RJG Introduces Autonomous Process Control Solution

RJG is introducing its Autonomous Process Control Solution, a significant advancement in injection moulding technology that not only moves the industry beyond traditional process monitoring into true closed-loop control, but also enables processors to successfully mould difficult and variable resins, helping offset rising material costs.

Built on decades of expertise in scientific moulding, RJG’s new solution integrates constant-pressure moulding capabilities with The CoPilot System®, enabling machines to automatically adapt and maintain optimal processing conditions in real time. By using in-cavity pressure as the primary control variable, the system ensures decisions are based on what is actually happening inside the mould rather than relying solely on machine settings.

Unlike conventional systems that monitor processes and trigger alarms, RJG’s Autonomous Process Control Solution actively controls the moulding process. By combining in-cavity pressure sensing, real-time analytics, and RJG’s Master Moulder knowledge, the system maintains the ideal process trajectory, compensates for material and environmental variation, and prevents defects before they occur. Because the system controls based on in-cavity pressure, it can automatically compensate for viscosity variation, enabling moulders to run difficult materials, including recycled and lower molecular weight resins that have traditionally been challenging or inconsistent to process.

The solution is designed to be flexible and scalable across the industry. It can be retrofitted onto existing moulding machines and integrates with factory-level Industry 4.0 systems through The Hub, with OPC UA connectivity enabling seamless data exchange with MES, ERP, and quality platforms.

Early demonstrations have shown measurable improvements in production performance, including reduced startup scrap, improved part consistency, fewer unplanned machine stops, and decreased operator intervention. This capability also allows processors to expand the range of usable materials, including lower-cost and recycled resins, helping mitigate the impact of rising material costs while maintaining part quality. Additionally, lower pressure requirements can reduce energy consumption and, in some cases, allow for the use of smaller moulding machines, accelerating return on investment.

Early feedback from processors has positioned the solution as a potential game changer in how manufacturers approach both process control and material strategy.

The Autonomous Process Control Solution will be available to early adopters in 2026, with broader market availability planned as adoption expands.

“This launch represents a major step forward in our journey toward autonomous moulding,” said Rob Nugent, CEO. “For years, we’ve helped moulders gain visibility into their processes. Now, we’re enabling them to control those processes automatically using real data from inside the mould. It’s about helping manufacturers produce better parts with less intervention while preparing for the future of fully autonomous manufacturing.”

Read more from RJG here.

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