The Big Data Event, held at First Polymer Training Skillnet in Athlone in March 2026, brought together a strong line-up of technology providers and industry experts to explore how data-driven manufacturing is transforming plastics processing. Over two days, the event focused on how connected systems, machine data and integrated ancillary equipment can improve traceability, productivity, maintenance planning and overall process control.
First Polymer Training – Supporting the Industry
The Big Data event opened with a welcome from Alan Harrington, Technical Training Specialist at First Polymer Training Skillnet. Alan introduced First Polymer, established by Ibec in 1999 as a dedicated technical training and knowledge centre supporting the Irish polymer industry, including its work developing future talent through education and training.
bfa solutions – MES Systems and Data Integration
Beat Kämpfer, CEO and Frank Pribbernow, Head of Business Unit for Injection Moulding, from bfa solutions ltd opened the technical presentations with an engaging Q&A-style session focused on the realities of implementing MES systems in plastics manufacturing. Their session focused on the key challenges processors face when starting their digitalisation journey and how MES platforms deliver measurable value. The session clearly demonstrated how MES systems move production away from manual paperwork towards real-time, connected data environments that improve visibility, efficiency and control.
A key focus was the role of MES in enabling data-driven decision making. By consolidating data across machines and processes, manufacturers gain a unified view of production, improving traceability and response times. The presentation also addressed concerns around data security and integration, highlighting how modern systems are designed to be secure, scalable and adaptable to different production environments.
bfa solutions is represented across the UK and Ireland by Plastech Solutions, with Daley Williams and Jon Busby in attendance to discuss implementation.
Building on this, the event moved into how machine-level data is generated and utilised, with the injection moulding machine forming the core data source.
Sumitomo (SHI) Demag – Intelligent Machine Control and Connectivity
Ashlee Gough, Sales Director at Sumitomo (SHI) Demag, explored how big data is reshaping injection moulding, with a focus on practical application. Modern machines can use real-time data to improve productivity, quality and predictive maintenance.
Through OPC UA connectivity, Sumitomo demonstrated how machines can securely communicate with MES platforms and ancillary equipment, creating a fully connected production environment. This enables full traceability across the moulding process, supports faster diagnostics and allows for more informed, evidence-based decision making. The ability to capture, analyse and act on live production data is becoming a key driver in achieving more efficient and reliable manufacturing operations.
Sumitomo (SHI) Demag – Bridging Legacy Equipment into Industry 4.0
Also presenting on behalf of Sumitomo (SHI) Demag, Marcus Gill, Software Engineering Manager, introduced a solution designed to overcome one of the most common barriers to digitalisation: legacy machines. Many older injection moulding machines still hold valuable process data but lack the connectivity required to share it with modern MES platforms.
The solution presented uses an OPC UA data monitor to extract and convert machine data into a standardised, usable format without interfering with machine operation. With features such as cycle-based data capture, parameter mapping and live monitoring, the system allows legacy equipment to be integrated into connected production environments. This provides manufacturers with a practical, cost-effective route to digitalisation without the need for full machine replacement.
With both MES systems and machine connectivity covered, the focus then shifted to ancillary equipment, highlighting how processes that are often considered secondary can become critical sources of valuable production data.
Maguire Products – Vacuum Drying and Data-Driven Processing
Chris Crittenden from Maguire Europe presented ULTRA vacuum drying technology, highlighting the importance of drying in high-specification applications such as medical moulding. Unlike traditional methods influenced by ambient conditions, vacuum drying delivers consistent, repeatable results.
The ULTRA system transforms drying into a data-driven process, capturing key parameters such as temperature, vacuum pressure, cycle time and material throughput. These data points allow for real-time monitoring, trend analysis and full traceability, supporting validation, audit requirements and ongoing process optimisation. By integrating with MES platforms and machine-level systems, drying becomes a connected and visible part of the overall manufacturing process rather than a background utility.
Frigel – Dynamico and Intelligent Temperature Control
Temperature control was the final stage of the process explored during the event, demonstrating how cooling, often the largest portion of the moulding cycle, can be optimised through intelligent, connected systems.
The final presentation was delivered by Fabio Ferrari of Frigel, who introduced Dynamico, an advanced mould temperature control system designed to actively optimise cooling performance. Cooling can account for up to 40–80% of the total moulding cycle. Dynamico is designed to reduce this cooling phase by improving heat transfer, dynamically controlling temperature and synchronising with the moulding cycle to deliver more efficient processing. Frigel technologies are represented across the UK and Ireland by Summit Systems.
Dynamico combines intelligent control with data-driven optimisation, using embedded software to guide users towards the most efficient cycle settings. With OPC UA connectivity, the system integrates into MES platforms, enabling automated data capture, improved traceability and enhanced process transparency. This approach not only improves productivity and part quality but also supports compliance, validation and long-term performance improvements across the moulding operation.
Live Demo: Connected Manufacturing in Action at The Big Data Event
To bring all of these technologies together, the event concluded with a live demonstration, showcasing how connected systems operate within a real production environment.
A fully integrated production cell was set up, featuring a Sumitomo (SHI) Demag injection moulding machine connected via the bfa MES system, alongside Frigel Dynamico temperature control and Maguire ULTRA drying technology. Attendees were able to see how data flows between machines and ancillaries in real time, providing a clear and practical demonstration of how a connected manufacturing environment operates.
Closing: The Future of Data-Driven Manufacturing
The Big Data Event brought together manufacturers from across Ireland, providing both strategic insight and practical understanding of how these technologies can be applied within real production environments.
As manufacturing continues to evolve, the shift towards data-driven production is becoming increasingly important. Manual, time-consuming data collection is being replaced by connected systems that deliver real-time insight, improved traceability and greater control. With the right combination of machines, software and ancillary equipment, manufacturers can move towards a more efficient, reliable and future-ready production environment.