Manufacturing of Innovative Housing Parts for a Water Softener

04.05.2023

In 2023, Hans Sasserath GmbH & Co. KG is launching a new water softener, the NeoSoft Connect, which boasts advanced technology, user-friendliness, and high-quality aesthetics, making it an ideal choice for families and smaller residential buildings. Fried’s expertise in manufacturing high-quality casing parts played a comprehensive role in the development of this new product.

Project Entry

The collaboration between Hans Sasserath and Fried began, among other things, due to the TSG injection moulding technology. The capabilities and benefits of this manufacturing process convinced the customer from the outset. The experience in producing large plastic parts also played a decisive role. The largest component, in fact, measures over 70 cm in length. “There were special challenges due to the size of the components, but Fried was able to successfully overcome these challenges with a lot of experience and expertise,” says Mr. Pascal Leines, Deputy Head of Construction at Hans Sasserath GmbH & Co. KG.

Mix of TSG and Compact Injection Moulding Technologies

The housing comprises a total of 10 plastic components, 9 of which are manufactured using compact injection moulding technology. This technology enables the production of components of various shapes and sizes with the highest surface quality and is particularly well-suited for thin-walled components. However, the most important main component, to which all other components are attached, is produced using TSG technology and has a load-bearing function for the housing. TSG made it possible to achieve high functional integration and design freedom in a thick-walled component.

Flexibility in Terms of Color Variations

The housing parts are requested in custom colors by several OEM customers of Hans Sasserath GmbH & Co. KG. Therefore, flexibility and variation management are a Must during manufacturing. Currently, the parts are produced in three color variants: standard gray, white and blue. The compact injection-moulded parts are manufactured directly with the corresponding colored granules, so that no painting is necessary, as the surfaces already have a high quality finish. The remaining casing parts are painted with a high-gloss finish by Fried to achieve an attractive look. In addition, the logo is applied to the front of the device via pad printing.

Series Production

Fried experts accompanied the NeoSoft Connect project step by step from the plastic-appropriate construction through tool development and prototype phase to series release. A packaging concept was also developed to ensure safe transport of the parts. It remains to be seen how the production volumes will develop in the future. The customer expects significant growth potential and anticipates that several thousand units will need to be produced annually.

Key to Success

According to Mr. Leines, the open and honest communication between Hans Sasserath GmbH & Co. KG and Fried, as well as the high quality of the delivered plastic components, were particularly noteworthy. “From a technical point of view, the support is excellent. In every project, errors or difficulties can arise on both sides. If you are able to talk openly about them, look for solutions together, and achieve improvements from the given situations, then you can speak about good cooperation on an equal footing. In my opinion, that’s what we have with Fried,” Mr. Leines concludes.

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