Published 05/23/2025

Sensors, Sustainability and Skilled Labor

Q: What is the biggest challenges facing mold builders today?

One of the biggest challenges I see across the industry is the shortage of skilled molding process engineers. These professionals are crucial because they develop the settings and process parameters necessary to produce mold components that meet specifications and are statistically capable from a process perspective. In my experience, this issue is more prominent among suppliers than mold builders. However, as more mold builders recognize the value of having presses on-site to conduct mold Factory Acceptance Tests (FATs), this concern becomes increasingly relevant. One of the biggest challenges facing OEMs today is the lack of viable and qualified sources of recycled resin to support the industry's growing sustainability initiatives.

Q&A with Bob VanCoillie, MoldMaking Technology EAB member and senior manager of Kenvue’s mold management center of excellence.

Christina Fuges

Editorial Director, MoldMaking Technology

Q: Where does your research and work with tooling digitalization stand today?

A: I currently have 100 molds equipped with digital systems that track various information, including cycle time, cycle count, process overall equipment effectiveness (OEE), water temperatures and melt pressures/temperatures. Based on my experience with these installations and data analysis, I have optimized certain aspects, such as the types and sizes of sensors, to minimize their impact on the molds. I also have collaborated with my digital monitor supplier to create dashboards that summarize and display real-time data, enabling effective process monitoring and decision-making regarding releases.

Q: Have you made any progress with your tooling and molding vendors?

A: It has been a lengthy process, and while I am still working to achieve alignment with some suppliers, I have made significant strides in coordinating with others and installing systems on my molds.

Q: What are some additional findings of your extensive DOE on mold sensors and digitalization and the impact and benefits to OEMs, molders and mold builders?

A: One key to overcoming challenges with suppliers was, in some cases, taking a step back and agreeing to implement a pilot approach rather than seeking alignment on implementation of every production mold from the start. This strategy allowed suppliers to become comfortable with the technology and to see and use the data generated for our mutual benefit as the OEM. In many instances, the sharing and analysis of data have led to closer and stronger partnerships with suppliers.

Q: What does sustainability mean to you?

A: Sustainability, in my view, centers around the plastic components produced by molding processes. Currently, at Kenvue and across the industry, there is a significant emphasis on sustainability, particularly regarding the selection of resins used for molded products like bottles and closures.

“I envision a future where most molds will have this digital capability integrated. So, moldmakers will need to think about how to incorporate embedded digital components alongside the design of the mold itself.”

Q: How do you see your products and processes contributing to a more sustainable economy?

A: As I mentioned, there is a significant emphasis on sustainability within Kenvue. One of my primary roles involves supporting projects related to mold development and qualification. Specifically, we are transitioning from using 100% virgin resin to incorporating 50-100% recycled resin for producing components. As these projects are successfully completed, they will lead to more sustainable products in the retail marketplace.

Q: What is the biggest challenges facing mold builders today?

A: As an OEM, one of the biggest challenges I see across the industry is the shortage of skilled molding process engineers. These professionals are crucial because they develop the settings and process parameters necessary to produce mold components that meet specifications and are statistically capable from a process perspective. In my experience, this issue is more prominent among suppliers than mold builders. However, as more mold builders recognize the value of having presses on-site to conduct mold Factory Acceptance Tests (FATs), this concern becomes increasingly relevant.

One of the biggest challenges facing OEMs today is the lack of viable and qualified sources of recycled resin to support the industry's growing sustainability initiatives.

Q: What technological advancements do you predict will have the biggest impact on the moldmaking industry in the next five years?

A: I believe that mold digitalization will have the most significant impact in the next five years. This technology is still quite new, but as more suppliers begin to recognize its benefits and as the technology continues to improve, I envision a future where most molds will have this digital capability integrated. So, moldmakers will need to think about how to incorporate embedded digital components alongside the design of the mold itself.