Innovation

ALways ahead

Turning possibilities into realities

Customer lead innovation is a core to the success of Thormac. Always striving to exceed client requirements Thormac invests in research and development, and technologies to stretch the boundaries of injection moulding and be at the forefront of new breakthroughs in the plastic moulding industry.

Flexible and adaptable Thormac will work closely with you to understand your needs and requirements and help you meet your goals.

To appreciate how we engage with out customers browse through our case studies below.

Case Studies

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Sustainability

Thormac journey to sustainability has involved adopting practices that minimize negative environmental and social impacts while maximizing economic benefits.

Our milestones on our journey

Collaborating with customers to reduce waste in the production of plastic components.
Movement from hydraulic injection moulding machines towards Electric injection moulding machines, which have much greater efficiency.
Adopting more environmentally friendly materials like Bioplastic compounds and, in some cases, recycled polymer materials.
Developing product using 80% single-sourced recycled plastic.
40% reduction in electricity usage using Smart power machines.
10% reduction in water usage using closed loop chilling systems.
Reducing process waste by 20%
Replacing light fittings with more sustainable LED lights in 2019.

Comparing the plastic injection moulding process

Plastic Processing	Specific Energy Usage
Type	kWh/kg
Injection Moulding	3.118
Pipe and Profile Extrusion	1.506
Film Extrusion	1.346
Thermoforming	6.179
Rototional Moulding	5.828
Compression Moulding	3.168
Film Extrusion	1.346
Fibre Extrusion	0.850
Compounding	0.631
Overall Average	2.811

Working In partnership with our customers

Alu metal box converted. to PP GF40%.
- Part weighs 33% less.
- Reduced Noise Pollution.
- Easier to recycle.

Formerly metal tripod covert to PA6 GF20% FR.
- Part weights 23grms.
- 27 sec cycle-time.
- Easier to recycle

While turnover goes up our electricity use comes down

Year	Total Units kWh	Reduction Kwh	Total kg CO2	Total CO2 Tonne	Reduction CO2	Total kg Carbon	Total Carbon Tonne	Reduction Carbon
15	1,143,791	0%	544,444	544	0%	148,485	148	0%
16	1,234,178	-8%	502,311	502	8%	136,994	137	7%
17	1,211,683	-6%	437,417	437	20%	119,296	119	20%
18	1,382,810	-21%	470,156	470	14%	128,224	128	14%
19	1,024,390	10%	348,293	348	36%	94,989	95	36%
20	903,356	21%	307,141	307	44%	83,766	84	43%
21	993,622	-10%	298,087	298	45%	81,297	81	45%
22	930,478	6%	317,052	317	42%	86,469	86	42%

Working in partnership with Clean Ireland

None of our waste goes to landfill, it is either recovered or recycled.

Waste Stream 2022
Recycling	7.36%	12.00%	67.11%	0.00%	1.27%	4.77%	0.99%	0.00%	10.36%	7.30%	11.78%	14.51%
Recovery	92.64%	88.00%	32.89%	100.00%	98.73%	95.23%	99.01%	100%	89.64%	92.70%	88.22%	85 .49%
Landfill	0.00%	0.00%	0.00%	0.00%	0.00%	0.00%	0.00%	0.00%	0.00%	0.00%	0.00%	0.00%
	100.00%	100.00%	100.00%	100.00%	100.00%	100.00%	100.00%	100.00%	100.00%	100.00%	100.00%	100.00%

Research and Development

Innovative Technological Solutions

Dedicated to meeting the latest challenges posed by societal, scientific, and industrial problems, Thormac constantly strives to find innovative ways to meet customer demands, improve productivity and meet legislative requirements. Focusing on product development and satisfying the needs of our clients, we collaborate with specialist suppliers to bring next generation product to market.

Thormac is dedicated to providing the latest innovations in the parts that we provide. We work closely with OEM customers to design and implement advanced solutions while remaining cost-effective. We have developed solutions such as our plastic-for-metal substitutions and manufacture innovative products such as our District Heating End-Caps and Anti-static treated jars. We also continue to trial the latest and most progressive materials to guarantee quality.

PATH TO SUCCCESS

Leaders, Innovators. Out of the box Thinking.

Thormac are not afraid to take on difficult challenges. Our ability to develop new techniques and and employ alternative solutions means we can take on projects that others cannot.