Ensinger's thermoplastic polymer products are utilised across a variety of industrial sectors, including mechanical engineering, automotive aviation, and medical technology. The company's technical solutions predominantly based on thermoplastic polymers, are also prevalent in the food industry as well as in electrical and semiconductor technologies. Often, these high -performance plastics are used as substitutes for traditional materials like metals or ceramics.
To process the thermoplastic polymers, Ensinger uses a number of production methods, in particular compounding, extrusion, machining, injection moulding, casting, sintering and compression molding.
The range of polymers processed by Ensinger includes engineering plastics such as polyamide (PA), polyethylene terephthalate (PET), and polyoxymethylene (POM), as well as a category of temperature-resistance-high-performance plastics such as polyether ether ketone (PEEK), polyphenylene sulfide (PPS), polysulfone (PSU), polyimide (PI), and polyimide aurum TPI.
The company's organisational structure is based on a matrix system, which is segmented into different business areas reflecting its product lines including:
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Compounds: During the compounding process at Ensinger, plastic raw materials are melted and extruded into thin strands with various fillers or additives, and then cut into granules. This process tailors the properties of the plastics to meet the requirements of specific applications. Ensinger has developed a range of modified plastics through this method, including products that have enhanced sliding friction values and materials engineered to possess specific electrical properties.
Semi-finished Products: Traditionally the core of Ensinger's business, semi-finished products like extruded sheets, round rods, and hollow rods are prevalent in industries such as mechanical engineering. These materials are used to manufacture small quantities of technical parts such as bearings, bushings, levers, or gears. The semi-finished products can be simply cut or subjected to more complex processes like grinding, planing, or precise machining based on specific drawings. Ensinger primarily processes construction and high-performance plastics in this segment.
Injection-molded Finished Parts: The injection molding process at Ensinger facilitates the mass production of technical parts and assemblies using high-performance plastics. Examples include thrust washers, piston rings, and ball shells for the automotive industry, along with machine elements like bearings and gears. These materials are designed to be resistant to temperature fluctuations and exposure to fuels and oils. Injection-molded parts are also utilised in medical device technology and the aerospace industry.
Polyamide Casting (Semi-finished Products): This involves pressureless mold casting to create polyamide semi-finished and finished products.
Machined Finished Parts: Ensinger also crafts finished parts from semi-finished or injection-molded components through mechanical processes such as milling and turning. This technique is often used for small production runs of technical components and prototypes, including valve pistons and transmission levers.
Industrial Profiles and Pipes: Profiles and special pipes are manufactured using controlled extrusion processes, often reinforced with materials like carbon or aramid fibers or specialised friction-reducing additives to enhance durability under mechanical, thermal, or chemical stress. Techniques like coextrusion are employed to integrate reinforcing materials or combine plastics with different properties.
Thermal Insulation Profiles: Developed for window, door, and facade construction, these profiles create a thermal break between the inner and outer metal frames, aiding in energy cost reduction. In 2013, Ensinger pioneered an insulation profile made entirely from recycled polyamide.
Other Product Lines: Ensinger's portfolio includes compression-molded polyimide materials known for their durability and strength, suitable for temperatures ranging from -270°C to 300°C, with some materials capable of withstanding up to 470°C.
Furthermore, carbon fiber composites made from a PAEK-based polymer matrix (either PEEK or PEKK) embedded with carbon fibre are noted for their strength and heat resistance. These composites are primarily used in medical technology and orthopedics due to their biocompatibility and resistance to X-rays, steam, and chemicals.
Locations
The company group employs a total workforce of more than 2,500 at over 30 locations.
Production sites
Nufringen, Germany
Cham, Germany
Rottenburg-Ergenzingen, Germany
Seewalchen, Austria
Lenzing, Austria
Otelfingen, Switzerland
Beynost, France
Olcella di Busto Garolfo, Italy
Tonyrefail, Wales, UK
Bridgwater, UK
Rossendale, UK
Washington, Pennsylvania, USA
Grenloch, New Jersey, USA
Greenwood, Delaware, USA
Putnam, Connecticut, USA
Houston, Texas, USA
Huntersville, North Carolina, USA
Sao Leopoldo, Rio Grande do Sul, Brazil
Song Jiang, Shanghai, China
Johor, Malaysia
The company also owns subsidiaries in Denmark, Poland, Sweden, Spain, Czech Republic, Turkey, Japan, Singapore, Vietnam, India, Taiwan and South Korea.
