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The fully automated production of high-quality covers for car key fobs combines new machine technology from Arburg, an innovative IMD process from partner Leonhard Kurz, and an attractive product from Huf. Witosa contributed to the realization of the project with MONOLITH® hot runner technology.","Turnkey Joint Project |  High-Quality Remote Key Covers","sb-blog-item","2026-01-18 00:00","Turnkey Joint Project - High-Quality Remote Key Covers","schluesselfertige-gemeinschaftsleistung-hochwertige-funkschluessel-cover","en/insights/schluesselfertige-gemeinschaftsleistung-hochwertige-funkschluessel-cover",-230,[],132211792429913,"0f7b1978-05b9-4cc3-9386-5bd1b55a84b1","2026-04-29T07:03:02.958Z",[],{"name":5323,"created_at":5324,"published_at":5325,"updated_at":5326,"id":5327,"uuid":1877,"content":5328,"slug":5435,"full_slug":5436,"sort_by_date":112,"position":5437,"tag_list":5438,"is_startpage":34,"parent_id":5318,"meta_data":112,"group_id":5439,"first_published_at":5440,"release_id":112,"lang":214,"path":112,"alternates":5441,"default_full_slug":112,"translated_slugs":112},"MONOLITH® vs. Konventionelle Heißkanaltechnik - wenn Bauraum plötzlich zum Effizienztreiber wird","2026-02-18T13:51:09.077Z","2026-04-13T13:42:24.704Z","2026-04-23T09:49:57.051Z",146362650974075,{"_uid":5329,"body":5330,"tags":5426,"image":5428,"teaser":5431,"headline":5432,"component":5311,"seo_title":14,"custom_slug":1352,"released_at":5433,"seo_description":14,"short_description":5434},"3379f56c-4aba-4d10-a350-7016b905e326",[5331,5371],{"_uid":5332,"text":5333,"media":5350,"button":5364,"headline":5365,"settings":5368,"component":1641,"text_style":1066,"image_style":1066,"preheadline":14,"reverse_layout":34,"background_color":1643},"cedad54a-459d-432a-be95-48f51375a4cf",{"type":24,"content":5334},[5335],{"type":27,"attrs":5336,"content":5337},{"textAlign":112},[5338,5343,5344,5345],{"text":5339,"type":103,"marks":5340},"This is exactly where MONOLITH® shows its strength. The smaller cut-out combined with larger melt channels creates entirely new geometric possibilities. Designers can arrange items more flexibly, design tools more compactly, and often even use smaller injection molding machines. The result: higher efficiency throughout the entire production cycle.",[5341],{"type":2632,"attrs":5342},{"color":14},{"type":447},{"type":447},{"text":5346,"type":103,"marks":5347},"What often surprises: Despite the significantly reduced installation space, larger injection volumes and higher article weights can be achieved with MONOLITH® – even with demanding technical materials. The additively manufactured nozzles are slimmer, but have a larger material tube cross-section and are more stable than many conventional solutions. Closer nozzle distances and an overall smaller tool structure are often simply not feasible with standard market systems.",[5348],{"type":2632,"attrs":5349},{"color":14},[5351],{"_uid":5352,"img_lg":5353,"img_md":5355,"img_xl":5357,"img_xs":5359,"component":1779},"f4df4b09-527a-4c10-bc38-4e5629d9f92c",{"id":112,"alt":112,"name":14,"focus":112,"title":112,"source":112,"filename":14,"copyright":112,"fieldtype":32,"meta_data":5354},{},{"id":112,"alt":112,"name":14,"focus":112,"title":112,"source":112,"filename":14,"copyright":112,"fieldtype":32,"meta_data":5356},{},{"id":112,"alt":112,"name":14,"focus":112,"title":112,"source":112,"filename":14,"copyright":112,"fieldtype":32,"meta_data":5358},{},{"id":5360,"alt":5361,"name":14,"focus":14,"title":14,"source":14,"filename":5362,"copyright":14,"fieldtype":32,"meta_data":5363,"is_external_url":34},146674961763165,"8-fach Heißkanalsystem mit MONOLITH® Technik","https://a.storyblok.com/f/289738213692103/7680x6050/b32b85dd81/w21734.png",{"alt":5361,"title":14,"source":14,"copyright":14},[],[5366],{"_uid":5367,"element":1670,"headline":14,"alignment":14,"component":301,"element_style":302},"ded5fdd7-d47d-4125-b863-192f8c419b39",[5369],{"_uid":5370,"hide":34,"component":1639,"margin_top":14,"padding_top":1679,"margin_bottom":14,"padding_bottom":1679},"cff2c4b5-3160-4f8f-b5c6-569c8969a5ea",{"_uid":5372,"text":5373,"media":5405,"button":5419,"headline":5420,"settings":5423,"component":1641,"text_style":1066,"image_style":1066,"preheadline":14,"reverse_layout":43,"background_color":1643},"85e5cfb2-a187-459e-bebf-913c5b91470f",{"type":24,"content":5374},[5375,5385],{"type":27,"attrs":5376,"content":5377},{"textAlign":112},[5378,5383,5384],{"text":5379,"type":103,"marks":5380},"Another point that customers particularly appreciate: MONOLITH® is not bound by classic standards, such as nozzle length. This offers enormous advantages for existing tools. Our MONOLITH® hot runner systems can often be integrated into existing tools – even when hot runner systems from other manufacturers are in use and the process has previously caused problems. Adapting to existing geometries is not an exception but a lived practice.",[5381],{"type":2632,"attrs":5382},{"color":14},{"type":447},{"type":447},{"type":27,"attrs":5386,"content":5387},{"textAlign":112},[5388,5395,5399,5400],{"text":5389,"type":103,"marks":5390},"What personally convinces me:",[5391,5393],{"type":2632,"attrs":5392},{"color":14},{"type":5394},"italic",{"text":4017,"type":103,"marks":5396},[5397],{"type":2632,"attrs":5398},{"color":14},{"type":447},{"text":5401,"type":103,"marks":5402},"The applications in the field repeatedly confirm these arguments. MONOLITH® is not a theoretical concept, but a solution that works in everyday life—more efficiently, flexibly, and economically than conventional hot runner technology.",[5403],{"type":2632,"attrs":5404},{"color":14},[5406],{"_uid":5407,"img_lg":5408,"img_md":5410,"img_xl":5412,"img_xs":5414,"component":1779},"022bf2e7-dc04-4ae9-949b-6536c30a050b",{"id":112,"alt":112,"name":14,"focus":112,"title":112,"source":112,"filename":14,"copyright":112,"fieldtype":32,"meta_data":5409},{},{"id":112,"alt":112,"name":14,"focus":112,"title":112,"source":112,"filename":14,"copyright":112,"fieldtype":32,"meta_data":5411},{},{"id":112,"alt":112,"name":14,"focus":112,"title":112,"source":112,"filename":14,"copyright":112,"fieldtype":32,"meta_data":5413},{},{"id":5415,"alt":5416,"name":14,"focus":14,"title":14,"source":14,"filename":5417,"copyright":14,"fieldtype":32,"meta_data":5418,"is_external_url":34},146679392718433,"8-fach Heißkanal - konventionelle Technik","https://a.storyblok.com/f/289738213692103/1920x1512/7b4b3d4ab5/w21734_ds-1353.png",{"alt":5416,"title":14,"source":14,"copyright":14},[],[5421],{"_uid":5422,"element":1670,"headline":14,"alignment":14,"component":301,"element_style":302},"bf4142be-0710-45a8-b531-ffe0c1f74310",[5424],{"_uid":5425,"hide":34,"component":1639,"margin_top":14,"padding_top":1679,"margin_bottom":14,"padding_bottom":1679},"0a2dc7eb-bca9-46e8-aaa8-735293b7ac03",[5427],"insightStory",{"id":5172,"alt":5173,"name":14,"focus":5429,"title":14,"source":14,"filename":5174,"copyright":14,"fieldtype":32,"meta_data":5430,"is_external_url":34},"3021x795:3022x796",{"alt":5173,"title":14,"source":14,"copyright":14},"\"In many conversations with toolmakers and processors, the colleagues from our sales team and I repeatedly hear the same desire: more freedom in design – without compromising the process,\" says Stephan Ochse.","MONOLITH® vs. conventional hot runner technology - when installation space suddenly becomes an efficiency driver","2026-01-19 13:59","MONOLITH® vs. Conventional hot runner technology - when installation space suddenly becomes an efficiency driver","monolith-vs-konventionelle-heisskanaltechnik-wenn-bauraum-ploetzlich-zum-effizienztreiber-wird","en/insights/monolith-vs-konventionelle-heisskanaltechnik-wenn-bauraum-ploetzlich-zum-effizienztreiber-wird",-30,[],"4dc324cc-964e-46f9-9f1b-1c7b773832c4","2026-02-27T10:51:36.796Z",[],{"name":5443,"created_at":5444,"published_at":5445,"updated_at":5446,"id":5447,"uuid":1878,"content":5448,"slug":5474,"full_slug":5475,"sort_by_date":112,"position":5476,"tag_list":5477,"is_startpage":34,"parent_id":5318,"meta_data":112,"group_id":5478,"first_published_at":5440,"release_id":112,"lang":214,"path":112,"alternates":5479,"default_full_slug":112,"translated_slugs":112},"Funktionsbauteile für Sensorik fordern Werkzeugkonstruktion und Heißkanaltechnik heraus","2026-02-26T12:15:54.721Z","2026-04-13T13:45:27.683Z","2026-04-13T13:45:27.503Z",149170400166322,{"_uid":5280,"body":5449,"tags":5464,"image":5466,"teaser":5471,"headline":5472,"component":5311,"seo_title":14,"custom_slug":1342,"released_at":5312,"seo_description":14,"short_description":5473},[5450],{"_uid":5283,"hide":34,"text":5451,"button":5455,"headline":5460,"settings":5462,"alignment":1634,"component":4421,"margin_top":14,"padding_top":1679,"margin_bottom":14,"padding_bottom":1679,"background_color":1643},{"type":24,"content":5452},[5453],{"type":27,"attrs":5454},{"textAlign":112},[5456],{"_uid":5290,"link":5457,"label":5459,"variant":51,"component":52},{"id":14,"url":5458,"linktype":32,"fieldtype":41,"cached_url":5458},"https://a.storyblok.com/f/289738213692103/x/bbb729015e/i-pdf-witosa-kunststoffe_09_2024_.pdf","to the technical article",[5461],{"_uid":5296,"element":5297,"headline":14,"component":301,"element_style":5298},[5463],{"_uid":5301,"hide":34,"alignment":1634,"component":1639,"margin_top":1066,"padding_top":1679,"margin_bottom":1066,"padding_bottom":1679,"background_color":1643},[5465,5303],"factsheet",{"id":5467,"alt":5468,"name":14,"focus":14,"title":14,"source":14,"filename":5469,"copyright":14,"fieldtype":32,"meta_data":5470,"is_external_url":34},149174004602676,"Lukas Erhardt und Markus Schwab vor Produktionsanlage","https://a.storyblok.com/f/289738213692103/3779x3850/b801e24587/gek_lukas-erhardt_markus-schwab-vor-produktionsanlage.jpg",{"alt":5468,"title":14,"source":14,"copyright":14},"The automotive industry is under significant pressure to change, and the demands on the supply sectors are steadily increasing. It is clear that the quality characteristics for the materials used in each component must fully meet the required precision and functionality. However, in some cases, expectations go beyond the usual standards. GEK experienced this with a brewing group that protects the processor for sensors in a car. The family-run medium-sized company was able to rely on a competent hot runner partner in this process.","\"Built, sprayed, ready\"","Functional components for sensors challenge tool design and hot runner technology","funktionsbauteile-fuer-sensorik-fordern-werkzeugkonstruktion-und-heisskanaltechnik-heraus","en/insights/funktionsbauteile-fuer-sensorik-fordern-werkzeugkonstruktion-und-heisskanaltechnik-heraus",-40,[],"b18e6a24-9307-49a3-8813-4fb388fcc94c",[],{"name":5481,"created_at":5482,"published_at":5483,"updated_at":5484,"id":5485,"uuid":1879,"content":5486,"slug":5815,"full_slug":5816,"sort_by_date":112,"position":1556,"tag_list":5817,"is_startpage":34,"parent_id":5318,"meta_data":112,"group_id":5818,"first_published_at":5440,"release_id":112,"lang":214,"path":112,"alternates":5819,"default_full_slug":112,"translated_slugs":112},"Gleichmäßigkeit ist kein Detail – sie ist der Maßstab | Konventionell vs. MONOLITH®","2026-01-09T14:11:09.760Z","2026-04-13T13:39:20.300Z","2026-04-13T13:39:20.274Z",132211792966506,{"_uid":5329,"body":5487,"tags":5808,"image":5809,"teaser":5812,"headline":5813,"component":5311,"seo_title":14,"custom_slug":1222,"released_at":5433,"seo_description":14,"short_description":5814},[5488,5518,5548],{"_uid":5332,"text":5489,"media":5499,"button":5512,"headline":5513,"settings":5516,"component":1641,"text_style":1066,"image_style":1066,"preheadline":14,"reverse_layout":34,"background_color":1643},{"type":24,"content":5490},[5491],{"type":27,"attrs":5492,"content":5493},{"textAlign":112},[5494],{"text":5495,"type":103,"marks":5496},"In conventional hot runner systems, the plastic melt often follows a physically induced imbalance. The aim is always to generate processing-appropriate temperatures in the area of the injection point. However, to maintain the injection points at processing temperature, temperature zones build up in the rear part of the hot runner nozzles due to electric heating, which cannot directly heat the injection point, that are significantly above the target values. As a result, plastics degrade, form outgassing, and change the flow behavior. The outcome is fluctuations that can affect surface quality, dimensional accuracy, and process reliability. An air gap between the casing and the heated material pipe, as is common in conventional hot runner systems, can insulate the heat release to the mold but cannot prevent the unhindered entry into the melt—which inevitably leads to uneven temperature profiles.",[5497],{"type":2632,"attrs":5498},{"color":14},[5500],{"_uid":5352,"img_lg":5501,"img_md":5503,"img_xl":5505,"img_xs":5507,"component":1779},{"id":112,"alt":112,"name":14,"focus":112,"title":112,"source":112,"filename":14,"copyright":112,"fieldtype":32,"meta_data":5502},{},{"id":112,"alt":112,"name":14,"focus":112,"title":112,"source":112,"filename":14,"copyright":112,"fieldtype":32,"meta_data":5504},{},{"id":112,"alt":112,"name":14,"focus":112,"title":112,"source":112,"filename":14,"copyright":112,"fieldtype":32,"meta_data":5506},{},{"id":5508,"alt":5509,"name":14,"focus":14,"title":14,"source":14,"filename":5510,"copyright":14,"fieldtype":32,"meta_data":5511,"is_external_url":34},143172372413611,"Cross-sectional thermal simulation of a cylindrical object, displaying a gradient from red to blue, indicating temperature variation.","https://a.storyblok.com/f/289738213692103/604x170/687312b386/dt.png",{"alt":5509,"title":14,"source":14,"copyright":14},[],[5514],{"_uid":5367,"element":1670,"headline":5515,"alignment":14,"component":301,"element_style":302},"Conventional hot runner nozzles",[5517],{"_uid":5370,"hide":34,"component":1639,"margin_top":14,"padding_top":1679,"margin_bottom":14,"padding_bottom":1679},{"_uid":5372,"text":5519,"media":5529,"button":5542,"headline":5543,"settings":5546,"component":1641,"text_style":1066,"image_style":1066,"preheadline":14,"reverse_layout":43,"background_color":1643},{"type":24,"content":5520},[5521],{"type":27,"attrs":5522,"content":5523},{"textAlign":112},[5524],{"text":5525,"type":103,"marks":5526},"In classical hot runner systems, the plastic melt often follows a physically induced imbalance. The goal is always to generate processing-appropriate temperatures in the area of the injection point. However, to maintain the injection points at processing temperature, temperature zones build up in the rear part of the hot runner nozzles due to electric heating, which, after all, cannot directly heat the injection point, and significantly exceed the target values. This causes plastics to degrade, form outgassing, and alter flow behavior. As a result, there are fluctuations that can affect surface quality, dimensional accuracy, and process reliability. The MONOLITH® nozzle, on the other hand, uses multiple strategically placed air gaps in the material tube, pressed between the melt and the heater, which ensures the heat is evenly distributed and only directed to the melt where necessary. This ensures a homogeneous temperature profile over the entire nozzle length and a stable basis for consistent component quality.",[5527],{"type":2632,"attrs":5528},{"color":14},[5530],{"_uid":5407,"img_lg":5531,"img_md":5533,"img_xl":5535,"img_xs":5537,"component":1779},{"id":112,"alt":112,"name":14,"focus":112,"title":112,"source":112,"filename":14,"copyright":112,"fieldtype":32,"meta_data":5532},{},{"id":112,"alt":112,"name":14,"focus":112,"title":112,"source":112,"filename":14,"copyright":112,"fieldtype":32,"meta_data":5534},{},{"id":112,"alt":112,"name":14,"focus":112,"title":112,"source":112,"filename":14,"copyright":112,"fieldtype":32,"meta_data":5536},{},{"id":5538,"alt":5539,"name":14,"focus":14,"title":14,"source":14,"filename":5540,"copyright":14,"fieldtype":32,"meta_data":5541,"is_external_url":34},143172409973937,"Colorful thermal simulation of a turbine blade, showing a gradient from blue at the center to orange at the edges, indicating temperature 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pipe",[5629],{"type":2632,"attrs":5630},{"color":14},{"type":3910,"content":5632},[5633,5645,5656],{"type":3913,"attrs":5634,"content":5635},{"colspan":3915,"rowspan":3915,"colwidth":112,"backgroundColor":112},[5636],{"type":27,"attrs":5637,"content":5638},{"textAlign":112},[5639],{"text":5640,"type":103,"marks":5641},"Conduction",[5642,5644],{"type":2632,"attrs":5643},{"color":14},{"type":5394},{"type":3913,"attrs":5646,"content":5647},{"colspan":3915,"rowspan":3915,"colwidth":112,"backgroundColor":112},[5648],{"type":27,"attrs":5649,"content":5650},{"textAlign":112},[5651],{"text":5652,"type":103,"marks":5653},"Uncontrolled overheating → uneven temperature profile",[5654],{"type":2632,"attrs":5655},{"color":14},{"type":3913,"attrs":5657,"content":5658},{"colspan":3915,"rowspan":3915,"colwidth":112,"backgroundColor":112},[5659],{"type":27,"attrs":5660,"content":5661},{"textAlign":112},[5662],{"text":5663,"type":103,"marks":5664},"Adjusted heat conduction into the melt → homogeneous 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In most cases, speed is of the essence to minimize the customer’s production downtime,” explains Arthur Dornseif. ",{"type":27,"attrs":5878,"content":5879},{"textAlign":112},[5880,5881],{"type":447},{"text":5882,"type":103},"Conventional hot runner systems wear out, particularly due to sensitive titanium seals or outgassing caused by imperfect temperature control, leading to production interruptions and increased repair costs. The many individual components of conventional hot runner nozzles make assembly complicated and costly, so the systems are usually sent in for repair.",{"type":27,"attrs":5884,"content":5885},{"textAlign":112},[5886,5887,5888],{"type":447},{"type":447},{"text":5889,"type":103,"marks":5890},"Kern Insight",[5891],{"type":459},{"type":27,"attrs":5893,"content":5894},{"textAlign":112},[5895,5896],{"type":447},{"text":5897,"type":103},"“We closely observed where conventional hot runner nozzles reach their limits,” says Dornseif. The analysis showed that too many wear parts, complex assembly processes, and short maintenance intervals lead to unnecessary downtime. ",{"type":27,"attrs":5899,"content":5900},{"textAlign":112},[5901,5902],{"type":447},{"text":5903,"type":103},"There was a clear need for a more robust, low-maintenance solution that operates reliably over the long term with extended maintenance cycles, even when processing technically demanding materials.",{"type":27,"attrs":5905,"content":5906},{"textAlign":112},[5907,5908,5909],{"type":447},{"type":447},{"text":5910,"type":103,"marks":5911},"Solution / Innovation - MONOLITH® Hot Runner Nozzle",[5912],{"type":459},{"type":27,"attrs":5914,"content":5915},{"textAlign":112},[5916,5917],{"type":447},{"text":5918,"type":103},"The answer is our MONOLITH® nozzle: precisely configured and manufactured for your application, leak-proof, and wear-resistant. 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