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With a new testing system from MiniTec, GAPLAST is optimizing its quality control. The result: greater process reliability, more efficient workflows, and maximum transparency.
As an owner-managed family business, GAPLAST has been manufacturing intelligent and sustainable plastic bottles, closures, and applications since 1989. GAPLAST’s innovative and exceptionally high-quality products are used in both the cosmetics industry and the healthcare sector worldwide. Extensive technological expertise enables GAPLAST to cover the entire process—from the initial product concept through development to series production—under one roof. The company utilizes modern manufacturing processes such as injection molding, injection blow molding, co-extrusion blow molding, and the associated system assemblies.
Since 2022, production has been based at the Peiting site, while development, design, the workshop, and administration remain in Altenau. Quality assurance plays a central role, particularly in the regulated environment of the healthcare and cosmetics industries.
GAPLAST also manufactures these types of bag-in-bottle containers.
To reliably meet high quality standards, GAPLAST relies on a new inspection system from MiniTec for in-process inspection. The system is specifically designed for inspecting co-extruded blow-molded liner bottles and is an integral part of ongoing quality control.
The primary motivation for the investment was to improve coordination with a key customer for the inliner bottles. This customer has been using MiniTec inspection technology in its own production environment for quite some time. By acquiring its own comparable system, GAPLAST was able to fully synchronize the inspection process and coordinate inspection results even more effectively throughout the supply chain.
Structured Project Execution and On-Time Implementation
After obtaining a cost estimate and placing the order, MiniTec provided a detailed schedule and timeline, which was reliably adhered to throughout the remainder of the project. The joint acceptance of the system took place together with the end customer at the MiniTec site in Schönenberg-Kübelberg. Following installation and qualification, the testing system went into operation as scheduled on July 1, 2025.
Standardized Testing Procedures in Daily Production
Today, the testing process is clearly structured and easily integrated into daily production. Every four hours, three different sizes of inliner bottles are filled with water and loaded into the testing system. The testing cycle is initiated using pre-programmed test sequences, after which half of the liquid is pumped out. The removed bottles are then temporarily stored for 24 hours before a final visual inspection is performed.
The system can accommodate up to 46 bottles per test cycle, enabling a high degree of parallel testing. A simple user interface, easy-to-create programs, password protection, and a high overall level of security contribute to the efficient and reliable operation of the system.
The MiniTec testing system.
From the user’s perspective, there are several key advantages: In addition to the ability to precisely synchronize tests with the customer in terms of timing and methodology, the system’s high capacity is particularly impressive. At the same time, its intuitive operation ensures that tests can be performed quickly and reproducibly.
With the new testing system, GAPLAST was able to further professionalize its in-process control and specifically strengthen quality assurance—a key component in continuing to meet the high demands of customers in the future.
GAPLAST also rates its collaboration with MiniTec as thoroughly positive. Project Manager Uwe Berthal, Head of Quality Assurance at GAPLAST, comments: “From the very beginning, we realized that we were dealing with experts in the field of test system design. We were kept well informed about the planning progress at all times, and during the acceptance process, we were greeted very warmly and received competent support. Even after the system was installed, we could contact MiniTec with our questions at any time. The collaboration worked out perfectly, and we will gladly order from MiniTec again if needed, as we can recommend this company without reservation.”
Copyright for all images: GAPLAST GmbH
Quality assurance is of the utmost importance to GAPLAST.
Do you have any questions or would you like to learn more about MiniTec’s testing systems? Then please feel free to contact us!