Thanks to 188,000 active customers, the record year was surpassed – igus increases delivery capacity and grows by 32 percent

32 percent growth and 80,000 more products available from stock – and igus GmbH continues to invest in production and delivery capacity: An additional 20,000 m² of factory space is under construction at the igus Campus Cologne (see image, completion in May 2023). (Source: igus GmbH)

A total of 500 new injection molding machines will be installed at igus GmbH in Cologne, with 100 older machines replaced by models that are 40 percent more energy-efficient. By 2025, production at igus is to be climate-neutral, currently at 95 percent. (Source: igus GmbH)

The customers of motion plastics products – from drive cables to gears – received their orders very promptly in 2021 as well. The plan from 2019 to invest in production and supply chain helped meet the sharply increased demand. Further expansion is planned through 2023, also considering the Ukraine conflict. The company's goal has become clearer: Improve what moves; CO2-neutral, without plastic waste, and "become the easiest company to deal with."

"€234 million more in revenue in one year, with nearly the same selling prices by the end of the year, and all self-produced and sourced – we've never achieved that before," says igus Managing Director Frank Blase. "Our colleagues have performed miracles. And we were lucky that we implemented our investment plans even in the difficult year 2020." Revenue in 2021 amounted to €961 million.

32 percent more revenue than in 2020 also means 26 percent more than in the record year 2019. This year also saw the implementation of the plan, called the "No. 1 Catalog" internally: Over 80,000 items have since been kept in stock or with higher quantities. In 15 global distribution warehouses, the share of catalog products shipped on the same day or within 24 hours increased to at least 25 percent. "This is probably why revenue growth across all product categories is nearly equal," says Blase. Improvements were also made to the online shop pages. Online sales increased by 55 percent in 2021. "Customers need to be able to decide immediately on the web whether the plastic solution is suitable and receive it quickly. That is part of the goal to be the 'easiest company to deal with'," explains Frank Blase.

500 new injection molding machines – major investments continue

The Ukraine war and shortages in many markets prompted igus to invest again at short notice to improve material availability. Simultaneously, investments in higher production capacities continue. Since 2020, production in Cologne has been increased or modernized with 300 injection molding machines. Another 200 are on order. The new production building in Cologne, with an additional 20,000 m² of space, is expected to be completed by May 1, 2023. New storage locations for 12,000 pallets were already built in 2021. Plans are currently underway for further expansion of the "igus Campus Cologne," for which the company acquired adjacent land totaling 20,000 m². The expansions for the 35 international subsidiaries amount to a total of 60,000 m² of floor space.

168 innovations – higher output in chip production

Customers from over 50 industries are constantly approaching igus with new challenges. For example, cleanroom cables for chip production: "Innovative flexible cable management solutions like the e-skin flat are in high demand, especially in the booming semiconductor industry," says Peter Mattonet, Industry Manager Cleanroom at igus. "Being able to replace a cable within a few minutes is a revolution for manufacturing and significantly increases the urgently needed output." The pace of innovation at igus did not slow down even in the second year of home office and remote work – demonstrated by 168 product developments, such as motion plastics gears, manufactured by injection molding and available with 740 different items in the online shop. The four-year-old business unit "smart plastics" alone launched twelve new products in 2021 for condition monitoring, preventive maintenance, and IoT. In conjunction with real-time cable monitoring for Ethernet cables and the integrated solar-powered condition sensor EC.I, customers can now completely avoid unexpected plant downtimes.

Digitalization – 5,000 do-it-yourself engineering projects online per day

Low-cost robot integration via online consultation and fixed-price offers – this promise is fulfilled by the RBTXpert, which igus launched in 2021 as a Digital + Human Service. In a 400 m² customer testing area, experts test customer requirements before making an offer. Typical solutions cost €8,500 in hardware and 20 hours of integration, resulting in a payback period of just a few months. The service is already available in seven countries, with 14 more in preparation. Three new online tools brought the total to 58. "Our customers' do-it-yourself engineering efforts doubled last year to 5,000 value-adding uses on the web per day," says Frank Blase.

Progress – 95 percent climate-neutral, resource-efficient, recycled

On the path to climate-neutral production by 2025 – currently at 95 percent according to Scope 1 and 2 (Greenhouse Gas Protocol) – igus undertook various projects last year: A total of 100 older injection molding machines were replaced with models that are 40 percent more energy-efficient; energy management was further optimized, and an ISO certificate is expected by the end of March. Additionally, igus planted 15,687 trees in 23 countries. Non-recyclable plastic waste from production decreased by 21 percent. The global energy chain recycling program chainge has grown in recent years and has been rolled out internationally. This spring, igus will introduce its first energy chain product made from 100 percent recycled materials from the chainge program.

A lubricating-free world

This and over 100 other motion plastics innovations from spring 2022 will be presented by the company starting in April, as the igus Motion Plastics Show enters its third year. Frank Blase: "Currently, we are all moved by the plight of people in the war and the great political struggles worldwide. But alongside many aid initiatives, we are trying to continue focusing on technological progress." Improving the world of motion with motion plastics is igus's dream. For example, with lubrication-free solutions. According to company figures, 1 liter of oil pollutes 1 million liters of drinking water in the environment. 22.7 million tons of lubricants are released into soils and waters worldwide each year, according to data from 2006. More and more customers are turning to igus in search of lubrication-free solutions. "We hope to see you at trade shows, and we look forward to many new igus innovations – including very different ones, in mobility."