Injection-molded plastic parts from 0.5 to 360 g in all thermoplastics, including mold making, automation, printing and assembly.
Plastic-Werk Kappich GmbH & Co. KG
HeusenstammNew on Amplifa
About Plastic-Werk Kappich
Plastic-Werk Kappich GmbH & Co. KG is a family-owned company now run by the third generation since 1945, headquartered in Heusenstamm near Frankfurt am Main. The company manufactures injection-molded plastic parts from all thermoplastics and flexible PVC in part weights from 0.5 g to 360 g on hydraulic and electric injection molding machines with clamping forces from 15 to 200 tons. The value chain includes not only injection molding in small and large series but also in-house mold making with CAD/CAM (Mastercam), automation with linear robots from Arburg and Demag, annealing of plastic parts, heat insertion of threaded bushings M3 to M20, two-color pad printing, film hot stamping as well as assembly and sub-assembly manufacturing. Customers come mainly from medical technology, laboratory technology, electrical engineering, mechanical engineering, the automotive industry as well as toys and model making, including Fresenius Medical Care and Harmonic Drive. Quality assurance is carried out on a CNC-controlled gantry measuring machine in a climate-controlled room with CAQ software and SPC evaluation.
- Site
- Heusenstamm
- Processes
- Plastic injection molding (hydraulic and electric injection molding machines, large/small series, at, Annealing of plastic parts, Two-color pad printing (all RAL colors, areas up to approx. 130×80 mm), Film hot stamping, Heat insertion of M3 and M4 nuts (threaded bushings M3–M20), Insertion of insert parts (e.g. threaded bushings M3–M20), Assembly of sub-assemblies (smaller assemblies), Mold making (in-house tool manufacture, CAD/CAM with Mastercam, tool transfers)
- Materials
- Thermoplastics, Flexible PVC, Polystyrene, Polycarbonate, Conductive plastic (10⁴ ohms), Thermoplastics (all types), Tool steel
- Certificates
- ISO 9001:2015
- Founded
- 1945
- Industries
- Medical technology, Laboratory technology, Electrical engineering/Electronics, Mechanical engineering, Automotive industry/Automotive suppliers, Kitchens, furniture, shop fitting
- 01
Engineering and project development
- 02
Mold making (CAD/CAM, Mastercam)
- 03
Injection molding (hydraulic and electric)
- 04
Automation with linear robots
- 05
Annealing, heat insertion, pad printing, film hot stamping
- 06
Assembly and sub-assembly manufacturing
- 07
Quality assurance and measurement
Materials and Processes
Thermoplastics (all types)
Base material for all injection-molded parts from 0.5 to 360 g, including individual coloring via color batch addition.
Flexible PVC
Used for elastic molded parts in the injection molding process.
Polystyrene
Named material for injection-molded parts across the entire weight range.
Polycarbonate
Used for crack-prone materials when heat-inserting threaded bushings.
Conductive plastic (10⁴ ohms)
Material for proprietary chip containers, packaging boxes and chip cassettes for ESD-compliant shipping of electronic components.
Tool steel
Material for in-house mold making of injection molds.
Sites
Heusenstamm
DEProduction, tool making, quality assurance, administration
- Part weight / size
- 0,5–360 g
- Lot size
- Small to large series
- Materials
- Thermoplastics, flexible PVC, polystyrene, conductive plastic
- Hydraulic and electric injection molding machines (15–200 t clamping force)
- All-electric injection molding machine Arburg
- Linear robot Arburg
- Linear robot Demag
- CNC gantry measuring machine (600×800×500 mm)
- Granulator
- Screening machine
- Conveyor belts and processing cells
Parts and Products
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Plastic injection molding (hydraulic and electric injection molding machines, large/small series, atPlastics | – | – | 0,5 g – 360 g | Small series – Large series | all thermoplastics, Flexible PVC, Polystyrene |
| Annealing of plastic partsHeat treatment | – | – | – | – | Thermoplastics |
| Two-color pad printing (all RAL colors, areas up to approx. 130×80 mm)Surface | – | 130 mm × 80 mm | – | – | Plastic |
| Film hot stampingSurface | – | – | – | – | Plastic |
| Heat insertion of M3 and M4 nuts (threaded bushings M3–M20)Joining | – | – | – | – | Thermoplastics, Polycarbonate |
| Insertion of insert parts (e.g. threaded bushings M3–M20)Joining | – | – | – | – | Thermoplastics |
| Assembly of sub-assemblies (smaller assemblies)Assembly | – | – | – | – | Plastic |
| Mold making (in-house tool manufacture, CAD/CAM with Mastercam, tool transfers)Engineering | – | – | – | – | Tool steel |
| Development of new projects/tools, technical consultingEngineering | – | – | – | – | – |
| 3D measurement of injection-molded parts and molds, series measurement, SPC (Pm/Pmk, Pp/Ppk, Cp/Cpk)Testing | Accuracy down to one thousandth of a millimeter | 600 mm × 800 mm × 500 mm | – | – | Plastic |
| Manufacture of proprietary products: chip containers, packaging boxes, chip cassettes made ofPlastics | – | – | – | – | conductive plastic |
7 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Hydraulic and electric injection molding machines (clamping force range 15–200 t) | – | – | – | – | Heusenstamm |
| All-electric injection molding machine | Arburg | 1 | – | 2018 | Heusenstamm |
| CNC-controlled gantry measuring machine (measuring range 600 x 800 x 500 mm XYZ) | – | 1 | 600 x 800 x 500 mm (XYZ) | 2015 | Heusenstamm (climate-controlled room) |
| Linear robot | Arburg | – | – | – | Heusenstamm |
| Linear robot | Demag | – | – | – | Heusenstamm |
| Granulator | – | 1 | – | 2012 | Heusenstamm |
| Screening machine | – | 1 | – | 2012 | Heusenstamm |
Additional services
Reference customers
Quality
Quality assurance is performed on a CNC-controlled gantry measuring machine (measuring range 600×800×500 mm, accuracy down to one thousandth of a millimeter) in a climate-controlled room, networked with the Compact.Net QM software from CAQ AG including SPC evaluation of the capability indices Pm/Pmk, Pp/Ppk and Cp/Cpk. The company is certified to DIN EN ISO 9001:2015 (DEKRA, no. 80814539/3, valid until 12.08.2026).
| Evidence | Heusenstamm |
|---|---|
| ISO 9001:2015 |
Company History
- 1945
Founded by master machine and toolmaker Gerhard Kappich in Berlin-Weißensee; core business bending, punching and pressing tools, later molds for plastic injection molding.
- 1958
The Kappich family moves to Frankfurt am Main; a tool making and injection molding operation is set up.
- 1960
Purchase of the first injection molding machine.
- 1964
Relocation within Frankfurt; the injection molding shop grows to four machines and the tool making department is completed.
- 1972
Move to own premises in Heusenstamm; expansion to ten injection molding machines and 24 employees.
- 1982
Commissioning of the first IBM system.
- 1990
Taken over by the sons Wolfgang and Wilfried Kappich after the founder's death; founding of the GbR Wolfgang und Wilfried Kappich.
- 1993
Dennis Kappich (today production manager) begins his apprenticeship at the company.
- 1998
Nadine Kappich takes over the management of the office.
- 1999
Office converted to an IT network; certification to QS ISO 9001:2000.
- 2000
Expansion of the production facility with a hall extension and a leased hall.
- 2005–2006
Investments in fully automated injection molding machines with robot systems and conveyor belts.
- 2010
Certification to QS ISO 9001:2008.
- 2011
Jürgen Walter (toolmaker, CAD/CAM specialist) joins the company.
- 2012
New granulator and screening machine optimize the regrind; sprue remnants and reject parts are returned to production.
- 2014–2015
Quality assurance moves into a climate-controlled room; installation of a CNC-controlled gantry measuring machine.
- 2016
Closed-loop water cooling system with heat recovery into the heating system.
- 2017
Installation of the QM software Compact.Net (CAQ AG) and Ape.Net; recertification to ISO 9001:2015.
- 2018
Purchase of the first all-electric injection molding machine from Arburg; company renovation to optimize workflows.