Precise processing of recyclates - with intelligent sensor technology and smart product design
Moldsonics and BOOXit were selected as part of an open call for the EU project DEREMCO . Together, we are working on an industrial use case that demonstrates how recycled fiber-reinforced composites can be reliably incorporated into high-quality plastic products—with the help of smart sensor technology and sophisticated product development.
What is Deremco?
DEREMCO (De- & Remanufacturing for Circular Economy) is an EU-funded innovation project involving over 30 partners from across Europe. Its goal is to enable the economic and technical reuse of fiber-reinforced plastic composites—and thereby establish a sustainable, circular plastics economy.
The project addresses one of the most pressing problems in the plastics industry: how can complex, connected plastic structures be efficiently dismantled at the end of their useful life, recycled and transferred to new high-quality applications? DEREMCO provides systemic approaches for this, in which material, design, processes and market are considered together.
Common goal: High-precision products made from recycled material
BOOXit and Moldsonics are pooling their expertise in the funded implementation experiment:
- BOOXit is developing a new generation of smart, stackable reusable boxes that require no additional outer packaging. This demands the highest level of dimensional accuracy and reproducibility—even with varying material batches.
- Moldsonics contributes ultrasonic sensor technology that measures the solidification process of the plastic directly in the injection mold. This allows process-critical parameters such as shrinkage and crystallization to be monitored inline and precisely controlled.
The main focus here is on the question: Is it possible to process recycled materials with high dimensional accuracy?
– The answer is: Yes – with the right sensors.
Why this is important
Recycled materials are still considered unreliable in plastics processing—too inconsistent, too unpredictable. This is precisely where the joint project between Moldsonics and BOOXit comes in: using data-driven processes and intelligent monitoring, it makes quality transparent and controllable.
The sensor technology used is not merely a monitoring tool, but an active component in optimizing the injection molding process. Thanks to this technology, companies can reduce their setup times, avoid scrap, and improve material efficiency. This makes a genuine contribution to sustainability in plastic injection molding—one that is economically measurable and technologically scalable.
In addition, the project is helping to increase acceptance of recycled plastics in high-end applications—such as logistics, the automotive sector, and medical technology—where dimensional accuracy is a key requirement.
© BOOXit
About the promotion
This project is co-financed by the European Regional Development Fund (ERDF) as part of the EU project DEREMCO. Moldsonics and BOOXit were selected as implementation partners in an open call.
Project ID: 101084037
Duration of the overall project: December 2022 - November 2025