When engineering meets sustainability, ideas that move things are born – quite literally. Our Managing Director, Bastian Michel, and J. Boldt from igus GmbH recently had the opportunity to discuss new approaches to collaboration in the field of plastics processing and rotational molding (RotoMoulding) in Cologne.

igus GmbH, known as an innovation leader for high-performance plastics and motion systems, has garnered worldwide attention in recent years with the RCYL Bike: a bicycle made entirely from recycled plastic that impressively combines sustainability, design, and functionality. The project demonstrates how plastic can become a key material in the circular economy – lightweight, robust, and recyclable.

Rotational Optimization as a Common Starting Point

The meeting focused on how rotational molding processes can be further optimized – a topic that drives both Henry Technologies and igus in their daily work. The aim is to make material usage, energy consumption and production times more efficient without sacrificing quality or precision.

Henry Technologies has previously conducted initial trials in the production of bicycle rims using the rotomoulding process. The collaboration with igus provided an opportunity to compare experiences, evaluate process parameters, and discuss new material approaches. Particularly exciting is the combination of innovative design and functional plastics technology – two areas where both companies can contribute their strengths.

The RCYL Bike – a symbol of sustainable mobility

The RCYL Bike from igus is far more than just a bicycle – it's a statement for sustainable thinking. Every component, from the frame and rims to the fork, is made from recycled plastic, manufactured using modern processes such as rotomoulding. This technology enables the production of durable, dimensionally stable components while minimizing material waste.

With the igus Bike World Tour, the company demonstrates worldwide how recycling, high-tech, and design can be harmonized. For Henry Technologies, this is an inspiring example of how environmental responsibility and industrial innovation can be combined.

Looking ahead – ideas that are getting rolling

The exchange between Henry Technologies and igus was characterized by openness, curiosity, and technical enthusiasm. Discussions about rotation optimization, material development, and future projects were very promising – and the next steps for collaboration are already being planned.

“The RCYL Bike is an excellent example of what is possible when sustainability and engineering are combined,” summarizes Managing Director Bastian Michel. “We look forward to further exchange and potential joint projects.”

Henry Technologies thus remains true to its guiding principle: shaping innovations, strengthening partnerships, and setting sustainable solutions in motion.

On August 11, the stakeholder meeting for the planned Wartburg District hydrogen pilot region took place at the Bad Salzungen District Office – a crucial milestone on the path to a sustainable energy future. Under the motto "Overall Concept for Building a Regional, Green Hydrogen Economy," representatives from politics, business, and research gathered to discuss the current status of the project and develop concrete implementation strategies.
District Administrator Dr. Brodführer chaired the event together with experts from Triveda GmbH, EurA AG, and representatives from the Wartburg District Office. Numerous regional companies also participated – including WerraEnergie, K+S, HFP Bandstahl, ACO Passavant, and Henry Technologies. The goal is to create a comprehensive hydrogen ecosystem that integrates production, storage, transport, and use within the region.

Technical Key Points and Planning Status

The project region extends across Vacha, Bad Salzungen, and Barchfeld-Immelborn. A 6 MW electrolysis plant is planned, powered by 8 MW of photovoltaics and 17 MW of wind energy. This would allow for the annual production of approximately 500 tons of green hydrogen – enough to power buses, trucks, and industrial applications. About one-third of the hydrogen produced is intended for use in the mobility sector, with the remainder going to industry, for example, through blending into the gas grid or direct delivery by trailer.

Key locations include the Merkers Adventure Mine, where the electrolysis plant is to be built, and the Unterbreizbach train station, where a hydrogen refueling station for trucks, shunting locomotives, and public transport is planned. The strategic proximity to the K+S 20kV overhead power line allows for optimal use of existing infrastructure and reduces transport costs.

Investments, Funding, and Outlook

The project's investment volume is approximately €60 million. Funding of up to €15 million is planned through EU, federal, and state funds – particularly via programs such as "Hydrogen Valleys" and the National Organisation for Hydrogen and Fuel Cell Technology (NOW). Funding applications are to be submitted by the beginning of 2026, and a decision on implementation is expected in October 2025.
The project team is currently working on finalizing the technical plans, the business plan, and obtaining acceptance certificates from the participating industrial partners. Investors are also being brought on board to secure long-term financing.

Regional Opportunities and Challenges

The vision is ambitious, yet achievable: a fully regional value chain for green hydrogen – from energy generation and production to its use in transportation and industry. This could make the Wartburg district a key location for the energy transition in Thuringia.

At the same time, economic viability remains a challenge. While industry is responding to declining CO₂ emissions and rising natural gas prices, hydrogen prices and technologies must continue to evolve to remain competitive in the long term.
Despite these uncertainties, there is a sense of optimism: "We have the opportunity to create a true model region for green energy here in the Wartburg district," emphasized District Administrator Dr. Brodführer in closing.

This plan could become a reality by 2027 – and the Wartburg district could become a shining example of a sustainable, decentralized energy economy.

We are excited to introduce our newest addition to the machine park: The modern "Haitian Jupiter III 13000" injection molding machine from ATR Solutions.

The 1,300 ton clamping force of this machine enables the production of larger parts with exceptional precision. The injection molding machine not only impresses with its remarkable shot weight of up to 10131g HP, but also enables a calculated injection volume of 11133 cc. In addition, the machine is equipped with a Sepro Strong 50 LDV TEER extraction robot. A combination that opens new horizons in manufacturing.

With increased capacity and the latest technology, we are setting new standards in the manufacture of high-quality products. This machine enables us to produce precisely and efficiently, while at the same time opening up a wide range of design options for innovative designs. The purchase of the new machine not only means technological progress, but also opens up free capacity for us to respond even better to your individual project requirements.

Our company is also focused on renewable energy. In the present day, especially as a company, we feel ourselves obliged to do our bit for the environment. For this reason, we decided to switch our lighting in the high rack hall to LED.