Discover How Companies Are Revolutionizing Their Processes With Cadmould Flex

For over a century, Bergi-Plast has embodied the hallmarks of German engineering: quality, precision, and innovation. As a trusted supplier to the packaging industry and other sectors, the company specializes in producing plastic closures and technical components. Long-term success demands continuous adaptation and evolution. For Bergi-Plast, this means focusing on two key priorities shaping the future of plastics: quality and sustainability.

To meet these goals, Bergi-Plast systematically invests in employee training and modern infrastructure. “Recently, we’ve upgraded our injection molding machinery, replacing outdated hydraulic systems with modern electric and energy-efficient alternatives,” says Innovation Manager Ronald Dietz. “This allows us to produce more sustainably. We’ve also introduced advanced measurement technology to monitor the energy consumption of each machine in greater detail.”

To further enhance efficiency, accelerate time-to-market, and improve first-time accuracy, Bergi-Plast adopted SIMCON's Cadmould simulation software. This tool helps optimize components, molds, production processes, and machine utilization, leading to less waste, fewer correction cycles, and better use of resources. Simulation isn't just for new molds; it can also significantly improve existing ones. Heiko Klöber, who handles design and operations planning, shares a compelling example: “We had a multi-cavity mold for canister lids that faced persistent challenges. The target tear-off force of the sealing ring, a key quality indicator, required absolute precision. However, due to complex, thin flow bridges, we experienced filling problems. Because this part is produced in high volumes, efficiency and cycle time were critical.” The mold’s cavities suffered from recurrent filling issues, causing incomplete parts and defects. Despite months of effort, the issue remained, forcing the team to underutilize the mold. “When we acquired the simulation software in mid-2020, solving this was a top priority,” Dietz explains. “The simulation quickly revealed the root cause: the machine’s clamping force was insufficient. While we suspected this might be an issue, the simulation provided clear, undeniable evidence. Once we switched to a larger machine, all cavities filled flawlessly, which improved quality, reduced waste, and boosted production efficiency.” Dietz notes that if simulation had been used from the start, they could have avoided months of physical testing and started production much earlier. The team estimated that using the correct machine from the beginning would have produced an additional 700,000 parts in the same timeframe—or achieved the same output 11 days sooner. The takeaway was clear: early simulation pays dividends.

Bergi-Plast has made simulation a standard part of its design workflow. By integrating it early in the component and mold design stages, the company can reduce material consumption, optimize quality, and shorten cycle times. Angela Kriescher, Head of Product Management at SIMCON, explains the benefits of tools like Cadmould and Varimos AI: “Varimos AI lets you define your goals for part and quality, then automatically simulates different parameter combinations to find the optimal solution. This eliminates tedious trial and error, enabling engineers to focus on analysis and decision-making. Using simulation early ensures that part and mold designs are optimized for plastic from the outset.” Dietz agrees, adding that a common mistake is finalizing mold designs in CAD before running a simulation. Bergi-Plast learned that simulating earlier prevents costly errors and allows precise adjustments, such as optimizing wall thickness to improve component properties.

Successfully integrating digitalization isn't just about choosing the right software; it's about implementing effective processes. Bergi-Plast's experience shows that by setting clear priorities, the company can achieve its quality and sustainability goals while reducing risk and inefficiency. Many German industrial leaders have a competitive edge due to their commitment to innovation and quality. Through continuous improvement, companies like Bergi-Plast are maintaining their advantage and building a foundation for success for decades to come.