We are experts in palletizing and depalletizing, as well as acoustic foaming and cavity sealing. 

Innovative. Reliable. Cost-efficient.

Company

About Polyplan

Passion for Automation

For over 30 years, Polyplan has led the way in robotic automation and advanced polyurethane processing. In the automotive sector, the company sets benchmarks with its NVH foaming and rustproofing solutions. At the same time, Polyplan develops high-precision equipment for the logistics industry, including solutions for automated palletizing and depalletizing.

As part of the Pepperl+Fuchs Group, we leverage global resources to drive innovation. With over 90 installations operating worldwide, a strong focus on sustainability, and a dedicated team, Polyplan is a trusted partner for efficient, cutting-edge manufacturing and material handling solutions. Polyplan: Your automation, our passion – your solution for future-ready, high-performance processes.

30 +
Years of Experience
50 +
Over employees
90 +
More than installations
100 %
flexible, reliable, innovative

Our Journey

Sustainability

Rethinking Sustainability in Production and Logistics

Resource efficiency and environmental responsibility are becoming increasingly important in both production and logistics. Modern technologies make it possible to design processes that reduce environmental impact and optimize resource use – without compromising on quality or performance

Polyplan delivers sustainable automation solutions that set benchmarks in both the automotive and logistics industries. Our acoustic foam injection systems enhance vehicle comfort and safety, while our automated palletizing and depalletizing solutions improve efficiency and precision in logistics. Throughout all our innovations, we remain focused on one key goal: aligning sustainability with progress.

Sustainability Through Deliberate Material Selection

Our NVH foaming machines are designed to operate safely with recycled materials, such as polyol and isocyanate recyclates. The unrestricted use of renewable materials can reduce petroleum consumption by up to 20%. Additionally, incorporating reusable multi-use filters cuts waste from disposable filters by up to 70%.

Sustainability Through Repairability, Long System Lifespan and Non-Destructive Quality Control

Our acoustic foam injection systems exclusively use wear-free magnetic couplings in their drive trains, providing a lifespan approximately ten times longer than mechanical seals. This ensures sustainable and efficient system operation with high availability. Additionally, all potential high-wear components are repairable and are refurbished rather than discarded in the event of damage – which often more than doubles their service life.

When shipping replacement parts, we primarily use reusable closed-loop packaging to minimize packaging waste. Nearly all modules in our systems are also protected by durable fixed piping, which reduces both replacement efforts during operation and waste generation by approximately 30%.

Sustainability Through Energy-Efficient System Technology

Using energy-efficient temperature control units to heat acoustic foam components reduces the heating energy needed by up to 20% compared to other systems. Dynamic temperature compensation and efficiency-optimized pump speed control save an additional 10% of the energy required to manage the temperature of the PU components. Our systems are also equipped with high-performance thermal insulation, cutting total heating energy needs by up to 40%. The standby during shorter downtimes further reduces energy use by up to 30%.

Sustainability Through New, Compact Design

Our new high pressure dosing unit HD-PUR 100AS and UC reduce physical footprint by up to 80% compared to the proven HD-PUR 100HR high-pressure unit, improving space utilization and overall system efficiency. With these sustainable automation solutions, we actively reduce environmental footprint, optimize resource use, and enhance both efficiency and competitiveness.

Our Values

Living Our Values Every Day Is the Foundation of Our Success

Our values are the cornerstone of everything we do. They serve as a compass, guiding us in our daily work and helping us achieve success together with our partners and customers. To uphold these principles, we have developed a Code of Conduct — a set of guidelines ensuring ethical and lawful behavior in all business activities.

With these values as our foundation, we shape the industry of tomorrow together with our customers and partners – efficiently, sustainably and innovatively.

Innovation

We think ahead and develop solutions that drive technological progress. With over 30 years of experience, we deliver state-of-the-art systems that meet today’s demands while being ready for the future.

Sustainability

Our mission is to optimize processes while reducing environmental footprint. We see resource-saving technologies and efficient automation as the key to sustainable industrial production.

Excellence

Quality is our top priority. Every solution we offer is designed for maximum precision and reliability – delivering optimal efficiency and long-term success stories.

Responsibility

We are aware of the consequences of our actions and always act with the big picture in mind.

Credibility

Our actions are fully aligned with what we think and communicate. We believe in transparency and stand by our word.

Trust

We see mutual trust as the foundation of successful, collaborative partnerships.

Partnership

We see ourselves not just as a supplier, but as a long-term partner. Through close collaboration with our partners, we develop customized solutions that create real value – we are your strategic ally for future-ready solutions.

Competence

Our competence for acting effectively is built on our technical expertise, social skills and structured problem-solving abilities.

Reliability

We honor our commitments regarding deadlines, tasks and requirements – both in our relationships with customers and colleagues.

Team Spirit

We achieve our goals through the strength of a highly motivated team that collaborates and supports one another.

Joy in Our Work

We enjoy what we do and celebrate our successes, drawing energy and satisfaction from them.

Factory Solutions – A Network for Sustainable Automation

As part of the Pepperl+Fuchs Group, Division Factory Solutions combines three leading companies – Polyplan GmbH, Neoception GmbH, and VMT Vision Machine Technic Bildverarbeitungssysteme GmbH – into a powerful network. Together, we deliver customized solutions that optimize your production processes and help you achieve your goals faster and more efficiently.

Numbers That Matter

12
locations worldwide
75 +
Over years of experience from the Pepperl+Fuchs Group
220 +
employees across 3 companies
Many
successful projects

Solutions

At Polyplan, customized automation solutions are at the core of what we do. Whether in the automotive industry, battery production for e-mobility, or logistics, we deliver cutting-edge technologies that enhance efficiency, ensure precision, and promote sustainability.

From robot-guided Polyurethane (PUR) acoustic foam systems and innovative door waxing solutions to automated palletizing and depalletizing systems for various packaging formats and containers – our tailored automation solutions not only provide precision and efficiency but also secure your long-term competitiveness.

Automotive

automotive – Polyplan-GmbH

Logistic

Roboterarm – Automatisierte Fertigung – Polyplan-GmbH

Battery Technology

batterie-technologie – Polyplan-GmbH

Technical Center

Technikum – Polyplan-GmbH

Automotive

automotive – Polyplan-GmbH
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Automotive

Precise and efficient operations are essential for automotive production – Polyplan delivers pioneering automation solutions to make them a reality. Our technologies support leading manufacturers worldwide in advancing innovative production processes.

We provide customized, turnkey systems for the PUR (Polyurethane) foam injection the automotive industry. Our technology is built on proprietary production systems that cover the entire range of applications. As part of Division Factory Solutions, we benefit from a strong industry network, delivering innovative solutions with maximum precision and efficiency — while ensuring long-term ROI (Return on Investment) and scalability for future needs.

Facts:

Flexible, Cost-Efficient and Reliable – Optimal Acoustic Insulation for Vehicles and vehicle interiors

  • One system for all vehicle types and production volumes – flexible, modular and scalable
  • Freely adjustable mixing ratio of both components – no pressure adjustments required
  • Integrated automatic shot volume calibration for maximum dosing precision
  • Turnkey integration into production environments – no interface risks
  • Scalable package – from standalone application to fully integrated robotic cell

Learn more: Factsheet

Test before implementation – ensuring the right solution for your needs Explore our Technikum and validate solutions firsthand or: Our mobile system can easily be used in your lab or production line.

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Our turnkey cavity preservation systems provide a sustainable and reliable solution for automotive manufacturing. Polyplan has continuously optimized cavity preservation technology. With minimal energy and material use, weld points and seams are precisely coated and fully protected – all in a highly stable, documentable process.

Thanks to this efficient solution, resource waste from manual wax application or cavity flooding is eliminated. The cleaning effort in the production line is also significantly reduced – no more wax runoff from cavities and no carry-over to downstream processes.

This allows a standard vehicle front door to be fully protected against corrosion with just 4.5 grams of wax – ensuring an efficient and future-ready production process.

Facts:

Precise and Economical Application of Preservation Waxes – Minimum-Quantity Cavity Preservation

  • Suitable for doors, closures and add-on parts requiring high precision and cleanliness
  • No frequent tool changes required – adaptable for multiple applications.
  • No overspray or dripping – ensuring clean components, less rework, and reduced cleaning effort
  • No aerosols – no additional extraction or enclosed robotic cell needed
  • TThree application methods: AirLess (Klick und PopUp*) for weld points and seams, AirMix (Klick und PopUp*) for broader surfaces and areas, AirPush for driving wax around obstacles without a direct line of sight (Klick und PopUp*)
  • Inline wax jet and spray cone measurement with VMT Toolbox 3D

Learn more: Factsheet

Taking precise measurements for a perfect fit – our wax laboratory. Discover our Technikum Technical Center.

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Our cavity preservation solutions deliver not only maximum precision but also a sustainable, material- and energy-efficient process. By selectively applying liquid wax with robot-guided nozzles, we ensure meticulous protection of cavities – without unnecessary waste of resources.

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Logistic

Roboterarm – Automatisierte Fertigung – Polyplan-GmbH
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Logistics – Robotic Palletizing and Depalletizing

Fully automated palletizing and depalletizing of mixed loads is a complex challenge. Our AI-powered solution handles this task reliably and cost-effectively. We tailor every detail to your specific requirements, delivering customized solutions that make your logistics processes more efficient and secure.

Facts:

  • Fully automated palletizing and depalletizing of small load carriers such as SLCs (Small Load Carriers), EPPs, cartons, etc.
  • Application can also be integrated into an existing cell control system or conveyor control without requiring a dedicated PLC
  • Specifically developed, modular multi-gripper for robotic handling of totes / SLC‘s expanded polypropylene boxes and cardboards
  • Handles all stacking patterns, sizes, types, and colors seamlessly

Learn more: Factsheet

Complex tasks, precise solutions – our vision and robotics lab. Discover our Technikum Technical Center.

Battery Technology

batterie-technologie – Polyplan-GmbH
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Corrosion Protection for Battery Packs – Efficient and Sustainable

Polyplan provides customized automation systems for corrosion prevention in battery packs. Proven technology from automotive manufacturing is adapted to battery cell production, ensuring precision and resource efficiency. This approach guarantees long-term protection while optimizing production processes.

Facts:

Applications in Battery Cell Production

  • Automated cavity sealing for coolant connectors, screw heads, and battery enclosures using our proven AirLess and AirMix technology
  • Application of potting material – high-pressure polyurethane dispensing process
  • PU bonding systems for bonding module packs to the battery tray – high-pressure polyurethane dispensing process

Learn more: Factsheet

Technical Center

Technikum – Polyplan-GmbH
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Technical Center

Polyplan’s Technikum – Polyplan’s Technikum – Your Development Platform for Tailored Solutions Our technical center enables you to test and further develop your custom solutions – flexibly, efficiently, and precisely as your needs require. Our expertise in developing tailored solutions ensures that you not only receive high-performance machines but also make your processes more efficient and future-ready.

Our mobile compact systems allow you to conduct tests at your site or in our dedicated testing environment. They are ideal not only for testing but also as backup systems during maintenance or modifications, ensuring projects are executed successfully and on time. Since the compact system consists of the same components as a production system, testing already achieves the same quality as later full-scale production.

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In our wax lab, we determine the appropriate waxes, evaluate application strategies and assess machine designs to ensure that your cavity protection systems are perfectly tailored to your requirements.

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This is where we validate your automation solutions—from NVH foaming to wax application for door cavities and fully automated palletizing and depalletizing. We assemble the solutions exactly as they will be installed at your site to ensure smooth integration into the production process

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We meticulously tailor our solutions to your specific needs, ensuring the best possible implementation of your requirements. This is the key advantage that sets us apart from other providers.

  • designed for scalability and future production demands precisely tailored solutions for your competitive edge
  • Optimizing your processes with our expertise and sustainable solutions
  • Flexible adaptation of our solutions for quick responses to changes in your production
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Team

Polyplan is more than just an employer – we are an international team that embodies innovation and sustainability. With our headquarters in Germany, an office in Changchun, China, and soon another location in the US, we are shaping global solutions for a forward-thinking industry. As a subsidiary of the renowned Pepperl+Fuchs Group, we benefit from a strong network and resources that drive our worldwide success. Our customers – including leading names like BMW, Mercedes, and Lamborghini – value our expertise and reliability.

We combine international presence with a corporate culture that values personal development and flexibility. Discover our management team, learn about our leadership positions, and find out about the exciting career opportunities that await you with us. Become part of a team that thinks globally and acts locally – for the industry of tomorrow.

Team

Foresight and Experience – Our Team

At Polyplan we rely on a strong leadership team that shapes the future with long-standing experience, an innovative spirit, and a clear vision. Thanks to our global network, our team develops tailored solutions that are precisely aligned with your needs and – through this and other benefits – set new standards.

Our team stands for

Careers

Shape the future with us! Polyplan offers the opportunity to work in an innovative, international environment focused on efficiency, sustainability and continuous personal development. As specialists in automation solutions, we focus on dosing technologies in the automotive industry – such as acoustic foam systems or cavity preservation systems – and especially on the automation of logistics processes, like automated de-/palletizing of small load carriers and other containers.

Our solutions range from flexible, manual machines to highly complex robotic systems. Working at Polyplan means being part of a dynamic team, developing future-proof, sustainable solutions for the automotive industry and logistics sector together.

Seize the opportunity to advance your career in a globally oriented company with room for ideas and growth!

Company Culture

Polyplan offers its employees numerous benefits that go beyond the ordinary. These include:

News

Updates and Insights – Innovations and News

Here you will find the latest news, exciting insights into projects and product innovations, as well as company updates related to Polyplan. Learn how we set standards with our solutions and help to shape the future of automation.

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Latest News
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News Archive
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Highlights

Milestone Projects & Installations

Our “milestones” offer an overview of outstanding projects that highlight Polyplan’s expertise in developing innovative automation solutions. Our customers include leading companies in the automotive and logistics sectors across Europe, the US, Japan, India and China, as well as nearly all major vehicle manufacturers worldwide. Together, we create tailored, efficient and sustainable solutions – delivering real value for our customers.

References

Polyplan-GmbH Logo
Application
  • Select Everything
  • PUR (POLYURETHANE) Acoustic Foaming
  • Cavity preservation / Door waxing
  • Fully Automated De-/Palletizing
Map Image – Polyplan-GmbH
Qingdao
China
Changchun
China
Peking
China
Shenyang
China
Tiexi
China
Dadong
China
Dingolfing
Deutschland
München
Deutschland
Regensburg
Deutschland
Leipzig
Deutschland
Ingolstadt
Deutschland
Neckarsulm
Deutschland
Sindelfingen
Deutschland
Bremen
Deutschland
Oxford
Großbritannien
Rastatt
Deutschland
Kecskemet
Ungarn
Rosslyn
Südafrika
Araquari
Brasilien
Aurangabad
Indien
Bratislava
Slovakei
Emden
Deutschland
Berlin/Grünheide
Deutschland
Göteborg
Schweden
Bologna
Italien
Spartanburg
USA
Chennai
Indien
San Luis Potosi
Mexiko
Brussel
Belgien
Gyor
Ungarn
Born
Niederlande

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