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Discover how companies are revolutionizing their processes with Cadmould Flex

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Getting canister lids right the first time

Consumer goods & packaging
Injection Moulding Optimization
Subheadline: By combining simulation and modern measurement, Bergi-Plast improved closure quality, reduced scrap, and accelerated time-to-market.
Close-up of white plastic jerrycans used as industrial packaging, filled with blue liquid and sealed with blue screw caps, arranged in rows for storage and transport.

How Bergi-Plast is redefining German engineering

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.

Modern machinery and measurement save energy and materials

To meet these goals, Bergi-Plast invests systematically in employee training and modern infrastructure. “Recently, we’ve upgraded our injection moulding machinery, replacing outdated hydraulic systems with modern electric and energy-efficient alternatives,” says Innovation Manager Ronald Dietz.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.”
Three men stand together in a plastics manufacturing facility. They smile at the camera, with injection molding machines and industrial equipment visible in the background. One holds a small blue plastic cap in his hands.
Pictured from left: Waldemar Bauch, Head of Production Closures; Heiko Klöber, Design/Operations Planner; and Ronald Dietz, Innovation Manager, all from Bergi-Plast.
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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.
Ronald Dietz
Innovation Manager
Bergi-Plast

Simulation boosts efficiency and solves production issues

To further enhance efficiency, accelerate time-to-market, and improve first-time accuracy, Bergi-Plast adopted SIMCON's Cadmould simulation software. This tool helps optimise components, moulds, production processes, and machine utilisation, leading to less waste, fewer correction cycles, and better use of resources. Simulation isn't just for new moulds; it can also significantly improve existing ones. Heiko Klöber, who handles design and operations planning, shares a compelling example: “We had a multi-cavity mould 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 mould’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 mould. “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.

Simulation results indicated that a higher clamping force was required to resolve filling issues in this multi-cavity mould

Side-by-side comparison of blue plastic caps before and after optimization. The center shows Cadmould simulation results used for root cause analysis, leading to improved cap quality in the “After” section.
Initially, not all cavities in this multi-cavity mould were filled correctly. Several manual correction attempts failed to resolve the issue fully. Using Cadmould, it was quickly determined that a higher clamping force was required. This adjustment successfully addressed the challenges, ensuring all cavities now fill completely. As a result, each cycle now delivers significantly improved yield.

Early simulation becomes a standard practice to prevent costly errors

Bergi-Plast has now made simulation a standard part of its design workflow. By integrating it early in the component and mould 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 mould designs are optimized for plastic from the outset.” Dietz agrees, adding that a common mistake is finalizing mould 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.

Building a foundation for the future through digitalization and clear processes

Successfully integrating digitalisation 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.

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Close-up of white plastic jerrycans used as industrial packaging, filled with blue liquid and sealed with blue screw caps, arranged in rows for storage and transport.
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Getting canister lids right the first time

By combining simulation and modern measurement, Bergi-Plast improved closure quality, reduced scrap, and accelerated time-to-market.

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Cadmould stands out for its user-friendliness, fast computation, precise results, and excellent support. Its price-performance ratio sealed the deal for us.
Lutz Kreykenbohm
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Our collaboration with SIMCON has resulted in a 30% reduction in iteration cycles. I would unequivocally recommend Cadmould and Varimos AI without hesitation.
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We opted for Cadmould Flex primarily because it allows us to perform multiple simulation runs concurrently, ensuring both rapid results and high accuracy.
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Over two years, Cadmould optimized gating, controlled warpage, and prevented air entrapment for critical galvanized parts.
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Easy to use, fast processing, and an intuitive interface—plus quick results, most of the time. Simulation moves us forward and is jolly good fun!
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Cadmould is fast and ideal for early geometry validation. It optimises mould projects by cutting costs, reducing scrap, and ensuring high-quality parts.
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Cadmould's Varimos AI add-on simplifies advanced Design of Experiments, optimizing process parameters, boosting efficiency, and improving part quality.
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Choose your way to smarter simulation

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Cadmould Flex

Scalable simulation for every challenge

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Ideal for engineers and companies needing regular simulations with flexibility, control, and AI support.
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Prevent weld lines, air traps, and warpage by anticipating defects early in the design phase.
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Cut cycle times, reduce energy consumption, and lower scrap rates to boost efficiency.
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Scale features flexibly with add-ons and adjust subscription plans to fit evolving needs.
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Simulation on Demand

Capacity when you need it most

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Ideal for those seeking expert simulations without software or training, ensuring precise results under tight deadlines.
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Optimise cycle times, part quality, and process stability without software investment.
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Access the experts at SIMCON to run advanced simulations and deliver actionable insights.
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Stay agile with on-demand services that bridge capacity gaps and meet tight deadlines.
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