At KOH-I-NOOR MACHINERY a.s., development and innovation are firmly integrated into the manufacturing process. Research and development play a key role in designing technical solutions as well as ensuring the company’s long-term sustainability and growth. Their focus is primarily on plastics manufacturing – from mold design and construction, through material flow simulations, to the production of prototypes, technical moldings, and the testing of new processes. To support this, they use advanced tools such as Moldex3D and Autodesk Moldflow, which allow optimal material flow to be verified already in the design phase and help eliminate potential production issues before manufacturing begins.
The development department is integrated into the production process from the very beginning, starting at the stage of customer inquiry, where it evaluates the manufacturability of the requested part and proposes design modifications for efficient production. It then develops and manufactures molds according to specifications and works closely with customers to refine products and ensure their functionality within the overall system.
Development at KOH-I-NOOR MACHINERY is not based solely on internal know-how, but also on long-term collaboration with universities, especially the Technical University of Liberec. Together, they create innovative projects such as unconventional mold cooling using CO₂, research in the field of bionics, and liquid silicone rubber (LSR) injection technologies. These initiatives bring energy-efficient and effective manufacturing processes that enhance the company’s competitiveness in international markets.
With increasing industry demands, the emphasis on digitalization is also growing. KOH-I-NOOR MACHINERY invests in technologies that connect development with production – including the MES Pharis system for monitoring production process stability, maintenance, and toolmaking operations, as well as 3D scanners, CMMs, and optical measuring devices. Engineers design molds and processes with automation and robotic production lines in mind. In this way, traditional Czech engineering is combined with the digital era, where human expertise is complemented by simulations, precise data, and autonomous systems.
The group also includes G D K spol. s r.o., whose research and development focuses on the design and innovation of extrusion blow molding machines. Its in-house design office develops machines with horizontal mold movement and variable drive types – from pneumatic to servo-electric – depending on customer requirements for control precision, performance, and operational efficiency. Development activities include optimization of structural design, innovation of extrusion blow molding technologies, testing of prototypes and pre-production series, and adaptation of machines for specific applications. The company has also previously implemented a project supported by the OP PIK program, aimed at developing a new type of blow molding machine with an innovative design and control system.
Through the integration of design, technological research, and practical validation in operation, the group expands its competencies not only in molds and molded products, but also in the development and production of specialized machinery for plastics processing.
An important direction of development is the production of higher value-added products responding to changes in the automotive industry. KOH-I-NOOR MACHINERY therefore focuses on the production of headlights, interior components, electronic modules, and precision technical parts. This direction opens up new opportunities for further expansion and technological growth. The transition to electromobility also brings fundamental changes in vehicle design, along with growing demand for specialized components, to which the company actively responds by expanding its expertise in parts for electric vehicles.
For this reason, KOH-I-NOOR MACHINERY invests in automation and production consolidation, diversifies its product portfolio, and emphasizes quality and innovation that are not easily replicated. Development is seen as a key investment in the future and a pathway to maintaining competitiveness in international markets.
The tool shop is a key center for the production and maintenance of tools and special equipment essential for various manufacturing processes. It represents a specialized area of the company responsible for producing tools that are either used internally in production or supplied to customers for their own manufacturing operations. The tool shop handles not only the production of tools and molds, but also their maintenance, repair, and optimization, with a strong focus on precision, quality, and durability—factors that significantly influence the overall performance of manufacturing processes.
At KOH-I-NOOR MACHINERY, the tool shop is where vision becomes reality. It is a critical hub that drives both production and innovation. This specialized facility is where precision molds, tools, and development prototypes are created—elements without which it would not be possible to deliver high-quality products for the automotive, electrical engineering, medical, and consumer goods industries.
Each mold produced is the result of close collaboration between designers, technologists, and operators. The creation of a finished tool involves numerous steps, including design, engineering, manufacturing, testing, and subsequent adjustments and optimization. The tool shop also carries out mold maintenance and repairs—all under one roof. This enables KOH-I-NOOR MACHINERY to offer comprehensive services, from the initial 3D model to the final product.
Within the KOH-I-NOOR MACHINERY group, tool shops operate primarily in two locations: Polička and Rožnov pod Radhoštěm. Each site has its own history, expertise, and technological background, yet both share a common goal—to produce molds with exceptional precision, quality, and reliability. At the same time, their capacities are flexibly shared, allowing the group to respond more effectively to specific customer requirements and to efficiently utilize its overall production capabilities.
The KOH-I-NOOR MACHINERY group also includes GDK spol. s r.o., a company focused on the design and manufacture of machinery for plastics processing, particularly extrusion blow molding machines used to produce hollow plastic products. These technologies are applied in the production of packaging and technical plastic components, such as bottles, canisters, containers, and technical parts for the automotive and healthcare industries.
The company’s manufacturing program is based on in-house design and development of machines, while individual components are supplied by specialized partners (e.g., SMC, Exlar, Ziehl-Abegg, OMRON, Eaton, and others) and subsequently assembled in the company’s assembly hall. This approach enables flexible adaptation of machine design to specific customer requirements and the creation of tailor-made technical solutions for various applications.
The product portfolio primarily consists of the GM series of extrusion blow molding machines, which enable the production of items across a wide volume range—from small plastic packaging of approximately 5 ml to large-capacity containers of up to 30 liters, depending on the configuration.
The machines are manufactured in several size categories:
GM 250 – a compact machine suitable for small plastic products and packaging (0–0.35 L)
GM 750 – designed for small to medium-sized hollow products (0–1.5 L)
GM 2000 – a universal blow molding machine for a wide range of applications (0.3–3 L)
GM 5000 – intended for larger products and higher production output (0.2–10 L)
GM 10k / GM 20k / GM 30k – large-capacity machines for industrial applications (0.4–20 L)
The machine design concept is based on a horizontal mold movement system (the so-called shuttle system) and supports various drive options—pneumatic, hybrid, or fully servo-electric. Machines can be configured as single- or dual-station units, allowing production capacity to be optimized according to specific requirements. This variability makes it possible to tailor machines in terms of performance, control precision, and energy efficiency.
GDK provides not only machine design and assembly, but also comprehensive technical support throughout the entire lifecycle of the equipment. It also offers technological consulting, mold testing, and assistance with installation and commissioning.
Through the integration of in-house development, engineering, and technical support, the KOH-I-NOOR MACHINERY group extends its competencies not only in toolmaking, but also in the development and production of specialized machinery for plastics processing.
The plastics injection molding shop represents a key operation within the manufacturing process, enabling the actual production of injection-molded parts. Production is carried out in compliance with very strict standards that meet customer requirements. These processes are subject to regular audits by both customers and certification bodies, which consistently verify the high standards delivered to customers.
Production and assembly form two fundamental pillars of the entire manufacturing process at KOH-I-NOOR MACHINERY. Production involves the transformation of technical materials or semi-finished products into precise plastic components through injection molding or blow molding. Advanced technologies, a high level of automation, and tools manufactured in the company’s own tool shops play a crucial role. The molding shops are equipped with modern injection molding machines featuring robotic handling of molded parts, ensuring precision, repeatability, and process stability.
Subsequent assembly operations integrate individual components into functional units. These processes include automated assembly lines equipped with feeders and insert-loading systems. Inspection and assembly stations are integrated directly into production, such as optical systems for measuring dimensions of complex plastic parts, pressure testers for verifying the tightness of functional components, and visual surface quality inspections. These technologies enable continuous quality monitoring and the immediate removal of non-conforming parts from production. All processes are designed to meet stringent customer requirements, with a strong emphasis on quality, traceability, and maximum reliability of each component.
The plastics molding shop is a key operation within KOH-I-NOOR MACHINERY’s manufacturing process. It is here that final molded products made from engineering thermoplastics are produced, primarily for the automotive, electrical engineering, and medical industries. Production is carried out on modern injection molding machines from renowned manufacturers such as Arburg, Engel, KraussMaffei, Haitian, Fanuc, and others, most of which are equipped with automation systems for part handling and in-cycle quality control.
Production and assembly are two key phases in the industrial process, together forming the fundamental pillars of the manufacturing cycle. Production involves the transformation of raw materials or semi-finished products into final products using various techniques and processes. This phase includes everything from machining and molding to the assembly of components and product testing to ensure functionality for our customers.
Each molded part undergoes a strictly controlled process, from the initial mold design to the final output. Production is managed in accordance with rigorous standards and is regularly subject to both customer and certification audits. Thanks to in-house mold design and close collaboration with the development department, a high level of precision, efficiency, and repeatability can be achieved. Plastics molding at KOH-I-NOOR MACHINERY thus ensures not only high technical quality but also the flexibility to respond to the specific requirements of each customer.
