MPT Case Studies – An invisible Director of Quality: our brand new distributed climate control for total process management

In an automated production system, every detail affects the final outcome. Even those invisible to the naked eye, yet capable of significantly impacting both product quality and working conditions.

That’s why MPT made a strategic investment in a distributed climate control system, extending it from the toolmaking department to the entire molding area, where presses heat plastic pellets to high temperatures.

This project wasn’t required by regulations, but was implemented to ensure stability, safety and consistent performance across operations.

Issue #1: Temperature is an invisible but tangible factor

The production environment directly influences the performance of molding technologies, the quality of the output, and worker well-being. MPT had already experienced the benefits of climate control in the toolmaking area. However, in the molding department, where presses and automated cells generate significant heat loads, temperature and humidity were not yet managed in a precise and localized manner.

There is clear data supporting the positive impact of tailored environmental control systems, which improve both product outcomes and working conditions — especially in terms of operator safety:

  • +20% increase in accuracy for robotic presses in climate-controlled environments (source: Mitsubishi Electric);
  • up to 30% fewer micro-defects in plastic parts thanks to thermo-hygrometric control;
  • humidity above 60% compromises material stability during cooling;
  • in environments over 30°C, operator reaction times drop by up to 20%, with direct safety implications;
  • improved environmental ergonomics leads to +12% higher productivity (source: ASHRAE).

Issue #2: Two interdependent departments must operate in sync

The misalignment between the toolmaking and molding areas created a discontinuity in the production process. Maintaining consistent and distributed climate conditions was no longer optional: it became a design necessity to ensure operational continuity.

This intervention represented the logical and coherent completion of a process already underway, creating a uniform environment across the entire production flow, with no thermal discontinuities between departments.

The solution: an intelligent and distributed climate control

The new distributed climate control system was designed as an integral part of a broader process optimization strategy. Engineered to operate silently in the background, like an invisible director,  the system intelligently manages microclimates based on actual thermal loads and external conditions.

The benefits are tangible and measurable:

✔️ Greater accuracy in press and automated cell performance;

✔️ Lower occurrence of micro-defects in molded plastic parts caused by environmental fluctuations;

✔️ Improved ergonomics and safety for operators, with reduced thermal stress;

✔️ A more stable and reliable production process across the entire value chain, with seamless integration between departments.

For MPT, this investment reinforces a core belief: quality is never a standalone result. It is an integrated system in which even the working environment plays an active role in overall performance. Technology and environment must operate in synergy. That is the only way to achieve production that is truly precise, continuous, and sustainable.

Are you interested in learning more about our approach to tool design, technical molding, and co-design? Read all of MPT’s Case Studies here: https://www.mptsrl.it/portfolio/

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