Sound insulation for plastics processing
For businesses of all sizes
Noise Protection for Plastics Processing
Noise protection in plastics processing is a key occupational safety requirement for manufacturing companies. Granulators and cutting mills generate sound levels of 90 to 105 dB(A), making them among the loudest individual sources in production halls. Employers are required to provide hearing protection from 80 dB(A), and wearing it becomes mandatory from 85 dB(A) under the German Noise and Vibration Occupational Safety Regulation (LärmVibrationsArbSchV). The typical noise levels of common machines in the plastics industry illustrate the need for action.
| Machine | Sound Level |
|---|---|
| Cutting mill / Granulator | 90 to 105 dB(A) |
| Hydraulic injection moulding machine | 75 to 85 dB(A) |
| All-electric injection moulding machine | 59 to 70 dB(A) |
| Extruder | 75 to 90 dB(A) |
| Hydraulic press | 80 to 95 dB(A) |
In a typical injection moulding hall with multiple machines, mills and peripheral equipment, the individual levels add up to an overall hall noise level of 80 to 90 dB(A). Pneumatic conveying systems, dryers and compressors contribute additional noise. In many facilities, the cumulative effect significantly exceeds the legal limits.
With over 300,000 employees in the German plastics industry, this issue affects a large number of companies. Professional noise protection in plastics processing safeguards your employees against irreversible hearing damage, ensures compliance with legal requirements and improves working conditions across your entire operation.
Effective noise protection for injection molding and extrusion systems
Machine enclosures offer the most effective protection against noise from injection molding machines, extruders, and presses. Double-walled steel constructions filled with mineral wool achieve a noise reduction of 20 to 30 dB(A) and reduce the sound level of a cutting mill from 100 dB(A) to below 75 dB(A). For particularly loud machines such as granulators, full enclosures with sound insulation values of up to Rw 43 can be implemented.
Machine enclosures specifically encapsulate individual noise sources without enclosing the entire machine. These partial enclosures are particularly suitable for hydraulic units and drive units, which generate most of the noise. Sound barriers also create defined noise areas within the production hall and effectively shield quieter workplaces.
Each solution is individually tailored to the machinery and spatial conditions. The sta Group’s state-of-the-art 3D scanner captures millimeter-precise digital measurements on site, ensuring that enclosures and cladding for sound insulation in plastics processing are manufactured to fit perfectly. Elements up to 6 m in length are produced in-house on an automated plasma system.
sta Group as your partner for sound insulation in the plastics industry
As a full-service provider, sta Group supports plastics processors from the initial analysis to the final installation. Experienced project managers assess the noise situation in your production hall, identify the critical sources of noise, and develop a customized protection concept. The sound insulation consultation also includes a well-founded cost-benefit analysis for your project.
With its own production facilities, in-house trained specialists, and experienced installation teams, sta Group guarantees on-time implementation with the highest quality standards. In 2024, the company was named a TOP 100 Innovator, making it one of the most innovative medium-sized companies in Germany. Since 1986, sta has been implementing challenging sound insulation projects for well-known industrial companies.
Whether it’s an enclosure for a single cutting mill or a comprehensive acoustic concept for an entire injection molding hall, the sta Group delivers tailor-made sound insulation for plastics processing on any scale. Get in touch and let us advise you without obligation. Together, we will develop a solution that protects your employees and optimizes your production in the long term.
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Employee protection through noise protection in the plastics industry
Noise-induced hearing loss (BK 2301) is the most common occupational disease in Germany, with 8,897 recognized cases in 2024. In the plastics industry, employees are often exposed to a double burden, as chemical emissions from thermal processing occur in addition to noise. Once damaged, hearing cannot regenerate, which makes prevention through technical sound insulation indispensable.
The LärmVibrationsArbSchV (Noise and Vibration Occupational Safety and Health Regulation) defines clear levels of action for employers. From 80 dB(A) daily noise exposure, hearing protection and instruction are mandatory; from 85 dB(A), a noise reduction program must be established and noise areas must be marked. The exposure limit of 87 dB(A) must not be exceeded, taking into account hearing protection.
Professional sound insulation in the plastics industry goes beyond mere compliance with regulations. Reduced noise levels increase concentration, reduce error rates, and increase employee satisfaction. Investments in noise protection pay off through reduced downtime, lower staff turnover, and measurably higher productivity.
Extraction and ventilation in sound insulation for plastics processing
Plastics processing places special demands on enclosed enclosures. Injection molding machines, extruders, and presses generate considerable process heat at processing temperatures of 150 to 350 °C. Without integrated ventilation, there is a risk of heat build-up, which impairs machine life and product quality. Silencers in the ventilation ducts prevent sound transmission to the outside.
When plastics are heated and processed, harmful decomposition products are produced, which must be collected by extraction systems. Each extraction opening breaks through the enclosed housing and creates potential sound bridges. Sophisticated designs combine efficient extraction with soundproofed ducts, thus keeping the overall noise level at the workplace within the standard limits.
Material feed via granulate conveyor and parts removal by robots require additional openings in enclosures. Soundproof airlocks, lamella curtains, and automatic closure systems minimize sound leakage at these points. The vibration decoupling of the machines from the hall floor additionally prevents structure-borne sound transmission via foundations and building structures.
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