Did you know that invisible variations cause people to make manual adjustments they aren’t even aware of—building inconsistency right into your product or service?
Or are visible variations forcing them to constantly intervene because an inconsistent process simply cannot deliver according to specification?
Our methods have proven results across industrial production—from raw materials to finished products—as well as in schools and hospitals. We connect senior knowledge consultants with consultants educated in the latest tools and insights to deliver the best results at the lowest cost.
PU Consulting AB can work with your existing materials and processes to automate and optimise these production steps. We make them run seamlessly in the background, eliminating human error and reducing material waste.
From Molecules to Market Leadership™
Polymer System Optimisation
Competitive manufacturing starts with understanding the whole system.
Higher Quality. Greater Efficiency. Lower CO₂ Emissions. Less Waste. Circular Solutions. Up to 40% Lower Costs.
From products and materials to processes, production and measurable business value.
More Financial data, statistics and digital systems show what is happening. Real improvement requires understanding why — and how materials, processes, equipment and production interact. The goal: better quality, higher efficiency and stronger cost competitiveness. Connecting Insight to Industrial Performance PU Consulting combines data, technical expertise and real-world production knowledge to identify improvement opportunities across the complete value chain — from materials and processes to equipment, production, packaging, waste, reuse and the final product. Coaching & Consulting · Distribution · New Development From Data to Decision Advanced analysis, modelling and AI can help reveal why things happen and what could happen next. PU Consulting combines these capabilities with deep understanding of materials, processes, equipment and production. Less
SAP, MATLAB, R, Python, AI and Moldflow are tools.
The value comes from knowing which question to ask, which method to use and how to turn the result into action.
PU Insights: The Polymer Process Is a Critical Business Decision
For an executive team, process optimisation is about more than technical details. It is about risk, margins and long-term competitiveness.
In many manufacturing companies, departments optimise their own areas without anyone looking at the entire system. Procurement may reduce material costs while Production faces instability, higher scrap rates or increased costs.
Outdated specifications for materials, machinery and processes can create further hidden constraints — driving unnecessary waste, cost and CO₂ impact.
No one always has the full picture.
With PU Consulting’s System Thinking Approach, we connect the entire chain — from polymer systems and process conditions through equipment, production, packaging, waste and reuse, all the way to the final product — to identify where the system can perform better.
We optimise what you already have first. When a new material, machine or technology can create genuine value, we work with selected partners to provide the right solution.
Our focus: better performance, lower hidden costs and stronger profitability.
24/7 Production Support
When production is disrupted, time matters.
PU Consulting provides rapid support for critical production disruptions, unstable polymer processes and high scrap rates — remotely or on-site.
We help identify the cause, stabilise the process and determine the next step.
URGENT 24/7 SUPPORT
Don’t Know Where to Start? Start with Coach.
You do not need to have the complete answer.
PU Consulting works with your team to identify where performance is being lost, what can be improved and where to start.
Remote or on-site. Practical. Independent. Focused on measurable improvement.
START WITH A CONVERSATION
When the Challenge Requires a Complete Technical Solution
Complex challenges cannot be solved by optimising one isolated part of the system.
Materials, processes, equipment, production, packaging, waste and recycling requirements interact.
PUspec® – Our Specialized Solution
PUspec® connects these requirements to define and secure the complete technical solution.
Design · Materials · Processes · Equipment · Production · Packaging · Waste · Recycling
READ MORE · CONTACT US
End-to-End Engineering Assessment™
Find the opportunities hidden across your value chain.
We independently analyse your complete system using engineering facts, measurable data and real-world production knowledge.
Molecular design & raw materials
Production & quality control
Automation & equipment
Packaging & logistics
Recycling & circular flows
We identify root causes and quantify where improvements can create the greatest technical and economic value.
Independent Analysis
Identify where your biggest opportunities are.
REQUEST AN INDEPENDENT ANALYSIS
Shared Savings
From identified opportunity to measurable value.
For selected projects, PU Consulting can share the financial result of implemented improvements.
This reduces upfront risk and aligns our success with the value created.
You benefit when the improvement delivers.
DISCUSS SHARED SAVINGS
From Industrial Insight to Boardroom Decision
For senior management and the Board, optimisation is ultimately about business value.
What is driving cost?
Where is value being lost?
What risks are hidden in the system?
What could improve profitability and competitiveness?
PU Consulting connects technical facts, data and analysis with economic impact and strategic decision-making.
What’s in it for the Board?
Clearer insight. Better decisions. Measurable value.
PUspec®
Optimized materials and processes without guesswork
Purchasing & Specifications
A successful purchase starts with a specification that reflects reality.
In complex polymer processing, the challenge is often not the purchasing process itself, but whether the purchasing specification accurately defines what the material, process and equipment must achieve in real production.
Purchasing teams can effectively procure what the organisation has specified. The critical question is whether the specification reflects the actual application, operating conditions, material behaviour and production requirements.
A supplier can deliver exactly what was specified — and the system can still fail to deliver the required result.
Technical specifications must connect purchasing requirements with real production conditions.
PU Consulting helps connect technical specifications and procurement requirements with real production conditions.
Polymer System Optimisation for Polymer Manufacturing
Polymer System Optimisation connects molecule-level knowledge with the finished end product, helping manufacturers optimise materials, processes and equipment.
From material selection and formulation to processing, equipment and production, we help manufacturers improve quality, productivity and global competitiveness — supporting our clients on the path to market leadership.
The objective is to ensure that technical specifications, supplier solutions and production requirements are aligned — before technical gaps become costly production problems.
More PU Consulting AB connects materials, processing technology, machinery, equipment and industrial applications to solve technical and production challenges. With more than 35 years of practical experience, we help manufacturers identify, develop, adapt and optimise solutions for specific applications. Our work can start with a material, a product, a production problem or a need for improved efficiency. Our experience covers a broad range of materials, material systems and combinations, including: We work with customers and specialist suppliers to select, formulate, adapt and develop materials according to specific performance, processing, cost and application requirements. The objective is not simply to select an existing material, but to find, adapt or develop the right material solution for the application. Material performance and production efficiency depend on the right processing technology, production conditions and equipment. Our experience includes: Through our international network of specialist suppliers and equipment manufacturers, we help identify technologies and equipment suited to specific materials, processes and applications. Efficient production is not only about reducing material consumption. It is also about minimising production waste and making better use of the material already in the process. We help manufacturers with: The objective is simple: Less waste. Better material utilisation. More value from the production process. This system-level approach connects material, formulation, process, equipment, production, recycling and the final application. Material → Formulation → Process → Equipment → Production → Recycling & Reuse → Final Application By connecting the complete chain, we help identify solutions that balance: Performance • Cost • Processability • Production Efficiency • Material Efficiency • Sustainability More than 35 years of experience have built an international network of: We use this network to connect customers with the relevant expertise, materials, technologies and equipment needed to solve specific material, process and application challenges. From an existing material that needs to perform better, to a new material solution, process, equipment or recycling approach — we help connect the right expertise to the right application. More productive hours. Efficiency is where sustainability begins. Less
What We Do
Materials & Material Development
Finding the right material for the application.
Process & Equipment
Connecting the material to the production process.
Waste, Recycling & Material Efficiency
More efficient production means making better use of every kilogram.
From Material to Application
We look at the complete system — not just one component.
Global Specialist Network
Connecting customers with the right technical expertise.
Sustainability Starts with More Efficient Production
Do it right the first time.
Less waste.
Less unplanned downtime.
Lower energy consumption.
Better material utilisation.
Polymer System Optimization for Polymer Manufacturing
Polymer System Optimization helps industrial manufacturers improve production stability, reduce scrap and optimise polymer systems across the entire value chain — from material science and formulation to processing, equipment, manufacturing and recycling.
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Polymer System Optimization Services
With Polymer System Optimization, we combine material expertise, process optimisation, consulting, equipment evaluation and development to improve performance across complete industrial polymer systems.
Our Services
- Process Optimization – production stability and efficiency
- Consulting – polymer troubleshooting & root cause analysis
- Distribution – supply Material & Equipment Solutions and system support
- Development – polymer materials and product engineering
- Education & Collaboration – guide through the entire product lifecycle — from molecule to market-ready solution.
- Sustainable manufacturing – minimize negative environmental impacts, conserve energy and natural resources, and ensure employee and consumer safety
System Thinking Approach
We believe that polymer performance can only be optimized when materials, process conditions and product design are understood as one connected system.
We evaluate the entire system, not just individual components.
Material selection should be based on service life, performance, manufacturing efficiency, maintenance requirements, total cost of ownership, resource consumption, waste generation, and environmental impact throughout the entire lifecycle of the product.
The following examples demonstrate PU Consulting’s systems-thinking approach applied to real industrial materials and process challenges:
• Challenging Legacy Specifications Through Systems Thinking
Many industrial specifications were developed years ago under different technical and economic conditions. Today’s materials and manufacturing technologies often offer opportunities for improved performance, longer service life, and lower lifecycle costs.
The best results are achieved when engineering, operations, maintenance, procurement, and sustainability objectives are evaluated together rather than in isolation.
At PU Consulting, we use testing, analysis, and systems thinking to identify solutions that optimize performance, economics, and sustainability across the entire lifecycle.
• Lifecycle Performance Matters More Than Material Weight
For polyurethane elastomers, wear parts, and industrial components, environmental performance should be evaluated per functional unit—such as operating hour, tonnes processed, or production output—rather than per kilogram of material.
A material with a higher manufacturing footprint may still be the more sustainable solution if it lasts significantly longer and reduces maintenance, downtime, transportation, and waste.
• Unlocking New Possibilities in Injection Moulding
Recent developments in mould technology, including advanced tooling concepts and mould reinforcement solutions such as Ironjaw®, can enable the production of larger plastic components in smaller injection moulding machines or improve production efficiency within existing machine capacity.
This creates opportunities to reduce capital investment, energy consumption, floor space requirements, and overall manufacturing costs while maintaining product performance and quality.
Despite these advantages, adoption is sometimes uneven across regions and industries. In some markets, legacy specifications, established design practices, and procurement structures can slow the implementation of new solutions, particularly where evaluation criteria are still primarily based on conventional machine and tooling configurations rather than the performance of the complete manufacturing system.
A systems-thinking approach encourages manufacturers to reassess existing assumptions and explore how advances in tooling technology, mould design, and processing systems can improve productivity, sustainability, and total cost of ownership.
• How Extrusion Systems Influence Final Material Performance and Mechanical Properties
The quality of extruded materials is not determined solely by the raw material, but by the entire processing system.
Differences in extrusion technology, process control, screw design, and operator knowledge can significantly influence the final mechanical properties, consistency, and performance of the material.
Higher levels of process control and engineering knowledge in extrusion systems can improve polymer orientation, mixing efficiency, and thermal stability, resulting in more consistent and higher-performance materials.
In contrast, lower-cost extrusion systems may reduce capital expenditure, but can also introduce greater variation in processing conditions, which may negatively affect mechanical properties and long-term performance.
From a systems-thinking perspective, the true cost of a material is therefore not only defined by raw material price or machine investment, but by the interaction between equipment, process control, and final application requirements.
• How Extrusion Systems and Material Selection (Recycled vs Virgin) Influence Final Material Performance
Final mechanical properties of extruded polymers are determined by both material selection and processing conditions.
Recycled and virgin polymers can differ in viscosity stability, contamination levels, molecular weight distribution, and thermal behaviour. However, these differences are strongly influenced by how the material is processed.
Extrusion system design, screw configuration, temperature control, and process stability all play a key role in defining the final structure and performance of the material.
In some cases, well-controlled processing can allow recycled polymers to approach the performance of virgin materials. In other cases, insufficient process control can increase variability and reduce mechanical properties in both material types.
From a systems-thinking perspective, material performance should always be evaluated as the result of an integrated system, not a single input factor.
This includes material origin, process technology, and application requirements.
• Industrial Furnace Systems and Remote Process Analysis
Industrial furnace and ventilated thermal systems play a critical role in many manufacturing processes involving polymers, curing, drying, and thermal treatment.
PU Consulting performs remote system-level analysis of furnace performance and process stability by evaluating available process data, temperature profiles, and airflow characteristics. This enables identification of inefficiencies and improvement potential without requiring immediate on-site inspection.
Typical findings include uneven temperature distribution, inefficient airflow design, process instability, and excessive energy consumption affecting both product quality and total cost of ownership.
By viewing thermal systems as part of the overall production chain, rather than isolated equipment, significant improvements can often be achieved in energy efficiency, process consistency, and lifecycle performance.
Industries We Serve
- Packaging
- Automotive
- Construction
- Recycling
- Industrial manufacturing
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Contact PU Consulting AB
Do you want to improve production stability, reduce variation or optimize your polymer system?
Featured PU Consulting Insights
Insights into today’s challenges and opportunities — and how we can help customers improve, develop and implement better solutions together with selected technology partners.
Why Manufacturing Specifications Are Becoming a Board-Level Decision
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Production specifications directly influence:
• Capital Efficiency (CAPEX): The amount of capital tied up in heavy machinery.
• Production Costs (OPEX): Floor space, maintenance, and energy costs.
• Asset Utilization: The flexibility to run high-requirement jobs in smaller machine cells.
• Global Competitiveness: The ability to scale quickly while keeping piece-part costs low.
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Manufacturing Excellence: Beyond Purchasing Specifications to Create Shareholder Value
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Lean Management – 3 Foundations to Reveal Hidden Waste and Achieve Sustainable Operational Excellence
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Featured News
Current developments, projects, technologies and market developments from PU Consulting and our selected technology partners.
Co-Rotating Twin-Screw Extrusion for Advanced Polymer Compounding, Direct Extrusion & Mechanical Recycling — ICMA
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ICMA’s co-rotating twin-screw extrusion technology enables advanced polymer compounding, direct extrusion and mechanical recycling, supporting manufacturers in improving material performance, process stability and resource efficiency.
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Industrial Ventilated Ovens for Controlled Post-Curing & Heat Treatment – CDTM – Sermac.
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PU Consulting AB works with CDTM Industrial Ventilated Ovens in Northern Europe and helps customers identify and configure oven solutions according to their specific process and production requirements.
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Technothane™ & CASTECH™ – High-Tech Polyurethane Elastomers & Elastomer Casting Machines
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Huntsman Tecnoelastomeri HTE – combines high-performance hot-cast polyurethane elastomers, engineering elastomer systems, elastomer casting machines and technical expertise to provide complete solutions for demanding industrial applications.
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Products, Services & Suppliers — By Industry
Measurable Results
Our projects are focused on measurable improvements across production, product performance and sustainability.
- Improved production stability
- Reduced process variation
- Lower scrap rates
- Better material utilization
- Improved recycling performance
- Increased profitability
- Reduced process carbon footprint
- Reduced product carbon footprint
- Increased use of renewable and recycled materials
- Extended product lifetime
- Increased material efficiency
- Higher profitability
