Ways Out of Competitive Pressure: Automate, Diversify, Lead the Way

Interview with Dr. Ronald Bernstein, Managing Director of BERGI-PLAST GmbH

Strategic mind with technical foresight: Dr. Ronald Bernstein drives the automation and future strategy of BERGI-PLAST with clear ideas and high demands for innovation

Rising costs, global competitive pressure, and rapid technological change challenge the plastics industry. BERGI-PLAST GmbH from Bad Gottleuba-Berggießhübel addresses these developments with consistent automation, digital progress, and a clear focus on new markets. With two closely interlinked locations, strong engineering know-how, and an exceptionally stable workforce, the company focuses on efficiency and future-proofing. Managing Director Dr. Ronald Bernstein explains how BERGI-PLAST aligns its course between innovation, sustainability, and employee orientation - and why strategic stability is more important than ever for SMEs today.

Automation as a Driver of Future Viability

In plastic processing today, the ability to automate processes and strategically bring value creation back into the company is crucial. BERGI-PLAST has consistently focused on this in recent years: External hand assemblies have been significantly reduced, and automation skills have been systematically expanded – a development that strengthens the company both in terms of costs and capacity.

A central project was completed in 2025: The complete intralogistics were restructured and today ensure that components go directly into packaging and are automatically palletized. "We cannot afford to lose momentum – the level of automation in Asia is tremendous," emphasizes Dr. Ronald Bernstein. For a medium-sized company, such projects are financially challenging but crucial for long-term competitiveness.

BERGI-PLAST GmbH Dr. Ronald Bernstein and an employee check the next optimization steps directly at the machine — Precision arises in dialogue: Dr. Ronald Bernstein and an employee directly check the next optimization steps at the machine – a synergy of leadership, expertise, and a hands-on mentality

BERGI-PLAST GmbH Highly Automated Injection Molding Line — Highly automated injection molding line: Modern facilities, structured planned processes, and consistent efficiency form the core of production at BERGI-PLAST

Broad Lineup, Strong Markets, and New Opportunities

BERGI-PLAST operates at two regional locations: In Berggießhübel, they produce closures for tube, bottle, and canister manufacturers, and in Dohma, they manufacture technical components for commercial vehicles and safety systems. Owning their own tool manufacturing — deliberately maintained despite international price pressure — allows for high speed, flexibility, and a deep understanding of the entire process chain.

BERGI-PLAST GmbH Technical Plastic Parts with System — Systematic canister closures: Functional components for various industries highlight the company's development and manufacturing expertise

BERGI-PLAST GmbH Flexible Small Series through Large Volumes — Flexible small series through large volumes: Samples of different closure variants demonstrate high adaptability to individual customer requirements

Currently, around 125 employees generate a turnover of about 22 million EUR. While the automotive business is experiencing noticeable declines, the closure sector remains stable. Additionally, a promising field for the future is opening up: near-patient diagnostics. An ongoing project is investigating the manufacturing of a rapid diagnostics system from biopolymers—a market with globally growing demand, especially in regions with limited medical infrastructure. The political framework also plays a role. Frequent changes in direction in German industrial policy make reliable planning difficult, according to Dr. Bernstein. The discussed phase-out of combustion engines makes it clear how changes in direction hinder investment decisions.

He wishes for more consistency and stability so that companies can strategically act in the long term. Nevertheless, sustainability remains a core concern: Recyclates, material reduction, design-for-recycling, and bio-based plastics are the focus of several research collaborations. The goal is not only to meet regulatory requirements but also to develop innovative solutions that are market-ready at an early stage.

BERGI-PLAST GmbH Toolmaking as a Strategic Engine — Toolmaking as a Strategic Engine: Precision mechanics and engineering expertise merge into solutions that ensure speed and manufacturing depth

BERGI-PLAST GmbH Coordinated Components — Precisely coordinated components: Where every detail fits, robust processes and components for demanding industrial applications are created

BERGI-PLAST GmbH Intelligent Intralogistics — Intelligent Intralogistics: Driverless systems autonomously move packaging units throughout the hall – a central element of the automation strategy

People as the Key – and a Vision of Full Automation

Despite high technological ambitions, people remain at the center of corporate strategy. Many employees have been with the company for over 20 years – a sign of attachment, experience, and a stable culture. BERGI-PLAST therefore consciously invests in further education, health programs, an in-house gym, job bicycle models, and company health insurance. Parallel to this, Dr. Ronald Bernstein consistently advances the production area: In the coming years, manufacturing is to be largely automated to reduce monotonous tasks and develop employees in more high-value tasks.

The goal is an efficient, almost continuously automated production flow – without job cuts, but with the qualitative development of the team. His personal drive is to strategically advance the company while simultaneously taking all employees along: a balance of courage, responsibility, and readiness for change.