Humanoid robots in plastics processing: innovation with potential

According to a study by Nexery, 20 million humanoid robots will be in use by 2030. More and more companies in the plastics industry are turning to humanoid robots to make processes more flexible and efficient. They also open up new opportunities for a healthier working environment. A recent survey and pilot projects at well-known industrial companies confirm this: The technology is on the verge of a breakthrough, even for medium-sized processors.

The advantages: high flexibility, low programming requirements and the ability to adapt to changing tasks thanks to artificial intelligence (AI). Another plus point: they can take over tasks that are harmful to health and thus protect employees.

David Reger, founder of Neura Robotics, sees his cognitive robots as the next step in industrial automation: “Cognitive robots can be used flexibly in a wide variety of scenarios and do not require extensive programming. The same robot can palletize today, glue tomorrow and check the quality of production lines the day after tomorrow.”

Automotive supplier Schaeffler is already running pilot projects with humanoid robots in plastics production. The aim is to use them in the global plant network. “In the future, humanoid robots could take on a variety of tasks - from machine loading to palletizing,” says Sebastian Jonas, Head of Advanced Production Technology at Schaeffler.

Plastics processor Pöppelmann also sees potential. Primarily because of the robots' greater freedom of movement. With over 30 degrees of freedom, they are similar to humans in complex handling tasks. For medium-sized companies, the widespread use of humanoid robots in factories could also be an answer to the shortage of skilled workers.

RKT Rodinger Kunststoff-Technik, on the other hand, emphasizes economic aspects: In times of staff shortages and cost increases, humanoids could help to maintain processes without putting additional strain on the workforce.

A recent study conducted by the Fraunhofer Institute for Manufacturing Engineering and Automation IPA with 100 industry experts confirms the positive basic attitude towards humanoid robots. Particularly frequently mentioned: Material transportation, machine loading and order picking. The greatest strength: flexibility. This makes humanoid robots particularly interesting for brownfield integration, i.e. existing production environments without major conversions.

Technically, we are still at the beginning. Simple tasks are therefore initially seen as application scenarios. Functional safety is also currently a critical issue. Nevertheless: 74% of respondents expect real applicability in the next three to ten years.

Despite all the euphoria, there are still hurdles. In addition to the price (many companies are prepared to invest up to 100,000 euros), industry representatives also see cultural challenges, such as the fact that people need to be introduced to the new technology and that acceptance will be a decisive factor. 

Ease of use is also key. Simple integration without complex programming is particularly desirable for SMEs. Supporting assistance systems are needed here to lower the barriers to entry.

Whether market leaders such as Schaeffler, medium-sized companies such as Pöppelmann or research institutes such as the Fraunhofer IPA: everyone agrees that humanoid robots can fundamentally change plastics processing. The technology is still in its infancy, but is already showing that it could become an integral part of tomorrow's production.

For innovation-driven companies, now is the time to gain initial experience in order to be one step ahead tomorrow.