Stabilizing Fluctuations in Recycled Material Processing Using AI

The " shop floor" Shannon assistance system from plus10 provides round-the-clock, real-time recommendations for troubleshooting and process optimization at the Aumovio megafactories in the Czech Republic, Romania, and Serbia. At the Brandýs plant, this has already increased production availability for large display assemblies by up to five percent.

How plus10, in collaboration with Aumovio, optimized highly automated display manufacturing at the Megafactory in Brandýs (Czech Republic): Using the AI assistance system Shannon and a new edge-to-cloud architecture, equipment availability increased by up to 5%—all implemented in less than six weeks.

At the ARBURG Technology Days, plus10, together with ARBURG, showcased Hopper, an AI-powered software tool integrated into the Gestica control system: This self-learning optimization solution analyzes quality-relevant parameters in real time and provides machine operators with guidance on process optimization—even before scrap can occur.

In AUMOVIO's mega factories, plus10-Shannon®, shop floor data-driven shop floor, optimizes the automated production of large automotive displays through real-time root cause analysis and situational recommendations for action. Just a few weeks after implementation, an increase in availability of up to 5% and a significant reduction in short stops were achieved.

How a casual after-work conversation at a trade show led to the founding of plus10: Fraunhofer Magazine tells the story of the IPA spin-off—from its first AI tools for error analysis to productivity gains of up to 20 percent for clients such as Freudenberg, Roche, Ypsomed, and Aumovio.

At K 2025, plus10 will demonstrate how its AI tool, Hopper, optimizes syringe production in the medical technology industry in real time and reduces scrap rates during batch changes from 10% to 0.3%.

The award recognizes innovative technologies that drive the digital transformation of industry. Hopper impressed the judges with its data-driven process optimization, which reduces scrap and cycle times by up to 20%.

How plus10 and ZAHORANSKY are using AI tools to speed up the commissioning of complex injection molding systems, reduce waste and support operators in 24/7 operation.

How plus10, in collaboration with machine manufacturer Zahoransky, shortened the startup time of an injection molding production line by 20% and reduced scrap during the ramp-up phase by 10–17%—using the live-learning AI tool Hopper in GMP-critical, fully automated 24/7 operation.

Felix Georg Müller, CEO of plus10, explains what AI is capable of today, where Germany has opportunities for success, and why now is the time to get started.

DER SPIEGEL features plus10 as one of the AI startups helping German industrial companies prepare for the future—with continuously learning analytics software that detects machine errors and prevents scrap.

Hopper increases efficiency in the highly regulated syringe manufacturing industry by up to 18%—and was recognized by Siemens for this achievement.

SKZ awards plus10 the coveted "Premium Partner Research" award for the first time

+ 17.4% throughput increase identified by data-based plus10 optimization software. On large, fully automated and therefore confusing fill & finish lines at Schwarzkopf & Henkel, Shannon® and Darwin proved to be particularly beneficial.

Similar or even identical machines with comparable processes often do not run at the same productivity level. To create more transparency about possible optimization potentials, plus10 offers the intelligent software tool Darwin.

Great success at the Microsoft Intelligent Manufacturing Award 2021

The automotive supplier Valeo has started an application-oriented research and development project with the Fraunhofer AI spin-off plus10 and the AI institute AImotion Bavaria of the Ingolstadt University of Technology. The aim of the project is to increase the efficiency of highly automated production lines with the help of novel machine learning algorithms.

plus10 is conducting application-oriented research together with the Southern German Plastics Center SKZ as part of the DarWIN project on new AI-based optimization tools for injection molding machines. The aim is to develop continuously learning models in a practical manner that adaptively enable higher quality with shorter cycle times around the clock

plus10 is one of the three best startups at the renowned industry competition Factory of the Year in the category "Startup Challenge". With an innovative AI optimization software for automated production, the young company from Augsburg and Stuttgart was able to convince the expert audience.

plus10 implements AI software in injection molding machines at Freudenberg Home and Cleaning Solutions and sets up high-frequency data acquisition and processing.

Every second mechanical engineering company has already entered into a partnership with a start-up. Concrete results do not always follow from such a partnership. Christian Riendl, Hosokawa Alpine, and Felix Müller, plus10, reported on the success factors and challenges of their joint collaboration at this year's tea Technology Transfer Congress in Augsburg.