Industries everywhere are under pressure to reduce waste, lower energy use, and improve efficiency. Particle foams are no exception — and Alessiohitech is leading the way.
With its ZERO tooling technology, Alessiohitech has introduced a new type of mould that delivers major improvements: lower energy use, faster production, and reduced need for water cooling. What once seemed impossible is now achievable.
Compared to traditional moulds, ZERO can achieve, depending on product specifications, the following performances:
- Energy Savings – Up to 50% less steam used
- Faster Cycles – Up to 50% shorter production times
- Dry Cooling – Less reliance on water
- Lightweight Design – Lower thermal inertia
- No Core Vents Needed – Advanced micro-cutting improves airflow and part quality
Combined with Alessiohitech’s electric moulding machines, ZERO sets a new standard for sustainable EPP moulding.
To test ZERO’s performance, Alessiohitech used an ARPRO EPP box as a benchmark product. The goal was to compare ZERO moulds with traditional ones and measure the results. Using built-in machine sensors and external validation, Alessiohitech tracked every detail of the process.
“With ZERO technology we managed to take particle foam moulding a step further — setting a new benchmark for performance and efficiency, said Mattia Alessio, Head of Engineering at Alessiohitech. “I see this innovation as a true contribution to the entire sector, as it opens the door to new markets and broadens the field of particle foam applications thanks to higher efficiency in production costs.”
JSP, a global leader in particle foams, partnered with Alessiohitech to measure the benefits of ZERO tooling using their sustainable moulding technology. Alessiohitech also integrated the Dynamic Data Exchange (DDE) Technology and Applications from Advanced Solutions into its machines. DDE turns machine signals into clear, reliable data. It allows real-time comparisons and helps factories confirm savings in energy, cycle time, and product quality.
This integration ensured the data was accurate and met industry standards.
The results were impressive:
- 30% faster production cycles — 63 seconds with ZERO vs. 90 seconds with traditional moulds
- Over 50% reduction in steam usage — 9 kg per cycle vs. 19 kg
(Results gathered on an EPP machine with standard steam chamber configuration, size 1500 × 1000.)
“The partnership with JSP and the integration of the new DDE (Dynamic Data Exchange) software into Alessiohitech’s shape moulding machines made data collection and analysis highly efficient. In my view, DDE can help any moulder move from working in ‘blind mode’ to having full awareness of their moulding processes, ultimately stepping up efficiency across the board,” concluded Mattia.
These are not small improvements — ZERO tooling has changed the game in EPP moulding. The partnership with JSP proves that combining smart engineering with digital tools can make sustainable manufacturing a reality.
