Sustainability in Injection Molding: RJG’s Commitment to a Greener Future

Empowering Sustainable Manufacturing  

In today’s manufacturing landscape, sustainability is not just a goal—it’s a necessity. With increasing environmental concerns and stringent regulations, the injection molding industry faces the challenge of producing high-quality parts while minimizing environmental impact. RJG is at the forefront of this transformation, providing innovative solutions that enable manufacturers to embrace sustainable practices without compromising on quality or efficiency.

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Challenges in Sustainable Injection Molding  

Sustainable manufacturing in plastics requires molders to reduce waste, use less energy, and increase the percentage of recycled materials in their processes. Key challenges include:

  • Inconsistent Material Properties in recycled plastics
  • Increased Scrap Rates due to poor process control
  • Higher Energy Use from inefficient cycle times and overpacking
  • Stricter Regulations around carbon emissions and recycled content

RJG’s Sustainable Solutions  

RJG addresses these sustainability challenges with an ecosystem of technologies and services that drive efficiency, repeatability, and material flexibility.

The CoPilot® Process Control System

The CoPilot® delivers real-time cavity pressure monitoring and intelligent process control to reduce variation and drive consistency on the shop floor.

  • Real-Time Monitoring
    Track cavity pressure and other key parameters as the process runs.
  • Automated Adjustments
    Make real-time corrections to maintain consistent process conditions.
  • Reduced Scrap and Energy Waste
    Optimize shot control to minimize material waste and lower energy usage.

DECOUPLED MOLDING® Techniques  

RJG’s DECOUPLED MOLDING® method separates the molding process into controlled phases for maximum stability and repeatability.

  • Separated Fill, Pack, and Hold Phases
    Achieve better part consistency and control over each stage of molding.
  • Reduced Overpacking and Defects
    Eliminate flash, short shots, and other common quality issues.
  • Stable Processing with Variable Materials
    Maintain high performance even with recycled or lower-grade resins.

Cavity Pressure Sensing

Cavity pressure sensors provide the most accurate view of what’s happening inside the mold—where quality is truly defined.

  • In-Mold Process Insight
    Measure pressure inside the cavity to detect variations immediately.
  • Accurate Fill and Pack Detection
    Ensure each cycle reaches optimal conditions for part quality.
  • Template-Based Part Sorting
    Use pressure templates to identify and reject bad parts automatically.

iMFLUX® Low, Constant Pressure Processing

iMFLUX® is a patented low, constant pressure injection molding process that adapts to material variability and enables greater sustainability.

  • Enhanced Quality and Repeatability
    Automatically adjust to viscosity shifts for consistent, high-quality parts.
  • Improved Material Flexibility
    Process recycled, PCR, or regrind materials with consistent quality.
  • Lower Energy Usage
    Reduce injection pressure, clamp force, and cycle times to save energy.
  • Reduced Peak Stress and Flash
    Minimize common defects and extend tool life with lower cavity stress.
  • Enable Machine Downsizing
    Use smaller, more efficient machines without compromising performance.

Achieve Regulatory Compliance and Sustainability Goals  

RJG’s tools and training help meet evolving mandates and customer demands:

  • Support for EU Circular Economy and U.S. Plastics Pact Goals
  • Process validation and documentation for audits
  • Reduced CO₂ footprint through lower scrap and energy waste
  • Enablement of PCR/resin mandates from OEMs and brands

Partnering for a Sustainable Future  

RJG offers the technology, expertise, and support manufacturers need to move confidently toward more sustainable practices while protecting profitability.

  • Reduce your environmental impact while improving your bottom line
  • Increase recycled content without sacrificing quality
  • Cut costs through better material utilization and fewer defects

Ready to Start?

RJG is your partner in sustainable injection molding—from tool trials to full-scale production, we’re helping molders worldwide build a better, cleaner future.

Contact us today to explore how RJG can support your environmental and business goals.