Application Spotlight: RCS Plastics Expands Integrated Packaging Production with HyCAP™4 Mold Technology
RCS Plastics GmbH is a German manufacturer of recycled PET materials, PET preforms, and HDPE beverage closures. Family-owned, the company got its start in waste processing in the 1980s, a foundation that carried it from recycling bottles into flakes, then into rPET production, where it grew into one of Germany's leading rPET suppliers.
To support its next phase of growth, RCS set out to strengthen its closure manufacturing capabilities, aiming for greater production stability and consistently high-quality closures while preparing for future production with recycled HDPE (rHDPE).
"Our goal was to increase Overall Equipment Effectiveness, reduce downtime, and ensure consistent product stability," says Matthias Strunck, Operations Manager at RCS Plastics.
The Husky Solution
RCS entered the closures market with a retrofitted Husky system, a success that gave the company the confidence to invest further in Husky's latest HyCAP™4 mold technology as its next step toward greater productivity, process stability, and long-term sustainability.
Building on this relationship, Husky delivered a new complete system, a high-performance closure injection molding machine - HyCAP™4 400 RS70/70 - with the latest 96-cavity Mold 4.0 technology. The installation also integrates a full IMD vision system with spark test, auxiliary equipment, and an external dehumidified air system to support stable, high-quality production.
As one of the first companies to adopt Husky's Mold 4.0 technology, RCS worked closely with Husky throughout implementation, with Husky providing technical expertise and responsive service support beyond the equipment itself.
Results
Since implementing HyCAP™4 and Mold 4.0 technology, RCS has achieved measurable improvements across its closure production, including:
- Increased Overall Equipment Effectiveness (OEE)
- Reduced downtime and maintenance requirements
- Lower reject rates
- Improved production stability and consistency
"The new mold technology provides excellent process consistency and good quality control, and in combination with the IMD system, it's allowed us to reduce defects on the caps and maintain the highest possible quality of our closures," says Pascal Renner, Head of Quality Management at RCS Plastics.
"The system also runs efficiently around the clock, enabling us to supply our customers reliably," Strunck says. "I would choose the HyCAP™4 again without hesitation."
These gains have given RCS the confidence to look further ahead. Husky has worked alongside RCS to test and validate materials capable of running both virgin HDPE and recycled HDPE on the same mold, helping the company prepare for broader adoption of rHDPE as sustainability requirements continue to evolve.
That long-term focus complements RCS's broader growth strategy. Following the acquisition of a PET production facility in Leipzig, the company now manufactures preforms in-house and can supply customers with both preforms and caps from a single source. With additional HyCAP™ systems planned for 2026, RCS is also preparing to expand into new markets, including Croatia.
How Does HyCAP™4 Improve Beverage Closure Manufacturing?
HyCAP™4 is Husky's fully integrated beverage closure manufacturing system, engineered to help manufacturers maximize productivity, improve part quality, and prepare for evolving sustainability requirements.
Key advantages include:
- Industry-leading cycle times, supporting maximum productivity
- Up to 30% energy savings through Electric Mold Stroke™ and Regenerative Clamp Stroke™ technologies
- Reduced defects through integrated IMD vision inspection and process consistency
- Mold ID™ integration for streamlined process setup and maintenance tracking
- Cavitation options from 24 to 128, supporting scalable production for evolving demand
Next Steps
Speak with a Husky closures expert to learn how HyCAP™4 mold technology can improve productivity, product quality, and sustainability in your closure manufacturing operations.