How MES Drives Digitalization in Plastics Production

When Ensinger Inc., a pioneer in high-performance plastics, set out to digitize its U.S. extrusion operations, its leadership knew the journey wouldn’t follow a conventional path. Founded by Wilfred Ensinger in the 1960s, the company has grown into an international player with over 500 employees in the U.S. alone and a reputation for innovation in engineered materials like PEEK, PAI, and PPS.

What made this Manufacturing Execution System (MES) project unique was the production method itself: extrusion rather than injection molding. Although authentig was originally developed around the short, repeatable shot and cycle times typical of injection molding, extrusion operates as a continuous process where output is measured in length and cuts, often over long runs that span hours instead of seconds.

Adapting a system designed for injection molding to support extrusion introduced new technical considerations, but close collaboration between Ensinger and ENGEL made it possible to tailor authentig effectively for this environment. The initial goal was to improve Overall Equipment Effectiveness (OEE) reporting, but once authentig was selected, it quickly became clear that the system could support a much broader digital transformation.

Ensinger’s U.S. team, unable to adopt the MES solution used at their German headquarters due to timing and infrastructure limitations, selected authentig for its flexibility, interface capabilities, and the strength of its local support within North America.

With ENGEL’s U.S. team providing close collaboration throughout the project, the implementation became a strong example of how ENGEL’s digital solutions can deliver value even in processes where ENGEL does not supply the production equipment.

“We don’t run injection molding machines,” explained Daniel Bertovich, Plant Manager at Ensinger’s Pennsylvania site, “but authentig stood out because of its data collection features, web-based monitoring, inspection module, and the ability to go digital with our production documentation. The system fits our needs and continues to evolve with us.”

One of the key success factors has been the close collaboration with ENGEL’s U.S. support team. Together, they overcame challenges such as OPCDA-to-OPCUA integration and customized the system to match extrusion-specific KPIs and workflows. This partnership ensured that authentig was not just installed but aligned with the realities of Ensinger’s production environment.

Since implementation, Ensinger has taken a deliberate, step-by-step approach to expanding authentig, adding capabilities such as digital job records and tailored dashboards that support more informed, data-driven decision-making.

To guide this evolution, the company formed a dedicated internal team of engineering, automation, and programming specialists that meet three times a week to review system performance, address data quality, and identify opportunities to further leverage the platform across extrusion operations.

This structured approach has translated into tangible operational gains, including a 15% increase in the number of set-ups completed per shift, along with a significant reduction in paper-based documentation. By eliminating up to 10 pages per order (approximately a 60% reduction), Ensinger has taken a meaningful step toward a more streamlined and paperless production environment.

“We’re proud to support a partner like Ensinger who challenges conventional MES boundaries,” said Martin Staudinger, Sales Manager Digital Solutions at ENGEL. “Their success with authentig proves that MES can bring real value in the production – even if KPIs and production flows look very different.”

The progress in Pennsylvania is only the beginning. Ensinger is already preparing to expand the system to its New Jersey facility, laying the foundation for a cross-site digital strategy that is scalable, resilient, and driven by accurate, real-time production data.

For plastics processors exploring their path into MES, whether extrusion or injection molding, Ensinger’s experience shows the impact of pairing the right digital solution with the right partner. The collaboration between Ensinger and ENGEL demonstrates how a flexible, well-supported MES can create meaningful value across different production environments, even outside ENGEL’s own machine base. As manufacturers continue to modernize, this project shows that digital transformation is most successful when technology and partnership move forward together.