Moulding machines run around the clock on regular cycles, and every so many cycles a box or pallet of finished goods needs to be taken away. This repetitive work on fixed routes is ideal for automation. An autonomous forklift in a plastics plant takes over these trips so drivers can concentrate on quality checks, mould changes and troubleshooting. This article looks at which steps to automate first and the matching STILL iGo trucks.
Why are plastics and rubber plants good candidates for automation?
- Steady rhythm: injection moulders, extruders and blow moulders run on known cycles, so transport trips are predictable.
- Fixed routes: from the machine to inspection, packing or the finished-goods store, changing little from day to day.
- Multi-shift operation: night shifts are often short of drivers while machines keep running.
- Light goods, uniform containers: plastic boxes and same-size finished pallets make pick-up and drop-off points easy to standardise.
By contrast, unloading containers of resin bags, lifting bulk bags onto hoppers or stacking in outdoor yards are still better done by driver-operated trucks.
Which steps to automate first?
End-of-line collection at moulding machines
The STILL AXV 12 iGo is a compact automated stacker for simple horizontal transport such as supplying and removing materials for production, stacking 1200 kg to a height of 1780 mm. It manoeuvres in tight spaces between machines, and STILL describes it as usable even with little automation experience.
Longer horizontal transport and block storage
The STILL EXV iGo suits production logistics and staging areas, with a 1,600 kg capacity, lift heights up to 3.8 metres and a top speed of 7.2 km/h. It navigates with laser positioning and has 360° pedestrian protection, so it can run alongside manned trucks.
Octabins and special containers
The STILL EXV-CB iGo uses cantilevered forks, carries 1,400 kg and stores up to 3.8 metres, handling standard pallets and special load carriers. It is the choice when a plant wants to move resin octabins or closed-bottom bins automatically.
Automated high-bay finished goods
The STILL FM-X iGo is an automated reach truck lifting up to 2,300 kg to storage heights of up to 10 metres, with a working aisle width under 3 metres. Its Pallet Positioning System and multi-level safety system meet the ISO 3691-4 standard according to STILL.
Truck loading
The STILL AXL iGo is an autonomous low-lift pallet truck that moves in the staging area and inside the trailer without fixed safety installations at the dock. According to STILL, two trucks working together can load 30 pallets in around 35 minutes.
| Step | Type / model | Reason |
|---|---|---|
| End-of-line collection at moulding machines | STILL AXV 12 iGo | Compact, easy entry |
| Horizontal transport, block storage | STILL EXV iGo | Laser navigation, 360° protection |
| Octabins, special containers | STILL EXV-CB iGo | Cantilevered forks |
| High-bay finished goods | STILL FM-X iGo | Up to 10 metres, PPS |
| Loading pallets onto trucks | STILL AXL iGo | No fixed dock infrastructure |
Preparing for automation
- Standardise containers and pick-up/drop-off points at each machine; broken pallets or misaligned boxes are a common cause of stops.
- Keep floors free of pellets and hydraulic oil so sensors and wheels work reliably.
- Start with a simple route using iGo easy in stand-alone mode, then connect a WMS as the fleet grows.
- Read more in autonomous forklifts AGV/AMR: when to automate and warehouse automation.
Range: STILL iGo automated trucks. Return to forklift solutions for plastics & rubber for driver-operated truck types.
Frequently asked questions
Should a mid-size moulding plant automate?
If there is a route repeated many times per shift, such as collecting finished goods from a row of machines to the store, a single AXV 12 iGo can be a sensible first step. Survey actual traffic before deciding.
Can autonomous trucks work alongside people and manual forklifts?
Yes. iGo trucks use laser scanners and sensors in a multi-level safety system for mixed operation with people and manual equipment.
Is a warehouse management system connection required?
No. iGo easy allows stand-alone operation or WMS connection, and the software scales as the automated fleet grows.
Send your hall layout and trips per shift via our quote page or call 0902 63 79 70 for an automation assessment.