Wittmann at Fakuma 2026 – consistent process integration

Wittmann will present the EcoFritz clamp at Fakuma 2026, held from October 12 to 16 in Friedrichshafen, Germany. Under the motto "Smart Choices, Smart Savings", the company will show how its system expertise can be used to support material cycle closure in injection molding. The EcoFritz clamp is an injection molded product developed by Wittmann for securing media lines and cables to corrugated hoses. The patented clamp is intended as a reusable alternative to cable ties, which are often discarded during installation because they cannot be repositioned without damage. The clamp can be removed and repositioned as required, reducing waste generated during the installation of material supply systems. At the trade fair, Wittmann will produce the component live at its booth in hall B1, using an integrated production cell designed to combine injection molding, part handling and in-line recycling.

Integrated production in a compact cell

The EcoFritz clamps will be manufactured in an Ingrinder work cell. In this configuration, the injection molding machine, robot, conveyor belt and granulator for in-line recycling of sprues and production scrap are integrated into one unit at the factory. The protective housing is attached to the machine, enabling a compact arrangement of all process components.

The production cell for the EcoFritz clamps will include a servo-hydraulic SmartPower 60 injection molding machine, a WX90 servo parts removal device and an S Max granulator. The clamps will be produced in a 2-cavity mold supplied by Röttger. Wittmann will process a glass-fiber-reinforced polyamide using Airmould gas-injection molding technology. The sprue will be ground directly inside the production cell and added back to the raw material as recycled content. This creates a closed-loop material cycle, with the sprue recycled immediately without leaving the cell.

Material transport will be handled by a Feedmax Clean vacuum loader. Wittmann has equipped this unit with a powerful dedusting system for applications involving recycled material. According to the company, when transporting recyclate the Feedmax Clean achieves separation rates of up to 80 percent for particles smaller than 1000 µm. Dust and other fine-particle contaminants can affect dosing and reduce the homogeneity of the plastic melt. Careful dust removal is therefore intended to make recycled materials suitable for applications with higher quality requirements.

Ingrinder production cells integrate all process components on a compact floor space. Sprue and other parts of production scrap are filled directly into the hopper of the granulator via a chute

Material efficiency and process control

In addition to dedusting, Wittmann will use the HiQ Flow digital assistance system to support process consistency. The software continuously analyzes melt viscosity during the injection phase. If the measured value deviates from the target value, HiQ Flow adjusts the changeover point and holding pressure within the same cycle. The objective is to maintain constant part weight from cycle to cycle and compensate for fluctuations in raw material or ambient conditions before scrap is produced.

Airmould internal gas pressure injection molding also contributes to material efficiency. In this process, nitrogen is injected into a cavity that is partly or completely filled with plastic melt. The pressurized gas forms a bubble in the central area of the molded part, counteracting shrinkage on the outside and helping to prevent sink marks. By reducing the amount of plastic and forming a hollow section in the part, the process enables lightweight components with short cycle times and good surface properties. The internal material displaced by nitrogen is reground together with the sprue and processed again within the production cell.

The nitrogen required for Airmould will be generated on site at the booth using N2easy. This nitrogen generator, developed and manufactured by Wittmann, extracts nitrogen from ambient air and supplies it to several consumers as required. According to Wittmann, the system becomes economical from a daily nitrogen consumption equivalent to one gas bottle and eliminates the need for nitrogen delivery by road transport.

Production at the technical center

Wittmann also produces EcoFritz clamps at its Nuremberg facility during weekends. Production at the German technical center runs autonomously and, when solar energy is available, climate-neutral, using electricity from the company’s own photovoltaic system. The share of recycled material can reach up to 100 percent. For this purpose, scrap from injection molding tests and sample production is collected and recycled on site.

EcoFritz clamps are available either together with auxiliary equipment or as separate components. They are produced in three sizes to fit commonly used corrugated hoses.

Wittmann will exhibit at Fakuma 2026 in hall B1, booth 1204.