concepts for the various parts in the vehicle – even demanding part shapes can be realized. Together with our development department, we solve your requirements precisely and with the highest quality.

Joining of small or large components - without imprints or impairment of the function We receive tasks from the electrical industry in the fields of electronics, electrical engineering and telecommunications. Here, the task is often very complex, the parts sensitive. The perfect function of the parts must not be impaired during the machining process, a beautiful appearance for housings, but also tightness are among the requirements. The gentle process is a particular advantage of ultrasonic. In addition, the ultrasonic process offers precise control of the welding or cutting process with high repeatability and precision. Ultrasonic makes it possible to achieve tight and undetachable joints in a very small area and in just a few milliseconds. For example, switches and buttons are sealed impermeably to external influences, even without an additional sealing ring. Alternatively, other technologies such as thermal forming (riveting), hot-air welding or infrared riveting can be used or used in combination to supplement ultrasonic technology.

In our in-house testing laboratory, we combine technical expertise with our extensive practical experience as a plastics specialist. We take on your task and work with you to develop a solution that will achieve your goal as quickly and cost-effectively as possible.

Modern plastics production - quantity plus quality Our production merges large capacities with extraordinarily high quality. We are currently working with 40 modern injection moulding machines which are mostly equipped with robots and removal grippers. This guarantees smooth and cost-effective production processes. Articles with injection weights from 1 g to 1,000 g as well as injection moulding machines with clamping forces of up to 5,000 KN emphasise our enormous production range which is further supplemented by multi-component and multi-colour injection moulding as well as by co-injection moulding processes. We are already manufacturing more than 8,000 plastic articles of all kinds, from small series to large quantities. Furthermore, we have a very comprehensive range of materials at our disposal. It covers everything from standard materials to high-tech requirements. A central material supply with material drying is the starting point for all subsequent, automated production processes. Continuous optimisations in all production processes, targeted material inspections, glow wire testing and documented measurements by our trained employees guarantee high-quality products. Thanks to our membership in the Kunststoff-Institut Lüdenscheid (Lüdenscheid Plastics Institute), we have active access to the latest plastics-related information and processing methods. This knowledge brings us up to date with the latest technologies.

High production output through the use of ultrasonic welding technology In the case of office products, ultrasonic is used for shape and separation welded products such as sleeves, insert pockets, cases, exercise book covers, and many more. A great advantage of using ultrasonic welding technology is the very flat and stable weld seams, which guarantee a visually perfect product. Even printer cartridge housings can be ultrasonically welded and score with absolute tightness and perfect function.

Comprehensive plastic solutions across the entire value chain Froli is your partner for end-to-end plastics processing – from development and series production to assembly. We develop and manufacture functional plastic solutions precisely tailored to industrial requirements – precise, durable, and cost-efficient. Thanks to a high level of vertical integration, state-of-the-art technologies, and extensive material expertise, we deliver series-ready products with consistent quality and high process reliability. From material and product development, including prototyping, to small and large series production and ready-to-assemble components, Froli offers everything from a single source. Modern injection molding systems, in-house toolmaking, and processes such as PUR integral foam enable cost-efficient production, even for complex requirements. This is complemented by our own ergonomics and testing laboratory as well as additional production capacities, including Froli Baltic in Latvia. Our plastic solutions are used in a wide range of industrial applications – from precise individual components to complex system solutions. Stable processes and high quality standards ensure reproducible results and efficient series production. As an experienced B2B partner, we support our customers from the initial idea to series production – in a collaborative, solution-oriented, and reliable manner. Froli stands for professional plastics processing “Made in Germany” – combined with international manufacturing expertise and many years of experience.

Solid connections with ultrasonic without needle and thread Ultrasonic technology is used primarily for welding tapes to injection molded parts of sports articles, for example ski goggles. A spot sonotrode is used to weld the elastic strap and the injection-molded part in a material- and space-saving manner. An absolutely tight connection is created. In addition, the elastic bands of ski goggles are also cut using ultrasonic. The cut edges are sealed and embossed during cutting so that the material does not fray. Fleece and Velcro straps can also be welded on with ultrasonic in a shapely and flexible manner. The resulting seam is firm and flat. For example, the Velcro fastener on ski jumping gloves is welded on with ultrasonic. In the fashion industry, fine and elastic materials (consisting of at least 70% synthetic fiber) are "sewn" with ultrasonic without needle and thread. In this process, continuous spot welding replaces the thread. The elasticity in the material is retained, and the overlap seams are gentle on the skin, not noticeable and flat, guaranteeing a high level of wearer comfort.

100 % fun thanks to safe welding processes with ultrasonic Product safety is an absolute priority in this industry. Other requirements for toys are functionality, protection against injuries, but of course also the beautiful appearance. Ultrasonic welding passes the absolute endurance test in this respect. This is also the case, for example, with the toys from Bruder GmbH. With the aim of ensuring that the Personal Water Craft does not sink, Bruder Spielwaren GmbH & Co. KG has found a reliable partner in the field of plastic joining in SONOTRONIC.

Economical production with low energy consumption White goods is the technical term used in the trade for household appliances such as refrigerators, washing machines, dishwashers, stoves and other household appliances. SONOTRONIC's ultrasonic technology more than meets the high demands in this area in terms of process reliability and appearance. In the manufacture of a washing machine door, ultrasonic is used to rivet the two injection-molded parts, the carrier and the panel, together and securely fix the sight glass in between. In order to determine the production-related variations in the material thickness of the glass body, a displacement measuring system measures the actual height of the parts before each welding process and thus determines the necessary welding depth. This not only guarantees the optimum joining of the materials, but also ensures quality assurance in the production of the washing machine doors.