Case Studies

Jan 18, 2018 | Sesotec

Metal-free granulate for SUZUKI motorcycle parts

Metal separators increase the productivity of injection-moulding machines


SUZUKI MOTORCYCLES INDIA PVT. LTD. is a subsidiary of Suzuki Motor Corporation, Japan, and in the Indian town of Gurgaon (Haryana) operates a plant with 1.700 employees and an annual capacity of 750.000 motorcycles and scooters. 

The core of Suzuki's philosophy always has been to provide bikes that are optimal in form and function. Their products are based on the effort to implement customer wishes and demands in development. 

Quality inspection is of outstanding importance for SUZUKI All the components of a bike undergo thorough inspection and quality testing. To ensure that material and aesthetic demands of the product are met, individual parts undergo performance testing before they are released for assembly. For efficient testing SUZUKI. has installed state-of-the-art inspection and testing machinery, which includes metal separators of the Protector range of Sesotec.


Plastic parts for motorcycles are produced in injection-moulding machines and are then painted. For the production of plastic parts for these 1.500 vehicles per day, SUZUKI. uses both new granulate and recycled material. The processing of recycled material and regrind, however, is complicated by contamination with  metal particles. This may cause unwanted downtime of the expensive injection-moulding machines and Hot Runner Systems of the mould due to damage or clogging.


Using metal separators to remove metal particles is the most reliable method to prevent machine downtime and quality defects. The Protector metal separator is installed directly above the material inlet of an injection-moulding machine, extruder, or blow-moulding machine. It detects all magnetic and non-magnetic metal contamination (steel, stainless steel, aluminium, ...) even if they are embedded in the product. Metal contamination is removed by the reject unit ("Quick-Valve").

At SUZUKI. a height of only 350 millimetres was available for installing the metal separators on the injection-moulding machines. With its slim and sturdy design the Protector is a perfect fit. The high-temperature version the Protector ensures perfect processing of the 90°C to 110°C hot granulate. External interference is compensated by the  Auto-learn function. Preset operating parameters ensure outstanding ease of operation.

Customer statement

Vipul Vikas, Project Manager at SUZUKI., is highly satisfied with the Sesotec Protector metal separators: "We were actively searching for a solution to solve the problem of metal contamination, and we found Sesotec through the manufacturer of our injection-moulding machines. Our Sesotec metal separators operate successfully, productivity has increased by five percent."

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